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WORKSHOP MANUAL

COMPACT TRACK LOADER

SVL97-2

KiSC issued 09, 2021 A

TO THE READER This workshop manual provides safety information for service activity, general information such as specifications and dimensions of the machine, mechanisms and structure descriptions of the machine, and service procedures. Safety This section contains safety service descriptions and safety label information. General This section contains general instructions, tightening torques, general machine information and special tools. Maintenance This section contains information for the recommended oil and general maintenance procedures. Each section basically consists of mechanism and servicing. Mechanism Mechanism part contains information and explanations for the structure, functions, and specifications of the machine or component parts. This part should be comprehended before proceeding with troubleshooting, disassembling, assembling, and servicing works. Servicing Servicing part contains information and procedures for maintenance, troubleshooting and repair works. The reader should follow these instructions in order to satisfy any servicing work safely, correctly and quickly. In this WSM, service specifications and service limits are defined as followings. Service specifications: Specification which corresponds to new machine's ex-factory. It is based on quality standard, drawings, or actual measurements conducted by Kubota. This value is used to determine whether there is a problem with the machine in the event of a troubleshooting. However, it is necessary to consider degradation due to wear, based on the operating time of the machine, application or maintenance condition. Service limits: Service limit is a value corresponding to the recommended performance limit by taking long term-use wear into account. When the service limit is reached, the machine is required to have proper repair, overhaul or replacement in order to keep safe and adequate performance. All of the illustrations, photographs, specifications, and other information in this manual were created based on the latest model at the time of publication. The parts names used in this manual are unified into names representing the functions of the parts. Therefore, it does not necessarily correspond to the names used in other materials (parts list, operators manual etc.) and the name on the label / identification plates on the product. Kubota reserves the right to change all information at any time without notice. December 2020 © KUBOTA Corporation

KiSC issued 09, 2021 A

SUPPLEMENTARY INFORMATION Information for engine For the engine servicing information, refer to the following engine WSM, DM, or DPF handling manual. NOTE • The PDF No. may be changed by revision. Manuals related to the engine (V3800-TIEF4-L) Manuals

Title

PDF No.

WSM

V3800-TIEF4, V3800-TIEF4C

9Y111-10855 (English) 9Y111-10865 (French)

Diagnosis Manual

V3800-TIEF4-L (SVL95-2S, SVL97-2)

RY910-23921 (English)

DPF handling manual

DIESEL ENGINE FOR COMPACT TRACK LOADER

RY910-22220 (English)

About trademarks Trademark AdBlue®

Owner AdBlue is a registered trademark of the VDA - Verband der Automobilindustrie e.V. (The German Association of the Automotive Industry).

Company names, product names and service names described in this manual are the trademarks or registered trademarks of their respective owners. In the text, those names are not accompanied by trademark symbols (®, ™).

SVL97-2

KiSC issued 09, 2021 A

REVISION HISTORY Revision number

Date (YYYY/MM)

2021/09

Revision description

Page

Added the crankcase relief valve.*1

5-1

Deleted 15W-40 from the recommended engine oil.

3-7

Added error code E:9127 (continuous crankcase pressure error).

7-11 7-66

*1: The crankcase relief valve is installed from serial number 65679 only for Canadian market.

SVL97-2 KiSC issued 09, 2021 A

CONTENTS 1. SAFETY SAFETY FIRST..................................................................................................................................................1-1 1. Working precautions .................................................................................................................................1-1 2. Preparing for emergencies ....................................................................................................................... 1-1 3. Working cautions ......................................................................................................................................1-2 4. Starting machine safely ............................................................................................................................1-2 5. Preventing fires.........................................................................................................................................1-3 6. Preventing acid burns ...............................................................................................................................1-3 7. Avoiding high pressure fluid...................................................................................................................... 1-3 8. Avoiding hot exhaust ................................................................................................................................1-4 9. Cleaning exhaust filter ..............................................................................................................................1-4 SAFETY LABELS ..............................................................................................................................................1-5 1. Safety labels placement ...........................................................................................................................1-5 2. Safety labels maintenance ..................................................................................................................... 1-11

2. GENERAL GENERAL WORKING INSTRUCTIONS ........................................................................................................... 2-1 1. General working precautions .................................................................................................................... 2-1 2. Tightening bolts and nuts.......................................................................................................................... 2-1 3. Applying thread-locking fluid..................................................................................................................... 2-1 4. Installing circlips .......................................................................................................................................2-2 5. Installing spring pins .................................................................................................................................2-2 6. Handling split pin ......................................................................................................................................2-2 7. Handling chain joint and split pin .............................................................................................................. 2-2 8. Handling liquid gasket ..............................................................................................................................2-3 9. Replacing O-rings .....................................................................................................................................2-3 10. Replacing oil seals..................................................................................................................................2-3 11. Replacing floating seals .......................................................................................................................... 2-4 12. Connecting hydraulic hoses ................................................................................................................... 2-4 13. Wrapping thread seal tape...................................................................................................................... 2-4 14. Installing elbows with male seat ............................................................................................................. 2-4 15. Connecting and disconnecting quick hose couplings ............................................................................. 2-5 16. Handling the battery ...............................................................................................................................2-5 17. Handling wire harness ............................................................................................................................ 2-5 18. Handling fuses ........................................................................................................................................2-7 19. Handling connectors ...............................................................................................................................2-7 20. Wiring color.............................................................................................................................................2-8 21. Washing the machine with a high pressure washer ............................................................................... 2-8 22. Dispose fluids correctly........................................................................................................................... 2-9 PRELIMINARY WORKING INSTRUCTIONS .................................................................................................. 2-11 1. Vacuuming the hydraulic tank................................................................................................................. 2-11 2. Tilting up the cab .................................................................................................................................... 2-11 3. Opening the rear bonnet......................................................................................................................... 2-11 4. Tilting the radiator ...................................................................................................................................2-12 5. Locking the lift arm .................................................................................................................................2-13 6. Collecting refrigerant ..............................................................................................................................2-13 7. Connecting the Diagmaster .................................................................................................................... 2-14 CONCLUDING WORKING INSTRUCTIONS .................................................................................................. 2-17 1. Bleeding the air from the hydraulic cylinder............................................................................................ 2-17 2. Charging refrigerant................................................................................................................................2-17 TIGHTENING TORQUES ................................................................................................................................2-19 1. Bolts and nuts tightening torque ............................................................................................................. 2-19 2. Stud bolts tightening torque .................................................................................................................... 2-19 3. Hydraulic hose fitting tightening torque .................................................................................................. 2-20

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KiSC issued 09, 2021 A

4. Hydraulic hoses tightening torque (taper thread) ................................................................................... 2-20 5. Locknuts of adapters with O-ring tightening torque (straight thread)...................................................... 2-20 6. Adapters tightening torque (taper thread)............................................................................................... 2-21 7. Hose clamps tightening torque ............................................................................................................... 2-21 GENERAL MACHINE INFORMATION ............................................................................................................ 2-23 1. Machine identification .............................................................................................................................2-23 2. Engine identification ...............................................................................................................................2-23 3. DPF muffler identification........................................................................................................................ 2-24 4. DPF muffler model identification............................................................................................................. 2-25 5. SCR parts numbers and serial numbers ................................................................................................ 2-26 6. Injector code identification ...................................................................................................................... 2-27 7. Specifications .........................................................................................................................................2-28 8. Machine dimensions ...............................................................................................................................2-29 GENERAL ELECTRICAL INFORMATION....................................................................................................... 2-31 1. Electrical circuit general description ....................................................................................................... 2-31 1.1 Electrical circuit diagram description ............................................................................................... 2-31 1.2 Electrical circuit diagram unit symbol .............................................................................................. 2-31 1.3 Electrical wiring color coding ........................................................................................................... 2-32 1.4 Electrical wiring clamp..................................................................................................................... 2-32 1.5 Bus description................................................................................................................................2-33 1.6 Composite terminal description ....................................................................................................... 2-33 2. Connector ...............................................................................................................................................2-33 2.1 Connector handling precaution ....................................................................................................... 2-33 2.2 Connector diagram description ....................................................................................................... 2-33 TRANSPORTING THE MACHINE................................................................................................................... 2-35 1. Loading and unloading the machine on a truck ...................................................................................... 2-35 2. Towing the inoperable machine .............................................................................................................. 2-36 SPECIAL JIGS AND TOOLS ........................................................................................................................... 2-39 1. Engine compression pressure measuring kit.......................................................................................... 2-39 2. Shaft seal press-fit jig .............................................................................................................................2-41 3. Needle bearing insertion jig .................................................................................................................... 2-41 4. U-joint tightening jig ................................................................................................................................2-42 5. Ring nut tightening jig .............................................................................................................................2-43 6. Angular bearing press-fit jig (upper) ....................................................................................................... 2-43 7. Angular bearing press-fit jig (lower) ........................................................................................................ 2-43 8. Roller bearing press-fit jig ....................................................................................................................... 2-44 9. Oil seal press-fit jig .................................................................................................................................2-44 10. Floating seal insertion jig ...................................................................................................................... 2-44 11. Inner race extraction jig......................................................................................................................... 2-45 12. Ring gear disassembly jig..................................................................................................................... 2-45 13. Seal ring insertion inner jig ................................................................................................................... 2-45 14. Seal ring insertion jig ............................................................................................................................ 2-46 15. U-ring insertion inner jig........................................................................................................................ 2-46 16. U-ring insertion jig.................................................................................................................................2-47 17. Wiper ring press-fit jig ........................................................................................................................... 2-47 18. Bushing punching jig ............................................................................................................................ 2-47 19. Bushing press-fit jig ..............................................................................................................................2-48 20. Handle ..................................................................................................................................................2-48 21. Bearing press-in jig ...............................................................................................................................2-48 22. Piston pump dimension measuring jig .................................................................................................. 2-49 23. Piston ring correction jig ....................................................................................................................... 2-50 24. Piston ring correction jig ....................................................................................................................... 2-50 25. Manifold gauge .....................................................................................................................................2-50 26. Charging hoses ....................................................................................................................................2-51 27. Refrigerant gas vacuum machine ......................................................................................................... 2-51 28. Refrigerant gas leak tester ................................................................................................................... 2-51 29. Refrigerant gas canister ....................................................................................................................... 2-51

SVL97-2 KiSC issued 09, 2021 A

3. MAINTENANCE MAINTENANCE INTERVALS TABLE ................................................................................................................ 3-1 LUBRICANT QUANTITY....................................................................................................................................3-5 RECOMMENDED LUBRICANT......................................................................................................................... 3-7 HANDLING THE DEF/ADBLUE......................................................................................................................... 3-9 1. Checking, draining and refilling the DEF/AdBlue.................................................................................... 3-10 DAILY CHECK .................................................................................................................................................3-13 1. Checking the coolant level...................................................................................................................... 3-13 2. Checking the fuel level ...........................................................................................................................3-13 3. Checking the engine oil level .................................................................................................................. 3-14 4. Checking the DEF/AdBlue level ............................................................................................................. 3-14 5. Checking the hydraulic oil level .............................................................................................................. 3-14 6. Greasing the lubrication point ................................................................................................................. 3-15 7. Checking the radiator and oil cooler ....................................................................................................... 3-15 8. Checking the engine and electrical wiring .............................................................................................. 3-16 9. Checking the fan belt ..............................................................................................................................3-16 10. Draining the water separator ................................................................................................................ 3-16 11. Checking the dust valve........................................................................................................................3-17 12. Checking the pre-cleaner ..................................................................................................................... 3-17 13. Checking the DPF muffler..................................................................................................................... 3-18 14. Checking the washer liquid level (closed cab specification) ................................................................. 3-18 15. Checking the battery condition ............................................................................................................. 3-18 16. Checking the fuel tank cap ................................................................................................................... 3-21 EVERY 50 HOURS ..........................................................................................................................................3-23 1. Draining the water from the fuel tank...................................................................................................... 3-23 2. Checking the track tension ..................................................................................................................... 3-23 3. Cleaning the outer element of the air cleaner......................................................................................... 3-23 4. Cleaning the dust valve ..........................................................................................................................3-24 EVERY 250 HOURS ........................................................................................................................................3-25 1. Replacing the air filter elements of the air cleaner ................................................................................. 3-25 2. Checking the radiator hoses and clamps ............................................................................................... 3-25 3. Checking the fuel line .............................................................................................................................3-26 4. Checking the intake air line .................................................................................................................... 3-26 5. Cleaning the main frame ........................................................................................................................3-27 6. Adjusting the fan belt ..............................................................................................................................3-27 EVERY 500 HOURS ........................................................................................................................................3-29 1. Replacing the engine oil .........................................................................................................................3-29 2. Replacing the engine oil filter ................................................................................................................. 3-30 3. Replacing the water separator element .................................................................................................. 3-31 4. Replacing the fuel filter ...........................................................................................................................3-31 5. Replacing the HST motor gear oil .......................................................................................................... 3-32 6. Replacing the return filter ....................................................................................................................... 3-32 7. Replacing the breather filter ................................................................................................................... 3-33 8. Replacing the HST filter..........................................................................................................................3-34 9. Cleaning the front window roller ............................................................................................................. 3-34 EVERY 1000 HOURS ......................................................................................................................................3-37 1. Replacing the front window roller ........................................................................................................... 3-37 2. Replacing the suction filter ..................................................................................................................... 3-37 3. Adjusting the engine valve clearance ..................................................................................................... 3-38 4. Replacing the hydraulic oil...................................................................................................................... 3-39 EVERY 1500 HOURS ......................................................................................................................................3-41 1. Checking the injector ..............................................................................................................................3-41 2. Replacing the oil separator element ....................................................................................................... 3-41 3. Checking the positive crankcase ventilation valve ................................................................................. 3-42 4. Checking the EGR cooler ....................................................................................................................... 3-43 5. Checking the DEF/AdBlue injector tip .................................................................................................... 3-43 6. Checking the DEF/AdBlue hoses ........................................................................................................... 3-44

SVL97-2

KiSC issued 09, 2021 A

EVERY 2000 HOURS ......................................................................................................................................3-45 1. Checking the starter motor ..................................................................................................................... 3-45 2. Checking the alternator .......................................................................................................................... 3-45 EVERY 3000 HOURS ......................................................................................................................................3-47 1. Checking the EGR valve ........................................................................................................................ 3-47 2. Checking the turbocharger ..................................................................................................................... 3-48 3. Replacing the DPF muffler...................................................................................................................... 3-48 4. Replacing the DEF/AdBlue pump filter ................................................................................................... 3-49 5. Checking the DEF/AdBlue injector ......................................................................................................... 3-49 EVERY 8000 HOURS ......................................................................................................................................3-53 1. Replacing the filter in the DEF/AdBlue tank ........................................................................................... 3-53 EVERY 3 MONTHS .........................................................................................................................................3-55 1. Checking quality of DEF/AdBlue ............................................................................................................ 3-55 EVERY 1 YEAR ...............................................................................................................................................3-57 1. Checking the exhaust gas line................................................................................................................ 3-57 2. Checking the intake air line .................................................................................................................... 3-57 3. Checking the DPF muffler....................................................................................................................... 3-57 4. Checking the EGR and EGR pipes ........................................................................................................ 3-58 5. Checking the CCV heater ....................................................................................................................... 3-58 EVERY 2 YEARS.............................................................................................................................................3-61 1. Replacing the radiator hoses and clamps .............................................................................................. 3-61 2. Replacing the fuel line ............................................................................................................................ 3-61 3. Replacing the intake air line ................................................................................................................... 3-62 4. Changing the coolant..............................................................................................................................3-62 5. Replacing the oil separator hoses .......................................................................................................... 3-63 6. Replacing the DPF differential pressure sensor rubber hoses ............................................................... 3-63 7. Replacing the EGR cooler hose ............................................................................................................. 3-64 MAINTENANCE FOR A/C SPECIFICATION ................................................................................................... 3-65 1. Daily check .............................................................................................................................................3-65 1.1 Checking the air conditioning belt ................................................................................................... 3-65 2. Every 250 hours .....................................................................................................................................3-65 2.1 Cleaning the air filters ..................................................................................................................... 3-65 2.2 Checking the condenser ................................................................................................................. 3-66 2.3 Adjusting the air conditioning belt ................................................................................................... 3-67 3. Every 1000 hours ...................................................................................................................................3-67 3.1 Replacing the air filters.................................................................................................................... 3-67 4. Every 1 year ...........................................................................................................................................3-68 4.1 Checking the air conditioning and heater hoses ............................................................................. 3-68 5. Every 2 years..........................................................................................................................................3-69 5.1 Replacing the air conditioning and heater hoses ............................................................................ 3-69 6. Service as required.................................................................................................................................3-69 6.1 Checking the refrigerant .................................................................................................................. 3-69

4. MACHINE BODY SERVICING .......................................................................................................................................................4-1 1. Machine layout .........................................................................................................................................4-1 2. Cabin ........................................................................................................................................................4-2 2.1 Removing/Installing cabin ................................................................................................................. 4-2 2.1.1 Collecting the refrigerant gas .................................................................................................... 4-2 2.1.2 Draining the coolant .................................................................................................................. 4-2 2.1.3 Removing the cabin .................................................................................................................. 4-2 3. Armrest .....................................................................................................................................................4-5 3.1 Armrest parts drawing ....................................................................................................................... 4-5 4. Seat and seat belt.....................................................................................................................................4-6 4.1 Seat and seat belt parts drawing....................................................................................................... 4-6 5. Front window ............................................................................................................................................4-6 5.1 Assembling the front window ............................................................................................................ 4-6 5.1.1 Assembling window parts ......................................................................................................... 4-6 vi

SVL97-2 KiSC issued 09, 2021 A

5.1.2 Assembling the front window linkage...................................................................................... 4-10 5.1.3 Assembling the front window frame ........................................................................................ 4-11 5.2 Front window components .............................................................................................................. 4-14 6. Upper window .........................................................................................................................................4-16 6.1 Removing/Installing the upper window............................................................................................ 4-16 6.1.1 Removing the upper window .................................................................................................. 4-16 6.1.2 Installing the upper window .................................................................................................... 4-16 7. Rear window ...........................................................................................................................................4-17 7.1 Removing/Installing the rear window .............................................................................................. 4-17 7.1.1 Installing the rear window trim ................................................................................................ 4-17 7.1.2 Installing the glass for rear window......................................................................................... 4-17 8. Side window ...........................................................................................................................................4-18 8.1 Removing/Installing the side window .............................................................................................. 4-18 8.1.1 Removing the side window ..................................................................................................... 4-18 8.2 Side window parts drawing ............................................................................................................. 4-19 9. Lift arm/linkage .......................................................................................................................................4-20 9.1 Removing/Installing the lift arm / linkage......................................................................................... 4-20 9.1.1 Removing the cabin ................................................................................................................ 4-20 9.1.2 Installing the vacuum pump .................................................................................................... 4-20 9.1.3 Rear bonnet lock..................................................................................................................... 4-20 9.1.4 Removing the lift arm .............................................................................................................. 4-20 9.1.5 Removing the linkage 1 .......................................................................................................... 4-22 10. Quick hitch ............................................................................................................................................4-23 10.1 Quick hitch parts drawing .............................................................................................................. 4-23 10.1.1 Mechanical quick hitch parts drawing ................................................................................... 4-23 10.1.2 Hydraulic quick hitch parts drawing ...................................................................................... 4-24 11. Accelerator pedal ..................................................................................................................................4-25 11.1 Removing/Installing the accelerator pedal..................................................................................... 4-25 11.1.1 Removing the accelerator pedal ........................................................................................... 4-25 11.2 Accelerator pedal parts drawing .................................................................................................... 4-25 12. Rear bonnet/rear cover......................................................................................................................... 4-25 12.1 Removing/Installing the rear bonnet/rear cover ............................................................................ 4-25 12.1.1 Removing the rear bonnet .................................................................................................... 4-25 12.1.2 Collecting the refrigerant gas ................................................................................................ 4-26 12.1.3 Removing the rear cover ...................................................................................................... 4-26 12.2 Rear bonnet parts drawing ............................................................................................................ 4-28 12.3 Rear cover parts drawing .............................................................................................................. 4-29 12.3.1 Rear cover parts drawing (Open cab model) ........................................................................ 4-29 12.3.2 Rear cover parts drawing (Closed cab model) ..................................................................... 4-30 13. Radiator ................................................................................................................................................4-31 13.1 Removing/Installing the radiator.................................................................................................... 4-31 13.1.1 Draining the coolant .............................................................................................................. 4-31 13.1.2 Removing the battery............................................................................................................ 4-31 13.1.3 Installing the vacuum pump .................................................................................................. 4-32 13.1.4 Removing the radiator .......................................................................................................... 4-32 13.2 Radiator parts drawing .................................................................................................................. 4-33 14. Rubber crawler .....................................................................................................................................4-36 14.1 Removing/Installing the rubber crawler ......................................................................................... 4-36 14.1.1 Removing the rubber crawlers .............................................................................................. 4-36 14.2 Rubber crawler parts drawing ....................................................................................................... 4-37 15. Front idler, tension spring, and grease cylinder .................................................................................... 4-37 15.1 Front idler, tension spring, and grease cylinder parts drawing ...................................................... 4-37 15.2 Front idler components ................................................................................................................. 4-38 15.3 Tension spring components .......................................................................................................... 4-38 15.4 Grease cylinder components ........................................................................................................ 4-38 16. Track roller............................................................................................................................................4-39 16.1 Track roller parts drawing.............................................................................................................. 4-39 16.2 Track roller components................................................................................................................ 4-39 SVL97-2

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17. Rear idler ..............................................................................................................................................4-40 17.1 Rear idler parts drawing ................................................................................................................ 4-40 17.2 Rear idler components .................................................................................................................. 4-40 18. Pin, bushing ..........................................................................................................................................4-41 18.1 Pins, bushing and shims list .......................................................................................................... 4-41

5. ENGINE MECHANISM .....................................................................................................................................................5-1 1. Engine device layout ................................................................................................................................5-1 2. Engine specifications ................................................................................................................................5-5 3. Engine dimensions ...................................................................................................................................5-6 4. Engine performance curve ....................................................................................................................... 5-7 5. Engine control system ..............................................................................................................................5-9 5.1 Engine control system general description ....................................................................................... 5-9 6. Common rail system ............................................................................................................................... 5-11 6.1 Common rail system general description ........................................................................................ 5-11 7. EGR system............................................................................................................................................5-12 7.1 EGR system general description..................................................................................................... 5-12 8. Supercharger system .............................................................................................................................5-13 8.1 Supercharger system general description....................................................................................... 5-13 9. DPF.........................................................................................................................................................5-14 9.1 DPF general description.................................................................................................................. 5-14 9.2 DPF output limit and warning lamp ................................................................................................. 5-15 10. SCR system..........................................................................................................................................5-16 10.1 SCR system general description ................................................................................................... 5-16 10.2 SCR output limit and warning lamp ............................................................................................... 5-17 10.2.1 Diesel Exhaust Fluid (DEF/AdBlue) level in SCR ................................................................. 5-17 10.2.2 DEF/AdBlue concentration and quality ................................................................................. 5-18 10.2.3 SCR defrost control .............................................................................................................. 5-19 10.2.4 DEF/AdBlue pump (Tampering) ............................................................................................ 5-20 10.2.5 SCR system error (Tampering) ............................................................................................. 5-21 10.2.6 SCR system error (Derating) ................................................................................................ 5-22 SERVICING .....................................................................................................................................................5-23 1. Intercooler...............................................................................................................................................5-23 1.1 Removing and installing the intercooler .......................................................................................... 5-23 1.2 Intercooler parts drawing................................................................................................................. 5-25 2. Air cleaner ..............................................................................................................................................5-27 2.1 Air cleaner parts drawing ................................................................................................................ 5-27 3. SCR muffler ............................................................................................................................................5-28 3.1 Removing/Installing the SCR muffler .............................................................................................. 5-28 3.1.1 Removing and installing the intercooler .................................................................................. 5-28 3.1.2 Removing the SCR muffler ..................................................................................................... 5-29 3.1.3 Installing the SCR muffler ....................................................................................................... 5-30 3.2 SCR muffler pipe parts drawing ...................................................................................................... 5-33 4. DPF muffler.............................................................................................................................................5-33 4.1 Removing/Installing the DPF muffler............................................................................................... 5-33 4.1.1 Removing and installing the intercooler .................................................................................. 5-33 4.1.2 Removing the SCR muffler ..................................................................................................... 5-35 4.1.3 Removing the DPF muffler...................................................................................................... 5-35 5. Engine ....................................................................................................................................................5-37 5.1 Removing/Installing the engine ....................................................................................................... 5-37 5.1.1 Removing the cabin ................................................................................................................ 5-37 5.1.2 Removing the battery.............................................................................................................. 5-37 5.1.3 Draining fuel............................................................................................................................5-38 5.1.4 Removing the radiator ............................................................................................................ 5-38 5.1.5 Removal of the air cleaner ...................................................................................................... 5-39 5.1.6 Removing and installing the intercooler .................................................................................. 5-39 5.1.7 Removing the HST pump ....................................................................................................... 5-41 viii

SVL97-2 KiSC issued 09, 2021 A

5.1.8 Removing the SCR muffler ..................................................................................................... 5-41 5.1.9 Removing the engine .............................................................................................................. 5-41 5.2 Engine parts drawing ...................................................................................................................... 5-44 5.2.1 Engine mount parts drawing ................................................................................................... 5-44 5.2.2 Oil separator parts drawing..................................................................................................... 5-46 5.2.3 Muffler bracket parts drawing.................................................................................................. 5-47 5.3 Removing/Installing the fuel tank .................................................................................................... 5-48 5.3.1 Cabin lock ...............................................................................................................................5-48 5.3.2 Draining fuel............................................................................................................................ 5-48 5.3.3 Removing the step .................................................................................................................. 5-48 5.3.4 Removing the fuel tank ........................................................................................................... 5-49 6. Fuel tank .................................................................................................................................................5-51 6.1 Fuel tank parts drawing ................................................................................................................... 5-51 6.2 Fuel pump parts drawing................................................................................................................. 5-52 6.3 Fuel hose route ...............................................................................................................................5-53 7. DEF/AdBlue tank ....................................................................................................................................5-54 7.1 Removing the DEF/AdBlue tank ..................................................................................................... 5-54 7.2 DEF/AdBlue hose routing................................................................................................................ 5-56 8. DEF/AdBlue pump ..................................................................................................................................5-57 8.1 DEF/AdBlue pump parts drawing .................................................................................................... 5-57 9. Coolant valve ..........................................................................................................................................5-58 9.1 Coolant valve parts drawing ............................................................................................................ 5-58 9.1.1 Coolant valve parts drawing (Open cab model)...................................................................... 5-58 9.1.2 Coolant valve parts drawing (Closed cab model) ................................................................... 5-58

6. HYDRAULIC SYSTEM MECHANISM .....................................................................................................................................................6-1 1. Hydraulic equipment layout ...................................................................................................................... 6-1 2. HST pump ................................................................................................................................................6-2 2.1 HST Pump specifications .................................................................................................................. 6-2 2.2 HST Pump functions and structures ................................................................................................. 6-3 2.2.1 HST pump working principles ................................................................................................... 6-3 3. Piston pump..............................................................................................................................................6-5 3.1 Piston pump specifications................................................................................................................ 6-5 3.2 Piston pump functions and structures ............................................................................................... 6-6 3.2.1 Piston pump working principles ................................................................................................ 6-6 3.2.2 Piston pump "Regulator" functions and structures.................................................................... 6-6 3.2.3 Piston pump "Relief cut" function.............................................................................................. 6-8 4. Gear pump................................................................................................................................................6-9 4.1 Gear pump specifications.................................................................................................................. 6-9 5. Control valve...........................................................................................................................................6-10 5.1 Control valve specifications............................................................................................................. 6-10 5.2 Control valve functions and structures ............................................................................................ 6-12 5.2.1 Control valve "Main relief valve" functions and structures ...................................................... 6-12 5.2.2 Control valve "LS relief valve" functions and structures.......................................................... 6-12 5.2.3 Control valve "Overload relief valve" functions and structures ............................................... 6-13 5.2.4 Control valve "Non-operation" hydraulic description............................................................... 6-14 5.2.5 Control valve "Lift arm down" hydraulic description ................................................................ 6-15 5.2.6 Control valve "Lift arm up" hydraulic description..................................................................... 6-16 5.2.7 Control valve "Bucket leveling mechanism" hydraulic description .......................................... 6-17 5.2.8 Control valve "Bucket operation" hydraulic description........................................................... 6-18 5.2.9 Control valve "AUX operation" hydraulic description .............................................................. 6-19 5.2.10 Control valve "Load Sensing (flow control)" hydraulic description ........................................ 6-20 5.2.11 Control valve "Anti-Saturation" hydraulic description ............................................................ 6-23 5.2.12 Control valve "Lift arm float operation" hydraulic description................................................ 6-24 5.2.13 Control valve "Hydraulic quick hitch" hydraulic description................................................... 6-25 6. Pilot valve (Travel) ..................................................................................................................................6-26 6.1 Pilot valve (Travel) specifications .................................................................................................... 6-26

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KiSC issued 09, 2021 A

6.2 Pilot valve (Travel) functions and structures ................................................................................... 6-28 6.2.1 Pilot valve (Travel) working principles..................................................................................... 6-28 6.2.2 Pilot valve (Shuttle valve) functions ........................................................................................ 6-29 7. Pilot valve (Front operation) ................................................................................................................... 6-29 7.1 Pilot valve (Front operation) specifications ..................................................................................... 6-29 7.2 Pilot valve (working equipment operation) functions and structures ............................................... 6-32 7.2.1 Pilot valve (working equipment operation) working principles ................................................ 6-32 8. Travel motor............................................................................................................................................6-33 8.1 Travel motor specifications.............................................................................................................. 6-33 8.2 Travel motor functions and structures ............................................................................................. 6-34 8.2.1 Travel motor working principles .............................................................................................. 6-34 8.2.2 Travel motor "Reduction gear" working principles .................................................................. 6-34 8.2.3 Travel motor (Flushing) hydraulic description ......................................................................... 6-35 8.2.4 Travel motor "Parking brake" working principles .................................................................... 6-36 8.2.5 Travel motor "Travel speed shift" working principles .............................................................. 6-36 8.3 Travel system ..................................................................................................................................6-37 8.3.1 Travel system "Forward" hydraulic description ....................................................................... 6-37 8.3.2 Travel system "Reverse" hydraulic description ....................................................................... 6-38 8.3.3 Travel system "Left swivel" hydraulic description ................................................................... 6-39 8.3.4 Travel system "right swivel" hydraulic description .................................................................. 6-40 8.3.5 Travel system "Pivot turn (forward left)" hydraulic description ................................................ 6-41 8.3.6 Travel system "Charge circuit" hydraulic description .............................................................. 6-42 8.3.7 Anti-stall function of the travel system .................................................................................... 6-43 9. Hydraulic cylinder ...................................................................................................................................6-44 9.1 Hydraulic cylinder specifications ..................................................................................................... 6-44 10. Unload valve (Travel speed shift, parking brake, working equipment) ................................................. 6-45 10.1 Unload valve (Travel speed shift, parking brake, work equipment) specifications ........................ 6-45 10.2 Unload valve (Travel speed shift, parking brake, work equipment) functions and structures ....... 6-46 10.2.1 Unload valve (Travel speed shift, parking brake, work equipment) working principles......... 6-46 11. Solenoid valve (Anti-stall, AUX) ............................................................................................................ 6-47 11.1 Solenoid valve (Anti-stall, AUX) specifications .............................................................................. 6-47 12. Solenoid valve (Hydraulic pressure quick hitch) ................................................................................... 6-48 12.1 Solenoid valve (Hydraulic pressure quick hitch) specifications ..................................................... 6-48 SERVICING .....................................................................................................................................................6-49 1. Troubleshooting hydraulic....................................................................................................................... 6-49 1.1 Troubleshooting hydraulic for working equipment........................................................................... 6-49 1.2 Troubleshooting hydraulic for traveling ........................................................................................... 6-51 2. Measuring this machine.......................................................................................................................... 6-53 2.1 Hydraulic performance list............................................................................................................... 6-53 2.2 Hydraulic operating time ................................................................................................................. 6-53 2.2.1 Measuring the operating time for lift arm cylinder ................................................................... 6-53 2.2.2 Measuring the operating time for bucket cylinder ................................................................... 6-53 2.2.3 Measuring the drift for working equipment.............................................................................. 6-54 2.2.4 Measuring the operating time for travel motor ........................................................................ 6-54 2.2.5 Measuring the block performance for travel motor ................................................................. 6-54 2.2.6 Measuring the travel straightness for the travel motor............................................................ 6-55 3. HST pump ..............................................................................................................................................6-55 3.1 Measuring the HST pump ............................................................................................................... 6-55 3.1.1 Measuring the flow rate for HST pump ................................................................................... 6-55 3.1.2 Measuring travel relief pressure for HST pump ...................................................................... 6-56 3.1.3 Adjusting the travel straightness for the HST pump ............................................................... 6-56 3.1.4 Adjusting swash plate neutral for HST pump.......................................................................... 6-57 3.2 Removing/Installing the HST pump................................................................................................. 6-57 3.2.1 Draining the hydraulic oil ........................................................................................................ 6-58 3.2.2 Removing the cabin ................................................................................................................ 6-58 3.2.3 Removing the step .................................................................................................................. 6-58 3.2.4 Removing the LS pump .......................................................................................................... 6-60 3.2.5 Removing the HST pump ....................................................................................................... 6-60 x

SVL97-2 KiSC issued 09, 2021 A

3.3 Disassembling the HST pump......................................................................................................... 6-61 3.3.1 Disassembling the shaft assembly ......................................................................................... 6-61 3.3.2 Disassembling the cylinder block............................................................................................ 6-63 3.3.3 Disassembling the relief valve ................................................................................................ 6-64 3.3.4 Disassembling the servo piston .............................................................................................. 6-64 3.4 Assembling the HST pump ............................................................................................................. 6-66 3.4.1 Assembling the servo cylinder ................................................................................................ 6-66 3.4.2 Assembling the relief valve ..................................................................................................... 6-68 3.4.3 Assembling the cylinder block (Engine side) .......................................................................... 6-69 3.4.4 Assembling the shaft (Engine side) ........................................................................................ 6-71 3.4.5 Assembling the cylinder block (Pump side) ............................................................................ 6-73 3.4.6 Assembling the the shaft (Pump side) .................................................................................... 6-73 3.4.7 Assembling the adapter .......................................................................................................... 6-75 3.5 HST pump components .................................................................................................................. 6-76 3.6 Installing adapter layout for HST pump ........................................................................................... 6-80 3.7 Pump coupling parts drawing .......................................................................................................... 6-81 4. Piston pump............................................................................................................................................6-82 4.1 Measuring the piston pump ............................................................................................................. 6-82 4.1.1 Measuring the flow rate for piston pump................................................................................. 6-82 4.2 Bleeding air from the piston pump .................................................................................................. 6-82 4.3 Removing/Installing the piston pump .............................................................................................. 6-83 4.3.1 Removing the cabin ................................................................................................................ 6-83 4.3.2 Removing the step .................................................................................................................. 6-83 4.3.3 Installing the vacuum pump .................................................................................................... 6-85 4.3.4 Removing the piston pump ..................................................................................................... 6-85 4.4 Disassembling the piston pump ...................................................................................................... 6-85 4.4.1 Removing the gear pump ....................................................................................................... 6-86 4.4.2 Removing the valve cover ...................................................................................................... 6-86 4.4.3 Removing internal parts for piston pump ................................................................................ 6-87 4.4.4 Disassembling the regulator for piston pump ......................................................................... 6-88 4.5 Assembling the piston pump ........................................................................................................... 6-89 4.5.1 Assembling the regulator for piston pump .............................................................................. 6-89 4.5.2 Assembling internal parts for piston pump.............................................................................. 6-89 4.5.3 Assembling valve cover for piston pump ................................................................................ 6-92 4.5.4 Assembling the gear pump ..................................................................................................... 6-93 4.6 Piston pump components................................................................................................................ 6-94 4.7 Installing adapter layout for piston pump ........................................................................................ 6-96 4.8 Servicing standards of piston pump ................................................................................................ 6-97 4.8.1 Measuring the piston clearance .............................................................................................. 6-97 4.8.2 Measuring the play for shoe crimping section ........................................................................ 6-97 4.8.3 Measuring shoe thickness ...................................................................................................... 6-97 4.8.4 Measuring the length for cylinder spring ................................................................................. 6-98 4.8.5 Measuring the sinkage for spherical bushing ......................................................................... 6-98 5. Control valve...........................................................................................................................................6-98 5.1 Measuring the control valve ............................................................................................................ 6-98 5.1.1 Measuring the unload LS valve .............................................................................................. 6-98 5.1.2 Measuring the LS relief valve ................................................................................................. 6-99 5.1.3 Measuring the overload relief valve ........................................................................................ 6-99 5.1.4 Adjusting the flow dividing valve ........................................................................................... 6-100 5.2 Removing/Installing the control valve............................................................................................ 6-100 5.2.1 Removing the cabin .............................................................................................................. 6-101 5.2.2 Installing the vacuum pump .................................................................................................. 6-101 5.2.3 Removing/Installing the control valve ................................................................................... 6-101 5.3 Disassembling the control valve.................................................................................................... 6-102 5.3.1 Removing the section for control valve ................................................................................. 6-102 5.3.2 Removing the flow divider section for the control valve ........................................................ 6-104 5.3.3 Removing the relief valve for the control valve ..................................................................... 6-105 5.3.4 Removing the float solenoid valve for the control valve........................................................ 6-107 SVL97-2

KiSC issued 09, 2021 A

5.4 Assembling the control valve ........................................................................................................ 6-108 5.4.1 Assembling the section for control valve .............................................................................. 6-108 5.4.2 Assembling the flow divider section for control valve ........................................................... 6-110 5.4.3 Assembling the relief valve for the control valve................................................................... 6-112 5.4.4 Assembling the float solenoid valve for the control valve ..................................................... 6-114 5.5 Control valve components............................................................................................................. 6-116 5.6 Installing adapter layout for control valve ...................................................................................... 6-119 6. Travel motor..........................................................................................................................................6-121 6.1 Removing/Installing the travel motor ............................................................................................. 6-121 6.1.1 Removing/Installing the rubber crawler ................................................................................ 6-121 6.1.2 Installing the vacuum pump .................................................................................................. 6-121 6.1.3 Removing the travel motor.................................................................................................... 6-121 6.2 Disassembling the travel motor ..................................................................................................... 6-122 6.2.1 Disassembling the gear case for travel motor ...................................................................... 6-122 6.2.2 Disassembling the hydraulic motor for the travel motor........................................................ 6-125 6.3 Assembling the travel motor.......................................................................................................... 6-128 6.3.1 Assembling the gear case for travel motor ........................................................................... 6-128 6.3.2 Assembly of travel motor ...................................................................................................... 6-133 6.4 Travel motor components.............................................................................................................. 6-139 6.5 Installing adapter layout for travel motor ....................................................................................... 6-141 7. Pilot valve .............................................................................................................................................6-141 7.1 Measuring the piston pump ........................................................................................................... 6-141 7.1.1 Measuring pressure for pilot valve ........................................................................................ 6-141 7.1.2 Measuring pressure for the pilot valve (Lift arm, bucket) ...................................................... 6-142 7.2 Disassembling the pilot valve ........................................................................................................ 6-142 7.2.1 Removing the reducing valve ............................................................................................... 6-143 7.2.2 Disassembling the reducing valve ........................................................................................ 6-144 7.3 Assembling the pilot valve............................................................................................................. 6-145 7.3.1 Assembling the reducing valve ............................................................................................. 6-145 7.3.2 Assembling the pilot valve .................................................................................................... 6-146 7.4 Pilot valve components ................................................................................................................. 6-148 8. Lift arm cylinder ....................................................................................................................................6-149 8.1 Disassembling/Installing the lift arm cylinder ................................................................................ 6-149 8.1.1 Removing the lift arm ............................................................................................................ 6-149 8.1.2 Removing the battery............................................................................................................ 6-149 8.1.3 Removing the lift arm cylinder .............................................................................................. 6-149 8.2 Disassembling the lift arm cylinder................................................................................................ 6-150 8.2.1 Disassembling the cylinder rod for lift arm cylinder .............................................................. 6-150 8.2.2 Disassembling the cylinder head for lift arm cylinder............................................................ 6-152 8.3 Assembling the lift arm cylinder .................................................................................................... 6-153 8.3.1 Assembling the cylinder head for lift arm cylinder ................................................................ 6-153 8.3.2 Assembling the cylinder rod for lift arm cylinder ................................................................... 6-154 8.4 Servicing standards for hydraulic cylinder..................................................................................... 6-157 8.4.1 Measuring the bend for cylinder rod ..................................................................................... 6-157 8.4.2 Measuring the wear for cylinder rod and cylinder head ........................................................ 6-158 8.4.3 Measuring the wear for the cylinder tube and piston wear ring ............................................ 6-158 8.5 Lift arm cylinder components ........................................................................................................ 6-159 9. Bucket cylinder .....................................................................................................................................6-160 9.1 Removing/Installing the bucket cylinder ........................................................................................ 6-160 9.1.1 Removing the bucket cylinder............................................................................................... 6-160 9.2 Bucket cylinder components ......................................................................................................... 6-162 10. Hydraulic quick hitch cylinder ............................................................................................................. 6-163 10.1 Removing/Installing the hydraulic quick hitch cylinder ................................................................ 6-163 10.1.1 Removing the quick hitch cylinder ...................................................................................... 6-163 10.2 Hydraulic quick hitch cylinder components ................................................................................. 6-163 11. Unload valve .......................................................................................................................................6-164 11.1 Removing/Installing the unload valve .......................................................................................... 6-164 11.1.1 Installing the vacuum pump ................................................................................................ 6-164 xii

SVL97-2 KiSC issued 09, 2021 A

11.1.2 Cabin lock ...........................................................................................................................6-164 11.1.3 Removing the unload valve................................................................................................. 6-164 11.2 Installing adapter layout for unload valve .................................................................................... 6-166 12. Solenoid valve (Anti-stall, AUX).......................................................................................................... 6-167 12.1 Disassembly/Assembly of solenoid valves (Anti-stall, AUX) ....................................................... 6-167 12.1.1 Installing the vacuum pump ................................................................................................ 6-167 12.1.2 Cabin lock ...........................................................................................................................6-167 12.1.3 Removal of solenoid valve (Anti-stall, AUX) ....................................................................... 6-167 12.2 Installing adapter layout for solenoid valve (Anti-stall, AUX)....................................................... 6-168 13. Solenoid valve (Hydraulic pressure quick hitch) ................................................................................. 6-168 13.1 Installing adapter layout for solenoid valve (Hydraulic quick hitch) ............................................. 6-168 14. Hydraulic oil tank ................................................................................................................................6-168 14.1 Removing/Installing the hydraulic oil tank ................................................................................... 6-168 14.1.1 Draining the hydraulic oil .................................................................................................... 6-168 14.1.2 Cabin lock ...........................................................................................................................6-169 14.1.3 Removing the step .............................................................................................................. 6-169 14.1.4 Removing the LS pump ...................................................................................................... 6-171 14.1.5 Removing the hydraulic oil tank .......................................................................................... 6-171 14.2 Hydraulic oil tank components .................................................................................................... 6-173 14.3 Installing adapter layout for hydraulic oil tank ............................................................................. 6-175 15. Hydraulic hoses ..................................................................................................................................6-176 15.1 Total length for hydraulic hoses................................................................................................... 6-176 15.2 Hydraulic hose fittings ................................................................................................................. 6-176 15.3 Hose route...................................................................................................................................6-177 15.3.1 Piston pump ........................................................................................................................6-177 15.3.2 HST pump, HST filter.......................................................................................................... 6-179 15.3.3 Control valve .......................................................................................................................6-181 15.3.4 Bucket cylinder ................................................................................................................... 6-184 15.3.5 Unload valve .......................................................................................................................6-185 15.3.6 AUX solenoid valve............................................................................................................. 6-187 15.3.7 Relay, pilot valve ................................................................................................................. 6-189 15.3.8 Quick hitch model ............................................................................................................... 6-191

7. ELECTRICAL SYSTEM MECHANISM .....................................................................................................................................................7-1 1. Electrical device........................................................................................................................................7-1 1.1 Layout of electrical device ................................................................................................................. 7-1 2. Meter panel...............................................................................................................................................7-4 2.1 Meter panel display ........................................................................................................................... 7-4 2.2 Lamps ...............................................................................................................................................7-5 2.3 Buzzer ...............................................................................................................................................7-5 2.4 Meter panel functions ........................................................................................................................ 7-6 2.5 Normal mode.....................................................................................................................................7-6 2.5.1 Normal mode display ................................................................................................................ 7-6 2.6 User settings mode ........................................................................................................................... 7-7 2.6.1 AUX flow rate setting in user setting mode ............................................................................... 7-7 2.7 Service mode ....................................................................................................................................7-8 2.7.1 Service mode settings list ......................................................................................................... 7-8 SERVICING .......................................................................................................................................................7-9 1. Troubleshooting electrical issues.............................................................................................................. 7-9 1.1 Troubleshooting electrical ................................................................................................................. 7-9 2. Troubleshooting errors.............................................................................................................................. 7-9 2.1 Error warning list ...............................................................................................................................7-9 2.2 Engine error warning list ................................................................................................................. 7-11 2.3 E:001 CAN communication error .................................................................................................... 7-13 2.3.1 Checking on the meter panel for E:001 CAN communication error ........................................ 7-13 2.3.2 Checking on the meter panel for E:001 CAN communication error ........................................ 7-13 2.3.3 Checking with circuit tester for E:001 CAN communication error ........................................... 7-14

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2.4 E:005 High hydraulic oil temperature .............................................................................................. 7-14 2.4.1 Checking on the meter panel for E:005 high hydraulic oil temperature .................................. 7-14 2.4.2 Checking devices for E:005 high hydraulic oil temperature .................................................... 7-14 2.5 E:008 Fuel sensor error .................................................................................................................. 7-15 2.5.1 Checking on the meter panel for E:008 fuel sensor error ....................................................... 7-15 2.5.2 Checking devices for E:008 fuel sensor error ......................................................................... 7-15 2.5.3 Checking circuit tester for E:008 fuel sensor error.................................................................. 7-16 2.6 E:009 Accelerator dial sensor (Break or short) ............................................................................... 7-17 2.6.1 Checking on the meter panel for E:009 accelerator sensor error ........................................... 7-17 2.6.2 Checking devices for E:009 accelerator sensor error ............................................................. 7-18 2.6.3 Checking with circuit tester for E:009 Accelerator sensor error .............................................. 7-18 2.7 E:010 Travel speed shift solenoid error........................................................................................... 7-19 2.7.1 Checking on the meter panel for E:010 travel speed shift solenoid error ............................... 7-19 2.7.2 Checking devices for E:010 travel speed shift solenoid error ................................................. 7-20 2.7.3 Checking with circuit tester for E:010 travel speed shift solenoid error .................................. 7-20 2.8 E:011 Parking brake solenoid error ................................................................................................. 7-22 2.8.1 Checking on the meter panel for E:011 parking brake solenoid error..................................... 7-22 2.8.2 Checking devices for E:011 parking brake solenoid error....................................................... 7-22 2.8.3 Checking with circuit tester for E:011 parking brake solenoid error ........................................ 7-23 2.9 E:012 Float solenoid error ............................................................................................................... 7-24 2.9.1 Checking on the meter panel for E:012 float solenoid error ................................................... 7-24 2.9.2 Checking devices for E:012 float solenoid error ..................................................................... 7-25 2.9.3 Checking with circuit tester for E:012 float solenoid error....................................................... 7-25 2.10 E:013 Hydraulic lock release solenoid error.................................................................................. 7-27 2.10.1 Checking on the meter panel for E:013 hydraulic lock release solenoid error...................... 7-27 2.10.2 Checking devices for E:013 hydraulic lock release solenoid error ....................................... 7-27 2.10.3 Checking with circuit tester for E:013 hydraulic lock release solenoid error ......................... 7-28 2.11 E:014 Low hydraulic oil temperature error..................................................................................... 7-30 2.12 Checking on the meter panel for E:014 low hydraulic oil temperature .......................................... 7-30 2.13 Checking devices for E:014 low hydraulic oil temperature error ................................................... 7-30 2.14 Checking with circuit tester for E:014 low hydraulic oil temperature error .................................... 7-31 2.15 E:015 Hydraulic hitch solenoid error ............................................................................................. 7-32 2.15.1 Checking on the meter panel for E:015 hydraulic hitch solenoid error ................................. 7-32 2.15.2 Checking devices for E:015 hydraulic hitch solenoid error ................................................... 7-32 2.15.3 Checking with circuit tester for E:015 hydraulic hitch solenoid error .................................... 7-33 2.16 E:016 AUX knob-switch error ........................................................................................................ 7-35 2.16.1 Checking on the meter panel for E:016 AUX knob-switch error ........................................... 7-35 2.16.2 Checking devices for E:016 AUX knob-switch error ............................................................. 7-35 2.16.3 Checking with the circuit tester for E:016 AUX knob-switch error ........................................ 7-35 2.17 E:018 AUX right solenoid error ..................................................................................................... 7-36 2.17.1 Checking on the meter panel for E:018 AUX right solenoid error ......................................... 7-36 2.17.2 Checking devices for E:018 AUX right solenoid error........................................................... 7-37 2.17.3 Checking with circuit tester for E:018 AUX right solenoid error ............................................ 7-37 2.18 E:019 AUX left solenoid error........................................................................................................ 7-38 2.18.1 Checking on the meter panel for E:019 AUX left solenoid error ........................................... 7-38 2.18.2 Checking devices for E:019 AUX left solenoid error ............................................................. 7-39 2.18.3 Checking with circuit tester for E:019 AUX left solenoid error .............................................. 7-39 2.19 E:020 Anti-stall solenoid error ....................................................................................................... 7-40 2.19.1 Checking on the meter panel for E:020 Anti-stall solenoid error .......................................... 7-40 2.19.2 Checking devices for E:020 Anti-stall solenoid error ............................................................ 7-41 2.19.3 Checking with circuit tester for E:020 Anti-stall solenoid error.............................................. 7-41 2.20 E:021 5 V error ..............................................................................................................................7-42 2.20.1 Checking on the meter panel for E:021 5 V error ................................................................. 7-42 2.20.2 Checking devices for E:021 5 V error ................................................................................... 7-42 2.20.3 Checking external 5 V short with a circuit tester ................................................................... 7-44 2.21 E:023 Overvoltage ........................................................................................................................7-47 2.21.1 Checking on the meter panel for E:023 overvoltage............................................................. 7-47 2.21.2 Checking devices for E:023 overvoltage .............................................................................. 7-47 xiv

SVL97-2 KiSC issued 09, 2021 A

2.21.3 Checking with circuit tester for E:023 overvoltage ................................................................ 7-47 2.22 E:024 Hydraulic oil temperature sensor error ............................................................................... 7-48 2.22.1 Checking on the meter panel for E:024 hydraulic oil temperature sensor error ................... 7-48 2.22.2 Checking devices for E:024 hydraulic oil temperature sensor error ..................................... 7-48 2.22.3 Checking with circuit tester for E:024 hydraulic oil temperature sensor error....................... 7-48 2.23 E:026 CRS CAN communication error .......................................................................................... 7-50 2.23.1 Checking on the meter panel for E:026 CRS CAN communication error ............................. 7-50 2.23.2 Checking devices for E:026 CRS CAN communication error ............................................... 7-50 2.23.3 Checking with circuit tester for E:026 CRS CAN communication error ................................ 7-52 2.24 E:027 ACU CAN communication error .......................................................................................... 7-52 2.24.1 Check on the meter panel for E:027 ACU CAN communication error .................................. 7-52 2.24.2 Checking devices for E:027 ACU CAN communication error ............................................... 7-53 2.24.3 Check with circuit tester for E:027 ACU CAN communication error ..................................... 7-55 2.25 E:028 Foot accelerator sensor error ............................................................................................. 7-55 2.25.1 Checking on the meter panel for E:028 foot accelerator sensor error .................................. 7-55 2.25.2 Checking devices for E:028 foot accelerator sensor error .................................................... 7-56 2.25.3 Checking with circuit tester for E:028 foot accelerator sensor error ..................................... 7-56 2.26 E:9116 Engine overheating ........................................................................................................... 7-58 2.26.1 Checking on the meter panel for E:9116 Engine overheating............................................... 7-58 2.26.2 Checking devices for E:9116 engine overheating................................................................. 7-58 2.27 E:9118 Engine oil pressure error................................................................................................... 7-58 2.27.1 Checking on the meter panel for E:9118 engine oil pressure error....................................... 7-58 2.27.2 Checking devices for E:9118 engine oil pressure error ........................................................ 7-59 2.27.3 Checking with circuit tester for E:9118 engine oil pressure error.......................................... 7-60 2.28 E:9119 Battery charging error ....................................................................................................... 7-61 2.28.1 Checking on the meter panel for E:9119 battery charging error ........................................... 7-61 2.28.2 Checking devices for E:9119 battery charging error ............................................................. 7-61 2.28.3 Checking with circuit tester for E:9119 battery charging error .............................................. 7-61 2.29 E:9120 Water separator error........................................................................................................ 7-62 2.29.1 Checking on the meter panel for E:9120 water separator error............................................ 7-62 2.29.2 Checking devices for E:9120 water separator error ............................................................. 7-62 2.29.3 Checking with circuit tester for E:9120 water separator error ............................................... 7-63 2.30 E:9126 CCV pressure error........................................................................................................... 7-63 2.30.1 Checking on the meter panel for E:9126 CCV pressure error .............................................. 7-63 2.30.2 Checking devices for E:9126 CCV pressure error ................................................................ 7-63 2.30.3 Checking with circuit tester for E:9126 CCV pressure error ................................................. 7-64 2.31 E:9127 Continuous CCV pressure error ....................................................................................... 7-66 2.31.1 Checking on the meter panel for E:9127 continuous CCV pressure error............................ 7-66 3. Meter panel settings ...............................................................................................................................7-66 3.1 Meter panel switches operation ...................................................................................................... 7-66 3.2 AUX flow rate setting....................................................................................................................... 7-67 3.3 Service mode operations ................................................................................................................ 7-67 3.4 No-01 Tester mode.......................................................................................................................... 7-68 3.5 No-02 AUX knob setting.................................................................................................................. 7-71 3.6 No-03 AUX start-up point setting .................................................................................................... 7-71 3.7 No-04 AUX current fine setting ....................................................................................................... 7-72 3.8 No-05 HST start-up point setting..................................................................................................... 7-73 3.9 No-07 Accelerator pedal/dial setting ............................................................................................... 7-74 3.10 No-09 Read error history............................................................................................................... 7-74 3.11 No-10 Clear error history ............................................................................................................... 7-74 3.12 No-11 Read all error history .......................................................................................................... 7-75 3.13 No-12 AUX flow rate adjustment ................................................................................................... 7-75

8. AIR CONDITIONING AND HEATER SYSTEM MECHANISM .....................................................................................................................................................8-1 1. Air conditioning system............................................................................................................................. 8-1 1.1 Air conditioning equipments layout ................................................................................................... 8-1 1.2 Air conditioning system general description ...................................................................................... 8-3

SVL97-2

KiSC issued 09, 2021 A

2. Compressor ..............................................................................................................................................8-4 2.1 Compressor specifications ................................................................................................................ 8-4 2.2 Compressor functions and structures ............................................................................................... 8-5 2.3 Magnetic clutch functions and structures .......................................................................................... 8-5 2.4 Safety valve functions and structures ............................................................................................... 8-6 2.5 Temperature sensor functions and structures ................................................................................... 8-6 2.6 Compressor oil functions and structures ........................................................................................... 8-6 3. Air conditioning unit ..................................................................................................................................8-7 3.1 Air conditioning specifications ........................................................................................................... 8-7 3.2 Evaporator functions and structures ................................................................................................. 8-8 3.3 Heater core functions and structures ................................................................................................ 8-8 3.4 Blower motor functions and structures .............................................................................................. 8-8 3.5 Blower resistor functions and structures ........................................................................................... 8-9 3.6 Expansion valve functions and structures ......................................................................................... 8-9 3.7 Fin thermistor functions and structures ........................................................................................... 8-10 3.8 Hot water valve functions and structures ........................................................................................ 8-10 4. Condenser .............................................................................................................................................. 8-11 4.1 Condenser specifications ................................................................................................................ 8-11 4.2 Condenser functions and structures ............................................................................................... 8-11 5. Receiver ................................................................................................................................................. 8-11 5.1 Receiver specifications ................................................................................................................... 8-11 5.2 Receiver functions and structures ................................................................................................... 8-12 6. Pressure switch ......................................................................................................................................8-12 6.1 Pressure switch specifications ........................................................................................................ 8-12 6.2 Pressure switch functions and structures........................................................................................ 8-13 SERVICING .....................................................................................................................................................8-15 1. Troubleshooting ......................................................................................................................................8-15 1.1 Troubleshooting the air conditioning system ................................................................................... 8-15 1.2 Troubleshooting the compressor..................................................................................................... 8-17 2. Fuse........................................................................................................................................................8-17 2.1 Checking the fuses..........................................................................................................................8-17 3. Relay ......................................................................................................................................................8-18 3.1 Checking the relays.........................................................................................................................8-18 4. Air conditioning control panel ................................................................................................................. 8-19 4.1 Checking the air conditioning control panel .................................................................................... 8-19 5. Compressor ............................................................................................................................................8-20 5.1 Measuring and checking the compressor ....................................................................................... 8-20 5.2 Removing/Installing the compressor ............................................................................................... 8-21 5.3 Oil amount in the compressor ......................................................................................................... 8-22 6. Air conditioner unit ..................................................................................................................................8-23 6.1 Measuring and checking the air conditioning unit ........................................................................... 8-23 6.1.1 Measuring and checking the blower motor ............................................................................. 8-23 6.1.2 Measuring and checking the blower resistor .......................................................................... 8-23 6.2 Removing/Installing the air conditioning unit ................................................................................... 8-24 6.3 Air conditioning unit parts drawing .................................................................................................. 8-26 7. Condenser and receiver .........................................................................................................................8-26 7.1 Measuring and checking the condenser ......................................................................................... 8-26 7.1.1 Measuring and checking the condenser fan motor ................................................................. 8-26 7.2 Removing/Installing the condenser and the receiver ...................................................................... 8-27 8. Air conditioning hose ..............................................................................................................................8-29 8.1 Removing/Installing the air conditioning hose ................................................................................. 8-29 9. Heater hose ............................................................................................................................................8-30 9.1 Removing/Installing the heater hose ............................................................................................... 8-30

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ABBREVIATIONS Abbreviations

Abbreviations

Definitions

A/C

Air Conditioning

Inner Diameter

Alternating Current

ISO

International Standards Organization

ACC

Accessory

J/C

Joint Connector

AFS

Air Flow Sensor

JIS

Japanese Industry Standard

Auto Idle

LCD

Liquid Crystal Display

API

American Petroleum Institute

LED

Light Emitting Diode

Approximately

Left Hand side

Auto Stop

LSD

Limited Slip Differential

ASSY.

Assembly

MAX

Maximum

ASTM

American Society for Testing and Materials

MIL

Military Standards

AUX

Auxiliary

MIN

Minimum

C/V

Control Valve

Normally Closed

CAB

Cabin

Normally Opened

CAN

Controller Area Network

Outer Diameter

CCV

Closed Crankcase Ventilation

P/V

Pilot Valve

CECE

Committee for European Construction Equipment

P/L

Pressure Limiter

CNP

Canopy

Right Hand side

CRS

Common Rail System

RMS

Root Mean Square

DIN

Deutsches Institut für Normung (German Institute for Standards)

ROPS

Roll Over Protective Structure

DOC

Diesel Oxidation Catalysts

SAE

Society of Automotive Engineers

Diagnostic Manual

SBF

Slow Blow Fuse

DPF

Diesel Particulate Filters

SCV

Suction Control Valve

DTC

Diagnostic Trouble Code

Système Internationale (International system of units)

ECU

Electronic Control Unit

S/J

Swivel Joint

EGR

Exhaust Gas Recirculation

SOL

Solenoid

Europäische Norm (European standard)

spec.

Specification

Eng

Engine

Switch

FOPS

Falling Object Protective Structure

TEMP.

Temperature

GND

Ground

TPSS

Two Pattern Selection System

HST

Hydraulic Static Transmission

WSM

Work Shop Manual

IAT

Intake Air Temperature

W/H

Wire Harness

Approx.

SVL97-2

Definitions

xvii

KiSC issued 09, 2021 A

1. SAFETY

KiSC issued 09, 2021 A

SAFETY FIRST 1. Working precautions

1. SAFETY

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 assemble or use this unit.

• Stop the engine and remove the key when leaving the operator's seat for cleaning, maintenance, and servicing.

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, could result in minor or moderate injury. IMPORTANT • Indicates that equipment or property damage could result if instructions are not followed.

• Hang a DO NOT OPERATE tag near the operator's seat. • Do not use worn or cracked tools. Use tools in a proper way with enough strength. • In regards to the facility which is used in the workshop, follow each safety instruction.

2. Preparing for emergencies

NOTE • Gives helpful information.

1. Working precautions

• Keep a first aid kit and fire extinguisher ready at all times. • Keep emergency numbers near your telephone at all times.

• Understand all safety instructions and safety labels in this manual. • Park the machine on a stable and level ground then lower the attachment to check the machine safely. SVL97-2

1-1

KiSC issued 09, 2021 A

1. SAFETY

SAFETY FIRST 3. Working cautions

3. Working cautions

• Wear proper service attire when performing work. Do not wear loose clothing as they could get caught on machine components. • Wear the proper protective equipment when working around the machine. For example helmet, eye protector and protective shoes. • Do not work around the machine if you are tired or have consumed alcohol or drugs.

• Make sure you have the support of the 3 points with both hands holding the handle and one foot at the step when getting on and off the machine. • When working under the machine, make sure the machine does not move back and forth or side-toside. • When working under the machine, provide secure support for the machine. • When using a hydraulic jack, always use with a rigid rack to prevent the machine from falling.

4. Starting machine safely

• Keep the machine away from obstacles and hazardous materials. • Ensure the working environment is properly ventilated. • Do not allow third parties to come near the machine.

1-2

• Do not do the following work when starting the engine. – Short across starter terminals. – Bypass the safety start switch. • Make sure there are no bystanders or obstacles present around the machine before starting the engine. • Do not start the engine unless the operator is seated in the operator's seat. • Make sure that the pilot levers are in neutral before starting the engine.

SVL97-2 KiSC issued 09, 2021 A

SAFETY FIRST 5. Preventing fires

1. SAFETY • Connect the positive (+) terminal first when connecting the battery cable. • Do not short circuit the machine. • Do not splash the hydraulic oil on the exhaust components.

6. Preventing acid burns

• Lock the covers before starting the machine. • Keep away from rotating and moving objects. • Keep tools and waste cloth away from rotating and moving objects.

5. Preventing fires • Keep the electrolyte away from your eyes, hands, and clothes. Sulfuric acid in the battery electrolyte is poisonous: it can cause blindness and is strong enough to burn your skin and clothing. If you spill electrolyte on yourself, clean yourself with water and get a medical aid immediately.

7. Avoiding high pressure fluid

• Keep fire (welding sparks, grinding sparks, cigarettes) away from the fuel. • Wipe the fuel off when spilled. • Keep fire (welding sparks, grinding sparks, cigarettes) away from the battery. The battery produces oxygen and hydrogen gas that are flammable. • Disconnect the negative (-) terminal first when disconnecting the battery cable.

SVL97-2

• Keep away from high pressure fluids bursting from a hose or pipe. The fluid can penetrate your skin and cause serious injuries. • Get a medical aid immediately if an accident occurs.

1-3

KiSC issued 09, 2021 A

1. SAFETY

SAFETY FIRST 8. Avoiding hot exhaust • Do not work immediately after stopping the engine. The engine, muffler, radiator, and hydraulic components are extremely hot. • Do not remove caps and plugs soon after stopping the engine. The temperature and pressure of the coolant, hydraulic oil, and fuel are still high.

9. Cleaning exhaust filter

• Release residual pressure in the hydraulic circuit before removing the hydraulic components. • Pay attention when releasing pressure in hydraulic circuit, because the machine or attachment might move unexpectedly. • Check the coolant temperature and release the pressure before opening the radiator cap.

8. Avoiding hot exhaust

• Avoid skin exposure and contact with hot exhaust gas or components. Exhaust gas and components are extremely hot during regeneration of the diesel particulate filter (DPF).

• Avoid skin exposure and contact with hot exhaust gas or components. • Exhaust gas and components are extremely hot during operation.

1-4

SVL97-2 KiSC issued 09, 2021 A

SAFETY LABELS 1. Safety labels placement

1. SAFETY

SAFETY LABELS 1. Safety labels placement Read the safety instructions on safety labels carefully to avoid personal injury.

SVL97-2

1-5

KiSC issued 09, 2021 A

1. SAFETY

1-6

SAFETY LABELS

SVL97-2 KiSC issued 09, 2021 A

SAFETY LABELS

SVL97-2

1. SAFETY

1-7

KiSC issued 09, 2021 A

1. SAFETY

1-8

SAFETY LABELS

SVL97-2 KiSC issued 09, 2021 A

SAFETY LABELS

SVL97-2

1. SAFETY

1-9

KiSC issued 09, 2021 A

1. SAFETY

1-10

SAFETY LABELS

SVL97-2 KiSC issued 09, 2021 A

SAFETY LABELS 2. Safety labels maintenance

1. SAFETY

2. Safety labels maintenance • • • •

Keep safety labels clean and free from obstructing material. Clean safety labels with soap and water, dry with a soft cloth. Replace damaged or missing safety labels with new safety labels from your KUBOTA dealer. If a component with safety label(s) affixed is replaced with new part, make sure that new safety label(s) is (are) attached in the same location(s) as the replaced component. • Mount new safety labels by applying on a clean, dry surface and pressing any bubbles to outside edge.

SVL97-2

1-11

KiSC issued 09, 2021 A

2. GENERAL

KiSC issued 09, 2021 A

GENERAL WORKING INSTRUCTIONS 1. General working precautions

2. GENERAL

GENERAL WORKING INSTRUCTIONS 1. General working precautions

2. Tightening bolts and nuts • Tighten the bolts and nuts to their specified torque. NOTE – Tighten the bolts and nuts alternately from top to bottom and left to right so the torque is distributed evenly. – Gradually tighten the bolts and nuts two or three times.

• When servicing, observe the safety instructions in the operator's manual and workshop manual. • Clean the machine before maintenance. • Service the machine at a clean location. • Park the machine on a stable and level ground then lower the attachment to check the machine safely. • Stop the engine and remove the key when leaving the operator's seat for cleaning, maintenance, and servicing. • Before working, remove the negative (-) terminal from the battery or turn off the battery isolator switch. • Whenever a special tool is required, use the special tool that Kubota recommends. • Use genuine Kubota parts to ensure safety and machine performance.

(A) Alternately (B) Diagonally

3. Applying thread-locking fluid 1. Clean and dry the location where a thread-locking fluid will be applied with a solvent to remove moisture, oil, and dirt. 2. Apply the thread-locking fluid to the tip of the bolt. 3. If the threads are large, apply the thread-locking fluid all around the bolt hole.

• Hang a DO NOT OPERATE tag near the operator's seat. • Observe workplace safety rules when performing service and work.

SVL97-2

2-1

KiSC issued 09, 2021 A

GENERAL WORKING INSTRUCTIONS 4. Installing circlips

2. GENERAL

5. Installing spring pins • When installing the spring pin, assemble the slit of the spring pin in the direction that receives force as shown in the figure.

(A) Bolt hole (bolts, nuts)

(B) Screw hole

4. Installing circlips • When installing the circlip, assemble the circlip's angular side (3) toward the side that receives force (4) as shown in the figure.

(1) Parallel movement

(2) Rotational movement

6. Handling split pin • Bend the split pin as shown in the figure to prevent it from coming off. • Tighten a grooved nut to the specified torque, align the hole of the split pin to the tighten direction and use an S-shaped split.

(1) Circlip (2) Rounded side

(3) Angular side

(A) Single side split (B) Double side split

7. Handling chain joint and split pin (4) Side that receives force (5) Force

2-2

(A) External circlip (B) Internal circlip

• Assemble the chain joint with its opening facing the opposite direction of travel. • Assemble the split pin with its opening facing the direction of travel.

SVL97-2 KiSC issued 09, 2021 A

GENERAL WORKING INSTRUCTIONS 8. Handling liquid gasket

2. GENERAL 3. Put the O-ring in the groove. NOTE • Do not twist the O-ring. • Remove the burr to avoid damage on the Oring caused by the burr.

(1) Chain joint (2) Split pin

(A) Direction of chain moving

8. Handling liquid gasket • Use the specified liquid gasket. • When using liquid gasket, fully remove the old gasket and grease or oil. • When applying liquid gasket, apply it on the joint surface with a thickness of 3.0 to 5.0 mm (0.12 to 0.13 in.) without making any gaps. • When applying liquid gasket near the bolt hole (2), apply it in the inner side. • If there is a risk of oil leakage or if the hole goes all the way through when applying liquid gasket near the dowel pin (3) hole, apply it in the inner side. If there is no concern of oil leakage, apply it on the outer side. • Reassemble within 15 minutes after applying; wait for 30 minutes or more then fill with oil.

(1) O-ring groove (2) O-ring

(3) Burr

10. Replacing oil seals 1. Do not face the lip of the oil seal in the wrong direction. Face the seal lip toward the material to be sealed. 2. Use a press to install the oil seal until firmly fixed to the boss. NOTE • In cases when installing an oil seal without a press, place a wooden board on the seal and gently tap the board with a hammer; install the oil seal straightly and evenly. 3. Grease the seal lip and dust lip. NOTE • If the seal has a dust lip, grease the gap between the lips. • After oil seals are replaced, grease the moving parts around the lip to prevent the dry surfaces from wearing against each other during engine start up.

(1) (2) (3) (A) (B)

Application route Bolt hole Dowel pin Correct Incorrect

(a) 3.0 to 3.5 mm (0.12 to 0.13 in.) (b) 3.0 to 5.0 mm (0.12 to 0.19 in.)

9. Replacing O-rings 1. Remove the burr and clean the O-ring groove. 2. Lubricate the O-ring. Do not apply any grease to the floating seal.

SVL97-2

2-3

KiSC issued 09, 2021 A

GENERAL WORKING INSTRUCTIONS 11. Replacing floating seals

2. GENERAL

NOTE • Do not loosen the taper thread after tightening to avoid oil leakage. • Do not wrap the thread seal tape on the first and second threads to avoid contamination in the hydraulic circuit.

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

Packing Metal ring Spring Seal lip

(5) (6) (A) (B)

Grease Dust lip Air side Oil side

11. Replacing floating seals 1. Apply oil appropriately to both sides of the O-ring and the contact surface. 2. Do not twist the O-ring when installing the floating seal. 3. Apply oil thinly to the sliding surfaces. 4. Install the floating seal in parallel to the sliding surfaces, O-rings, and housings. 5. After installation, rotate the floating seal for 3 times to make an oil film on the sliding surface.

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

Thread seal tape Male thread Female thread Clearance

(5) First and second threads from the screw tip

14. Installing elbows with male seat 1. Clean the male seat surface and seal. 2. Loosen the lock-nut until the top end. 3. Install and tighten the elbow by hand until the male seat touches the material surface.

(1) Sliding surface

(2) O-ring

12. Connecting hydraulic hoses 1. Clean the inside of the hose fittings. 2. Tighten with the specified torque. 3. Apply pressure on the hydraulic hose to check for oil leakage.

(1) Lock-nut (2) Seat

(3) Seal

4. Adjust the direction of the elbow. NOTE • Do not loosen to more than one turn.

13. Wrapping thread seal tape 1. Wrap the thread seal tape around the taper threads two or three turns. 2. Tighten the taper thread with the specified torque. 2-4

SVL97-2 KiSC issued 09, 2021 A

GENERAL WORKING INSTRUCTIONS 15. Connecting and disconnecting quick hose couplings

2. GENERAL 2. Pull the plastic part in the opposite direction of the arrow mark. 3. Disconnect the quick hose coupling. 4. Push the quick hose coupling in the direction of the arrow mark to connect. 5. Make sure that the hose is installed correctly.

16. Handling the battery CAUTION 5. Tighten the lock-nut with the specified torque. NOTE • Check for oil leakage.

(4) Wrench (5) Hose

• When removing battery cables, disconnect negative (-) terminal first. • When installing battery cables, connect positive (+) terminal first. • Do not install any battery with a capacity (Ah) other than is specified. • Securely attach the terminal covers on the cables when connecting the cables to the battery terminal posts. There is a danger of short-circuiting if the tip of the cables attached to the battery terminal post is exposed. • Do not allow dirt and dust to collect on the battery. • Connect the battery terminals after removing dust, old grease, blue rust and others. • Apply conductive grease thinly to the battery terminal posts to prevent corrosion.

(6) Torque wrench

15. Connecting and disconnecting quick hose couplings 1. Push the metal fittings in the direction of the arrow mark. (1) Battery negative (-) terminal

(2) Battery positive (+) terminal

17. Handling wire harness CAUTION

(1) Plastic part

(2) Metal fitting

• Do not let an unprotected wire harness to come in contact with other components. • Do not clamp the wire harness to fuel hoses. • If the wire harness is damaged, replace it immediately with a new one. • Do not alter the electrical device and wire harness. • Tighten the electrical terminals securely.

SVL97-2

2-5

KiSC issued 09, 2021 A

GENERAL WORKING INSTRUCTIONS

2. GENERAL

(A) Good

(B) Bad: Loose bolt

• Check the electrical terminal protection and clamping conditions before connecting the battery cable.

(H) Damaged

• Keep the wire harness away from hazardous positions such as rotating parts or high-temperature sections.

(G) Hazardous position

(K) Bad: poor installation

• Clamp the wire harness securely. Do not damage the wire harness by the clamp. • Clamp the wire harness correctly. Do not slack, twist, and pull.

(2) Wire harness (D) Hazardous position (E) Wiring position: bad (F) Wiring position: good

Torn

• Install the grommet securely.

(1) Grommet (J) Good (C) Covered completely with a protection cover

(I)

(3) Clamp

• Do not pinch the wire harness when installing parts.

• If wire harness is damaged or degraded, replace immediately.

2-6

SVL97-2 KiSC issued 09, 2021 A

GENERAL WORKING INSTRUCTIONS 18. Handling fuses

(4) Wire harness

(L) Bad

18. Handling fuses

2. GENERAL

(A) Press

• Hold on tightly to the disconnecting them. • Do not pull wire harness itself.

connectors

when

• Always use fuses of the specified capacity. • Do not use steel or copper wiring instead of fuse. • Do not install work light or radio without auxiliary power line. • Do not install auxiliaries to the fuses. The fuses may blow.

(B) Correct method

(1) Fuse (2) Fusible link

(3) Slow blow fuse

• Make sure the terminal condition of the connectors is not bent, rusty, and so on. • If the terminal is rusted, remove rust with sandpaper. However, do not polish the terminal of the waterproof connector or the plated terminal.

19. Handling connectors • When disconnecting the locking connectors, be sure to disengage the lock before disconnecting. There are two kinds of locks: one requires pressing and the other requires pulling.

(1) Missing terminal (2) Bent terminal (3) Sandpaper

(4) Rust

• Cover the female bullet terminals and male bullet terminals securely with the plastic covers.

SVL97-2

2-7

KiSC issued 09, 2021 A

GENERAL WORKING INSTRUCTIONS 20. Wiring color

2. GENERAL • Make sure that the bullet terminals are secure and connected securely to the tip.

(D) Good (E) Bad: damaged cover

(F) Bad: poor connection

• Cover the female connectors and male connectors securely with the plastic covers.

Wiring Colors

Color code

Black

Brown

BR, Br

Green

Gray

GY, GR, Gr

Blue

Light green

LG, Lg

Orange

OR, Or

Pink

Purple

PU, Pu, V

Red

Sky blue

SB, Sb

White

Yellow

• This symbol of "/" shows color with stripe(s). (An example) W/R: White with red stripe

21. Washing the machine with a high pressure washer Use a high pressure washer properly to avoid personal injuries and damages to the machine.

CAUTION (5) Cover (G) Good

(H) Bad: damaged cover

IMPORTANT • Water infiltration may cause machine problems.

20. Wiring color • Wire colors are specified in the color codes.

(1) Wire color

2-8

• Damaged or cut the wire harness may cause fire. • Damaged hydraulic hoses or oil seals may cause injury due to hydraulic oil gushing out.

• Adjust the high pressure washer nozzle for a wide spray. Do not adjust to pencil point spray. • Spray the water at least 2 m away from the machine.

(2) Stripe

SVL97-2 KiSC issued 09, 2021 A

GENERAL WORKING INSTRUCTIONS 22. Dispose fluids correctly

(1) (2) (A) (B)

Adjusting the washer power Washing distance Pencil point spray Wide spray

2. GENERAL

22. Dispose fluids correctly • Do not dispose fluids on the ground, down the drain, into a stream, pond, or lake. Obey related environmental protection regulations when you dispose of oil, fuel, coolant, electrolyte, and other dangerous materials.

SVL97-2

2-9

KiSC issued 09, 2021 A

2. GENERAL

2-10

GENERAL WORKING INSTRUCTIONS

SVL97-2 KiSC issued 09, 2021 A

PRELIMINARY WORKING INSTRUCTIONS 1. Vacuuming the hydraulic tank

2. GENERAL

PRELIMINARY WORKING INSTRUCTIONS 1. Vacuuming the hydraulic tank

5. Tilt up the cab until the latch engages.

When removing the hydraulic devices and hydraulic hoses, vacuum the hydraulic tank to reduce the hydraulic oil leakage. 1. Replace the oil tank cap with a vacuum plug. 2. Plug the air breather hose on the hydraulic tank. 3. Connect the vacuum pump and vacuum plug with a hose. 4. Connect an air hose to the vacuum pump and vacuum the hydraulic tank.

2. Tilting up the cab (2) Cab

WARNING • Do not tilt up the cab while the engine is running. 1. 2. 3. 4.

(3) Latch

6. Install the lock pin.

Park the machine on the firm and level ground. Lower the front attachment to the ground. Stop the engine. Remove the 2 bolts from the cab.

(4) Lock pin

3. Opening the rear bonnet 1. Pull the lever and open the rear bonnet. (1) Bolt (M16 × 80) ×2

SVL97-2

2-11

KiSC issued 09, 2021 A

PRELIMINARY WORKING INSTRUCTIONS 4. Tilting the radiator

2. GENERAL

4. Tilting the radiator CAUTION • Stop the engine before tilting the radiator. • Do not work soon after stopped the engine as the engine is extremely hot. 1. Open the rear bonnet. 2. Remove 3 bolts.

(1) Lever

(A) Pull

(1) Bolt (M14 × 40) ×3

3. Remove the radiator hose from the stay.

(2) Rear bonnet

2. Insert the pin into the lock position to fix the rear bonnet.

(2) Stay

(3) Radiator hose

4. Pull and tilt the radiator.

(3) Pin (B) Original position

CAUTION • Check that the rear bonnet is securely locked.

2-12

SVL97-2 KiSC issued 09, 2021 A

PRELIMINARY WORKING INSTRUCTIONS 5. Locking the lift arm

(4) Radiator (A) Pull

(B) Tilt

5. Place the radiator on the stopper to prevent the radiator from falling down.

2. GENERAL

(1) Lift arm stopper

(2) Bolt ×2

4. Engage the parking brake and slowly raise the lift arm to the maximum height. 5. Activate the hydraulic lock by raising the armrests. 6. Install the lift arm stopper from the front side and fix with the 2 bolts.

(5) Stopper

5. Locking the lift arm WARNING

(1) Lift arm stopper

(2) Bolt

WARNING

• Do not work on the machine with the lift arm up unless the lift arm is locked by the lift arm stopper.

• Fit the dented side of the lift arm stopper with the rod of the lift arm cylinder. • Fit the flat side of the lift arm stopper with the lift arm cylinder.

1. Park the machine on the level and firm ground, and lower the lift arm to the ground. 2. Remove the attachment if installed. 3. Remove the lift arm stopper.

7. Lower the armrests and press the hydraulic unlock switch. 8. Slowly lower the lift arm to place it on the lift arm stopper.

6. Collecting refrigerant CAUTION • Use protective gloves and goggles when removing the hose from the charging valve.

SVL97-2

2-13

KiSC issued 09, 2021 A

PRELIMINARY WORKING INSTRUCTIONS 7. Connecting the Diagmaster

2. GENERAL IMPORTANT • Follow the instructions of the manufacturer and discharge the refrigerant from the cooling system. • Always use a R134a-specific refrigerant recharging/collecting equipment. • Always use R134a-specific refrigerant and compressor oil. [Note] 1. Close the high-pressure and low-pressure valves of the manifold gauge. 2. Connect the yellow charging hose to the collection device.

(9) Collection device (10) Low-pressure gauge (11) Inlet valve

(12) Collection cylinder (13) Blue valve

6. Continue collection of refrigerant until the lowpressure gauge drops to -0.1 MPa. 7. Turn the power off and wait 5 minutes before checking that the pressure of the low-pressure gauge has not risen. NOTE If the pressure rises, there may be refrigerant remaining in the circuit, so you will need to collect the remaining refrigerant.

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

Manifold High-pressure (HI) valve Low-pressure (LO) valve Red charging hose

(5) Blue charging hose (6) Yellow charging hose

7. Connecting the Diagmaster

3. Connect the red charging hose to the high-pressure side, and the blue charging hose to the lowpressure side.

(7) High-pressure side (H)

(8) Low-pressure side (L)

4. Open the inlet valve of the collection device, and the blue valve of the collection cylinder. 5. Turn on the recharging equipment and collect the refrigerant.

2-14

8. Close the blue valve of the collection cylinder, and remove all of the charge.

1. Remove the 3 bolts to remove the cover.

(1) Cover

(2) Bolt (M6 × 16) ×3

2. Remove the service tool connector to connect the Diagmaster.

SVL97-2 KiSC issued 09, 2021 A

PRELIMINARY WORKING INSTRUCTIONS

(3) Service tool connector

SVL97-2

2. GENERAL

(4) Diagmaster connector

2-15

KiSC issued 09, 2021 A

2. GENERAL

2-16

PRELIMINARY WORKING INSTRUCTIONS

SVL97-2 KiSC issued 09, 2021 A

CONCLUDING WORKING INSTRUCTIONS 1. Bleeding the air from the hydraulic cylinder

2. GENERAL

CONCLUDING WORKING INSTRUCTIONS 1. Bleeding the air from the hydraulic cylinder

When the cylinder is in mid-stroke

Bleed air from the hydraulic cylinder after removing and disassembling the hydraulic cylinder to prevent cavitation and seizure of the internal parts. 1. Set the engine speed to less than 1500 rpm. IMPORTANT • If the engine speed is more than 1500 rpm, the seals and bushings may be damaged. 2. Compress and extend the hydraulic cylinder slowly to bleed air. IMPORTANT • Do not relieve the main relief valve of the hydraulic cylinder at the end of stroke. When the cylinder is fully retracted

2. Charging refrigerant Charging refrigerant from high pressure side

CAUTION • Do not start the engine while charging the refrigerant gas from the high pressure side, as this may cause an explosion of the refrigerant service canister or charging hose.

When the cylinder is fully extended

1. Open the high pressure valve. 2. Open the service canister valve, and charge the refrigeration circuit with approximately 500 g of refrigerant. 3. When the low pressure gauge reaches approximately 0.10 MPa (1 kgf/cm2), close the high pressure valve and service canister valve. 4. Use a gas leak tester to check if the refrigerant is leaking. 5. If the refrigerant is not leaking, resume charging the refrigerant. NOTE • If there is leakage, repair it. Then discharge the refrigerant, and charge again from the beginning. 6. When stop charging, close the high pressure valve and service canister valve of the manifold gauge. NOTE • When replacing the refrigerant service canister, always press the valve core to release the air from the charging hose (yellow).

SVL97-2

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KiSC issued 09, 2021 A

CONCLUDING WORKING INSTRUCTIONS

2. GENERAL • If unable to charge with the specified amount of refrigerant, charge from the low pressure side.

Charging amount Refrigerant

600 to 700 g

IMPORTANT • Always use R134a refrigerant and compressor oil for R134a refrigerant.

(1) Service canister valve (2) High pressure valve

(3) Low pressure valve (a) Valve core

Charging refrigerant from low pressure side 1. Tightly close the high pressure valve of the manifold gauge. 2. Start the engine, and set the engine speed to approximately 1500 rpm. 3. Open all of the cabin windows, set the A/C switch [ON], set temperature adjustment to maximum cooling, and set the air flow switch to [Hi]. 4. Open the low pressure valve of the manifold gauge. 5. Open the service canister valve and charge the refrigeration cycle with the specified amount of refrigerant. 6. After charging of refrigerant is complete, close the low-pressure valve of the manifold gauge. 7. Close the service canister valve and stop the engine. 8. Check for any refrigerant leakage with the gas leak tester. NOTE • Always keep the service canister upward while charging. • When replacing the service canister, always press the valve core to release the air from the charging hose (yellow).

(1) Service canister valve (2) High pressure valve

2-18

(3) Low pressure valve (a) Valve core

SVL97-2 KiSC issued 09, 2021 A

TIGHTENING TORQUES 1. Bolts and nuts tightening torque

2. GENERAL

TIGHTENING TORQUES 1. Bolts and nuts tightening torque NOTE • Screws, bolts and nuts which tightening torques are not specified in this workshop manual should be tightened according to the table below. Mark on top of bolt

No grade or 4T

Mark on top of nut

No grade or 4T

Material

Steel

Aluminum

6T Steel

Aluminum

Steel

Units

N⋅m

kgf⋅m

lbf⋅ft

N⋅m

kgf⋅m

lbf⋅ft

N⋅m

kgf⋅m

lbf⋅ft

N⋅m

kgf⋅m

lbf⋅ft

N⋅m

kgf⋅m

lbf⋅ft

7.9 to 9.3

0.80 to 0.95

5.8 to 6.8

7.9 to 8.8

0.80 to 0.90

5.8 to 6.5

9.81 to 11.2

1.00 to 1.15

7.24 to 8.31

7.9 to 8.8

0.80 to 0.90

5.8 to 6.5

12.3 to 14.2

1.25 to 1.45

9.05 to 10.4

18 to 20

1.8 to 2.1

13 to 15 17 to 19

1.7 to 2.0

13 to 14 24 to 27

2.4 to 2.8

18 to 20 18 to 20

1.8 to 2.1

13 to 15 30 to 34

3.0 to 3.5

22 to 25

M10

40 to 45

4.0 to 4.6

29 to 33 32 to 34

3.2 to 3.5

24 to 25 48 to 55

4.9 to 5.7

36 to 41 40 to 44

4.0 to 4.5

29 to 32 61 to 70

6.2 to 7.2

45 to 52

M12

63 to 72

6.4 to 7.4

47 to 53

78 to 90

7.9 to 9.2

58 to 66 63 to 72

6.4 to 7.4

47 to 53

103 to 117

10.5 to 12.0

76.0 to 86.7

M14

108 to 125

11.0 to 12.8

79.6 to 92.5

124 to 147

12.6 to 15.0

91.2 to 108

167 to 196

17.0 to 20.0

123 to 144

M16

167 to 191

17.0 to 19.5

123 to 141

197 to 225

20.0 to 23.0

145 to 166

260 to 304

26.5 to 31.0

192 to 224

M18

246 to 284

25.0 to 29.0

181 to 209

275 to 318

28.0 to 32.5

203 to 235

344 to 402

35.0 to 41.0

254 to 296

M20

334 to 392

34.0 to 40.0

246 to 289

368 to 431

37.5 to 44.0

272 to 318

491 to 568

50.0 to 58.0

362 to 419

2. Stud bolts tightening torque Material

Steel

Aluminum

Units

N⋅m

kgf⋅m

lbf⋅ft

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

SVL97-2

2-19

KiSC issued 09, 2021 A

TIGHTENING TORQUES 3. Hydraulic hose fitting tightening torque

2. GENERAL

3. Hydraulic hose fitting tightening torque

4. Hydraulic hoses tightening torque (taper thread)

(1) Union nut

(1) Taper thread

Units

N⋅m

kgf⋅m

lbf⋅ft

Units

N⋅m

kgf⋅m

lbf⋅ft

1/8

7.8 to 11.8

0.8 to 1.2

5.8 to 8.7

1/8

19.6 to 29.4

2.0 to 3.0

14.5 to 21.6

1/4

24.5 to 29.2

2.5 to 3.0

18.1 to 21.5

1/4

36.6 to 44.1

3.7 to 4.5

27.0 to 32.5

3/8

37.2 to 42.1

3.8 to 4.3

27.5 to 31.0

3/8

68.6 to 73.5

7.0 to 7.5

50.6 to 54.2

1/2

58.8 to 63.7

6.0 to 6.5

43.4 to 46.9

1/2

83.4 to 88.3

8.5 to 9.0

61.6 to 65.1

3/4

117.6 to 127.4

12.0 to 13.0

86.7 to 94.0

3/4

166.6 to 181.3

17.0 to 18.5

122.9 to 133.7

181.3 to 191.1

18.5 to 19.5

133.8 to 140.9

1-1/4

220.5 to 230.3

22.5 to 23.5

162.8 to 170.0

Units

N⋅m

kgf⋅m

lbf⋅ft

9/16-18 (ORS type)

35.2 to 43.1

3.6 to 4.4

26.0 to 31.8

11/16-16 (ORS type)

60.0 to 73.5

6.0 to 7.5

44.3 to 54.2

13/16-16 (ORS type)

70.6 to 86.2

7.2 to 8.8

52.1 to 63.6

1-14 (ORS type)

105.8 to 129.4

10.8 to 13.2

78.0 to 98.4

5. Locknuts of adapters with Oring tightening torque (straight thread)

(1) Locknut (2) Seat

2-20

(3) Seal (O-ring)

SVL97-2 KiSC issued 09, 2021 A

TIGHTENING TORQUES 6. Adapters tightening torque (taper thread)

2. GENERAL

Units

N⋅m

kgf⋅m

lbf⋅ft

1/8

15.0 to 16.5

1.5 to 1.7

11.1 to 12.1

1/4

24.5 to 29.4

2.5 to 3.0

18.1 to 21.5

3/8

49.0 to 53.9

5.0 to 5.5

36.2 to 39.7

1/2

58.8 to 63.7

6.0 to 6.5

43.4 to 46.9

3/4, 1

117.6 to 127.4

12.0 to 13.0

86.74 to 93.96

1-1/4

220.5 to 230.3

22.5 to 23.5

162.7 to 169.8

7. Hose clamps tightening torque Steel band type

6. Adapters tightening torque (taper thread)

Units

N⋅m

kgf⋅m

lbf⋅ft

ϕ13-ϕ20

2.5 to 3.4

0.3 to 0.4

1.9 to 2.5

4.9 to 5.9

0.5 to 0.6

3.7 to 4.3

ϕ15-ϕ25 ϕ19-ϕ28 ϕ22-ϕ32 ϕ26-ϕ38 ϕ32-ϕ44

(1) Taper thread

ϕ44-ϕ56 Units

N⋅m

kgf⋅m

lbf⋅ft

ϕ50-ϕ65

1/8

19.6 to 29.4

2.0 to 3.0

14.5 to 21.6

ϕ58-ϕ75

1/4

36.3 to 44.1

3.7 to 4.5

27.0 to 32.5

ϕ60-ϕ80

3/8

68.6 to 73.5

7.0 to 7.5

50.6 to 54.2

ϕ68-ϕ85

1/2

83.4 to 88.3

8.5 to 9.0

61.6 to 65.1

ϕ77-ϕ95

3/4

166.6 to 181.3

17.0 to 18.5

122.9 to 133.7

Wire band type

Units

N⋅m

kgf⋅m

lbf⋅ft

ϕ10-ϕ14

2.5 to 3.4

0.3 to 0.4

1.9 to 2.5 (Continued)

SVL97-2

2-21

KiSC issued 09, 2021 A

TIGHTENING TORQUES

2. GENERAL Units

N⋅m

kgf⋅m

lbf⋅ft

2.5 to 3.4

0.3 to 0.4

1.9 to 2.5

3.9 to 4.9

0.4 to 0.5

2.9 to 3.6

2.5 to 3.4

0.3 to 0.4

1.9 to 2.5

ϕ12-ϕ16 ϕ19-ϕ25 ϕ31-ϕ40 ϕ36-ϕ46 ϕ44-ϕ53 ϕ51-ϕ59 ϕ86-ϕ96

2-22

SVL97-2 KiSC issued 09, 2021 A

GENERAL MACHINE INFORMATION 1. Machine identification

2. GENERAL

GENERAL MACHINE INFORMATION 1. Machine identification IMPORTANT • Before contacting the customer support, note the loader model, serial number, product identification number, engine type, engine serial number, and hour meter indication.

(A) Model name (B) Product identification number (PIN)

Product identification number (PIN)

(D) Serial number of the machine

NOTE • The serial number of SVL97-2 starts from 60001.

2. Engine identification IMPORTANT • When performing repairs or making inquiries, make a note of the engine model, serial number, and hour meter reading on the meter panel.

SVL97-2

2-23

KiSC issued 09, 2021 A

GENERAL MACHINE INFORMATION 3. DPF muffler identification

2. GENERAL

(1) Engine model and serial number

Letter or number

Year

Letter or number

Year

2003

2017

2004

2018

2005

2019

2006

2020

2007

2021

2008

2022

2009

2023

2010

2024

2011

2025

2012

2026

2013

2027

2014

Month manufactured and lot number Month (2) D1703: Engine model (3) 7: Engine series (4) C: Year manufactured

(5) U: Month manufactured (6) 1237: Lot number (a) Engine serial no.

Engine serial no. A number used to identify the engine, that follows the engine model. Engine series Serial number or letters

Series

05 (include: WG)

SM (include: WG)

Air Cooled Gasoline

GZ, OC, AC, EA, E

EA, RK

03 (KET Production)

Lot number

January

A0001 to A9999

B0001-

February

C0001 to C9999

D0001-

March

E0001 to E9999

F0001-

April

G0001 to G9999

H0001-

May

J0001 to J9999

K0001-

June

L0001 to L9999

M0001-

July

N0001 to N9999

P0001-

August

Q0001 to Q9999

R0001-

September

S0001 to S9999

T0001-

October

U0001 to U9999

V0001-

November

W0001 to W9999

X0001-

December

Y0001 to Y9999

Z0001-

3. DPF muffler identification IMPORTANT • When servicing the DPF for cleaning, record the part number, serial number and catalyst part number on the form beforehand.

Year manufactured Letter or number

Year

Letter or number

Year

2001

2015

2002

2016 (Continued)

2-24

SVL97-2 KiSC issued 09, 2021 A

GENERAL MACHINE INFORMATION 4. DPF muffler model identification

2. GENERAL Year manufactured

(1) DPF muffler assembly part number and serial number

(2) B: Year manufactured (3) L: Month Manufactured (4) 0019: serial number

(a) DPF muffler assembly part number and serial number

Letter or number

Year

Letter 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 manufactured and lot number Month

(5) Body (DPF outlet) part number and serial number (6) Comp filter (DPF) part number and serial number

(7) Catalyst (DOC) part number and serial number

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

4. DPF muffler model identification IMPORTANT • Before replacing or disassembling the DPF or DOC, take a note of the part number and serial number.

SVL97-2

2-25

KiSC issued 09, 2021 A

GENERAL MACHINE INFORMATION 5. SCR parts numbers and serial numbers

2. GENERAL

(A) Muffler assembly part number and serial number (B) DPF muffler full assembly part number and serial number

Month

March

April

May

June

July

August

September

October

November

December

* Alphabetical letters "I" and "O" are not used.

Production day

(G) Production month (H) Production day

(E) Part number (F) Production year

Letter

DPF muffler serial number The DPF muffler serial number identifies the production year, month, and day. Production year

Number or letter

Day

Number or letter

Day

Number

Year

Number

Year

2010

2020

2011

2021

2012

2022

2013

2023

2014

2024

2015

2025

2016

2026

2017

2027

2018

2028

2019

2029

* Number are repeated 0 to 9.

Production month Letter

Month

January

February

* Alphabetical letters "I" and "O" are not used.

5. SCR parts numbers and serial numbers IMPORTANT • It is recommended to record the SCR muffler assy parts numbers and serial numbers beforehand.

(Continued)

2-26

SVL97-2 KiSC issued 09, 2021 A

GENERAL MACHINE INFORMATION 6. Injector code identification

(1) SCR muffler assy serial numbers

2. GENERAL

(2) SCR muffler assy parts numbers and serial numbers

6. Injector code identification IMPORTANT • When replacing the injector, take a note of the injector code of the replaced injector.

(A) Injector code

SVL97-2

2-27

KiSC issued 09, 2021 A

GENERAL MACHINE INFORMATION 7. Specifications

2. GENERAL

7. Specifications Specifications Type

Open Cab

Closed Cab

Operating weight including operator's weight

5125 kg (11299 lbs.)

5250 kg (11574 lbs.)

Type

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

Model name

V3800-TIEF4-L

Total displacement

3769 cc 230.0 cu.in

Engine

SAE J1995 gross

71.9 kW 96.4 HP

SAE J1349 net

64.9 kW 87.0 HP

Engine power

Rated speed

2400 rpm

Low idling speed

1150 rpm

Rated operating capacity

1451 kg 3200 lbs.

Tipping load

4147 kg 9143 lbs. Bucket

3611 kg 7961 lbs.

Lift arm

3058 kg 6742 lbs.

Fast

11.7 km/h 7.3 mph

Slow

8.0 km/h 5.0 mph

Breakout force Performance

Travel speed

31.0 kPa (0.32 kgf/cm2) [4.5 psi]

Ground pressure (With operator) Battery capacity

Max. displacement (Theoretical) AUX performance

12V RC: 160 min, CCA 900A Standard Flow

High-Flow

90 L/ min 24 US gal/ min

156 L/ min 41 US gal/ min

Max. pressure

24.5 MPa 250 kgf/ cm2 3553 psi

Fuel tank capacity

111 L 29.3 US gal

DEF/AdBlue tank capacity

13.0 L 3.4 US gal

NOTE • Specifications are based on the machine with the standard bucket. • Specifications are subject to change without notice.

2-28

SVL97-2 KiSC issued 09, 2021 A

GENERAL MACHINE INFORMATION 8. Machine dimensions

2. GENERAL

8. Machine dimensions

Dimensions (a)

Length of track on ground

1667 mm 65.6 in.

(b)

Track gauge

1512 mm 59.5 in.

(c)

Length w/o bucket

3137 mm 123.5 in.

(d)

Length w/bucket on ground

3929 mm 154.7 in.

(e)

Height to top of cab

2116 mm 83.3 in.

(f)

Bucket hinge pin height at max. lift

3264 mm 128.5 in.

(g)

Rollback angle at carry position

27°

(h)

Reach at max. lift and dump

1035 mm 40.7 in.

(j)

Ground clearance

293 mm 11.5 in.

(k)

Departure angle

31°

(m)

Max. dump angle

43°

(n)

Vehicle width

1962 mm 77.2 in.

(p)

Width with bucket

2061 mm 81.1 in.

(r)

Turning radius from center-machine rear

2587 mm 101.9 in.

SVL97-2

2-29

KiSC issued 09, 2021 A

2. GENERAL

2-30

GENERAL MACHINE INFORMATION

SVL97-2 KiSC issued 09, 2021 A

GENERAL ELECTRICAL INFORMATION 1. Electrical circuit general description

2. GENERAL

GENERAL ELECTRICAL INFORMATION 1. Electrical circuit general description 1.1 Electrical circuit diagram description

(a) Part name (b) Specification code

(e) Unit symbol (f) Pin name

(g) Pin number

1.2 Electrical circuit diagram unit symbol

(1) Variable (2) Nonlinear variable (3) Fixed setting (4) Step variable (5) Non-ionizing radiation (NIR) (6) Body GND (7) Thermistor (8) Resistor (9) Variable resistor (10) Potentiometer with sliding contact

SVL97-2

(11) Heating element (12) Capacitor (13) Electrolytic capacitor (14) Magnetic core inductance (15) PNP transistor (16) NPN transistor (17) Semiconductor diode (18) Light-emitting diode (LED) (19) Two-way breakdown diode (20) Coil (21) NO (normally open)

(22) Auto-resetting NC (normally closed) (23) Auto-resetting NO (normally open) (24) Relay coil (25) Fuse (26) Lamp (27) Buzzer (28) Horn (29) Speaker (30) AC voltage source

(31) Starter switch (32) STOP (33) RUN (34) START

2-31

KiSC issued 09, 2021 A

GENERAL ELECTRICAL INFORMATION 1. Electrical circuit general description

2. GENERAL

1.3 Electrical wiring color coding Wiring color

Color code

Wiring color

Color code

Black

Blue/Green

L/G

Green

Blue/Orange

L/O

Blue

Blue/Red

L/R

Pink

Blue/White

L/W

Red

Blue/Yellow

L/Y

White

Yellowish green/Blue

LG/L

Yellow

Yellowish green/Red

LG/R

Brown

Yellowish green/White

LG/W

Gray

Yellowish green/Yellow

LG/Y

Yellowish green

Orange/White

O/W

Orange

Pink/White

P/W

Light 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

W/B

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

2-32

(a) Electric wiring size (mm2) (b) Base color

• 1.25-Y/R 1.25 mm2 (electric wiring size) Y: Yellow (base color) R: Red (stripe color)

1.4 Electrical wiring clamp

(1) Anchor type (insert to the an- (4) Plug-in type (insert until it locks) chor) (A) Wire harness (2) Screw type (insert to the screw end) (3) Plug-in type (insert until it locks)

SVL97-2 KiSC issued 09, 2021 A

GENERAL ELECTRICAL INFORMATION 1. Electrical circuit general description

2. GENERAL

1.5 Bus description

2. Connector

Bus simplifies complex circuits with many branches.

2.1 Connector handling precaution IMPORTANT • When disconnecting a connector, grasp the connector to pull it out. Do not pull the wiring. • When disconnecting a locking type connector, release the lock and pull it out. • When removing the waterproof plastic cover of the connector, do not allow water to enter the connector. • Repair any connector terminal deformations. Ensure that there is no protruding, loose, or rusty wiring. • Ensure that the locking type connector is locked when inserted.

2.2 Connector diagram description Fewer than 10 pins Female

(A) Diagram with bus

(B) Diagram without bus

1.6 Composite terminal description Connects 2 or more terminals together to a device. (1) Non-waterproof

(2) Waterproof

• Numbers are arranged from the top right. • Number 1 is located on the top right. Male

(3) Non-waterproof

(4) Waterproofed

• Numbers are arranged from the top left. • Number 1 is located on the top left.

SVL97-2

2-33

KiSC issued 09, 2021 A

2. GENERAL

GENERAL ELECTRICAL INFORMATION 2. Connector

More than 11 pins Female

(1) Main ECU connector (female)

2-34

SVL97-2 KiSC issued 09, 2021 A

TRANSPORTING THE MACHINE 1. Loading and unloading the machine on a truck

2. GENERAL

TRANSPORTING THE MACHINE 1. Loading and unloading the machine on a truck DANGER • Do not use a wet loading ramp. The machine may fall from the loading ramp. • Do not make a turn or operate the front attachment while loading or unloading the machine. The machine may fall from the loading ramp. • Do not operate the machine with high speed while loading or unloading the machine. Preparing 1. Park the truck on the firm and level ground and stop the engine. 2. Set wheel stoppers.

(2) Support block (A) 4 times or more of the bed height

(B) Bed height

4. After loading the machine on the truck bed, lower the bucket to the bed. 5. Stop the engine and remove the key. 6. Tie down the machine at 4 tie-down points.

(1) Wheel stoppers

Loading 1. Set a ramp securely. 2. Set a support block under the loading ramp to prevent the front of the truck from being lifted by the machine weight. 3. Travel the machine backwards with low speed to load the machine. NOTE • Make sure to position the bucket not to hit the ground or loading ramp.

(3) Front tie-down points

(4) Rear tie-down points

7. Set wheel stoppers.

SVL97-2

2-35

KiSC issued 09, 2021 A

TRANSPORTING THE MACHINE 2. Towing the inoperable machine

2. GENERAL

(5) Nylon slings or chains

(6) Wheel stoppers

8. Keep the machine locked with the nylon slings or chains during transportation.

(1) HST motor

(2) Drain port

3. Remove the 8 bolts from the HST motor.

NOTE • Drive the truck carefully to prevent the machine from moving during transportation. Unloading 1. Start the engine. 2. Operate the machine forwards with low speed to unload the machine. NOTE • Make sure to position the bucket not to hit the ground or loading ramp. (3) Bolt (M6 × 25) ×8

2. Towing the inoperable machine

4. Remove the cover.

IMPORTANT Tow only with the rear tie down points. Do not tow for a long distance. Tow at walking speed. Use a tow chain or rope that is capable of towing an object 1.5 times heavier than the machine. • Towing should only be carried out by trained or licensed personnel. • • • •

1. Set wheel stoppers at the both sides, front and rear.

CAUTION • Since the machine can move freely after removing the sun gears of the HST motor, securely lock the tracks with wheel stoppers.

(4) Cover

5. Remove the 3 bolts to remove the plate.

2. Remove the drain plug to drain the gear oil from the HST motor.

2-36

SVL97-2 KiSC issued 09, 2021 A

TRANSPORTING THE MACHINE

(5) Bolt (M8 × 20) ×3

6. Remove the sun gear.

(6) Plate

2. GENERAL

(4) Cover

9. Repeat the above procedure on the HST motor on the opposite side. 10. Install 2 shackles to the rear tie down points and attach chain or rope to the shackles.

(7) Sun gear

7. Install the plate. (8) Shackle

(9) Rope

11. Tow the machine at walking speed.

(6) Plate

8. Install the cover. IMPORTANT • Install the sun gears and replenish the gear oil after towing.

SVL97-2

2-37

KiSC issued 09, 2021 A

2. GENERAL

2-38

TRANSPORTING THE MACHINE

SVL97-2 KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 1. Engine compression pressure measuring kit

2. GENERAL

SPECIAL JIGS AND TOOLS 1. Engine compression pressure measuring kit Diesel engine compression tester

(1) Pressure gauge

(2) Hose assembly

(3) L-joint

(4) Adapter

Adapter

SVL97-2

2-39

KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS

2. GENERAL

Dimension

2-40

(a)

ϕ3.0 mm drill ϕ0.12 in. drill

(b)

17.0 mm 0.67 in.

(c)

16.0 mm 0.63 in.

(d)

ϕ13.0 mm ϕ0.51 in.

(e)

ϕ9.5 mm ϕ0.37 in.

(f)

M8 × 1.0

(g)

ϕ6.50 to 6.70 mm ϕ0.256 to 0.263 in.

(h)

2.12 to 2.18 rad 121 to 125°

(i)

ϕ4.90 to 5.50 mm ϕ0.193 to 0.216 in.

(j)

0.52 rad 30°

(k)

5.0 mm 0.20 in.

(m)

1.0 rad 60°

(n)

1.0 mm 0.039 in.

(p)

17.0 mm 0.67 in.

(r)

47.0 mm 1.85 in.

(s)

15.0 mm 0.59 in.

(t)

10.0 mm 0.39 in.

(u)

100 mm 3.94 in.

(v)

65.0 mm 2.56 in.

(w)

190 mm 7.48 in.

C1.5

Chamfer 1.5 mm Chamfer 0.059 in.

Material

SS400

SVL97-2 KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 2. Shaft seal press-fit jig

2. GENERAL

2. Shaft seal press-fit jig

200 mm (7.874 in.)

Install a shaft seal to the HST pump with this jig.

182 mm (7.165 in.)

60.5 mm (2.382 in.)

ϕ25 mm (ϕ0.984 in.)

18 mm (0.709 in.)

ϕ17 mm (ϕ0.669 in.)

1 mm (0.0394 in.)

13 mm (0.512 in.)

6 mm (0.236 in.)

ϕ28 mm (ϕ1.102 in.)

ϕ34.5 mm (ϕ1.358 in.)

9 mm (0.354 in.)

ϕ17 mm (ϕ0.669 in.)

1 mm (0.0394 in.)

13 mm (0.512 in.)

8 mm (0.315 in.)

ϕ19 mm (ϕ0.748 in.)

ϕ24.5 mm (ϕ0.965 in.)

3.7 mm (0.146 in.)

ϕ17 mm (ϕ0.669 in.)

1 mm (0.0394 in.)

(a) 5° (b) 45° A

ϕ72 mm (ϕ2.853 in.)

ϕ35.5 mm +0.1, -0 (ϕ1.398 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.)

ϕ5 mm (ϕ0.197 in.)

ϕ50 mm (ϕ1.968 in.)

1 mm (0.0394 in.)

Material: S55C

3. Needle bearing insertion jig Install a needle bearing to the HST pump with this jig.

SVL97-2

2-41

KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 4. U-joint tightening jig

2. GENERAL

4. U-joint tightening jig Tighten an U-joint on the pilot control valve with this jig.

(1) Bushing (a) U-joint tightening jig detailed schematic

2-42

(b) Bushing detailed schematic (c) Assembled U-Joint

ϕ29 mm

ϕ26.5 mm

23.5 mm (nut width)

ϕ19 mm

13 mm

69 mm

54 mm

50 mm

46 mm

25 mm

17 mm

ϕ23 mm

ϕ27 mm

ϕ31 mm

Hole H6 mm

Axle 6 mm

ϕ16 mm

15.5 mm

0.5 mm × 15 mm

12.5 mm

9.5 mm

11.6 mm

6.5 mm

0.5 mm bevel

R 13 mm

R 5.8 mm

R 4.5 mm

SVL97-2 KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 5. Ring nut tightening jig

2. GENERAL

5. Ring nut tightening jig

ϕ25 mm (ϕ0.984 in.)

Tighten a ring nut of the HST motor with this jig.

ϕ200 mm (ϕ7.874 in.)

15 mm (0.591 in.)

110 mm (4.331 in.)

10 mm (0.394 in.)

95 mm (3.740 in.)

ϕ30 mm (ϕ1.181 in.)

M10×P1.25

1 mm (0.0394 in.)

5 mm (0.197 in.)

(1) Socket: P3SL29 (2) Material: SS400 (a) 4 equally spaced locations ×50

(b) Full circumference

100 mm (3.937 in.)

10 mm +2, 0 (0.394 in. +0.00787, 0)

4.5 mm (0.177 in.)

ϕ197 mm +0, -0.3 (ϕ7.756 in.+0, -0.0118)

ϕ191 mm (ϕ7.520 in.)

ϕ184.5 mm +0, -0.2 (ϕ7.26 in. +0, -0.00787)

13.5 mm (0.531 in.)

50 mm (1.968 in.)

1 mm (0.0394 in.)

6. Angular bearing press-fit jig (upper) Press-fit an angular bearing of the HST motor with this jig (upper side).

(1) Material: S45C-D (2) Material: SS400

SVL97-2

7. Angular bearing press-fit jig (lower) Press-fit an angular bearing of the HST motor with this jig (lower side).

(a) 6 equally spaced locations A

ϕ209.5 mm +0, -0.5 (ϕ8.248 in. +0, -0.0197)

ϕ203.5 mm (ϕ8.012 in.)

ϕ183 mm (ϕ7.205 in.)

75 mm (2.953 in.)

10 mm (0.394 in.)

3.2 mm (0.126 in.)

2 mm (0.0787 in.)

ϕ10.5 mm (ϕ0.413 in.)

1 mm (0.0394 in.)

(a) Full circumference

2-43

KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 8. Roller bearing press-fit jig

2. GENERAL

8. Roller bearing press-fit jig Press-fit a roller bearing into the shaft of the HST motor with this jig.

ϕ35 mm (ϕ1.378 in.)

130 mm (5.118 in.)

30 mm (1.181 in.)

ϕ31 mm (ϕ1.220 in.)

ϕ40.5 mm (ϕ1.594 in.)

ϕ45 mm (ϕ1.772 in.)

0.5 mm (0.0197 in.)

19.5 mm (0.768 in.)

20 mm (0.787 in.)

1 mm (0.0394 in.)

10. Floating seal insertion jig A

ϕ80 mm (ϕ3.150 in.)

ϕ62 mm +0.1, -0.05 (ϕ2.441 in.+0.00394, -0.00197)

ϕ35 mm (ϕ1.378 in.)

35 mm (1.378 in.)

10 mm (0.394 in.)

1 mm (0.0394 in.)

Install a floating seal to the HST motor with this jig. Floating seal insertion jig (pusher)

9. Oil seal press-fit jig Press-fit an oil seal of the HST motor with this jig.

2-44

ϕ240 mm (ϕ9.449 in.)

ϕ218.9 mm (ϕ8.618 in.)

ϕ186 mm (ϕ7.323 in.)

ϕ216 mm +0.2, -0 (ϕ8.504 in. +0.00787, -0)

ϕ218.9 mm +0.2, -0 (ϕ8.618 in. +0.00787, -0)

30 mm (1.181 in.)

10 mm (0.394 in.)

9.8 mm (0.386 in.)

C0.5

0.5 mm (0.0197 in.)

1 mm (0.0394 in.)

SVL97-2 KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 11. Inner race extraction jig Floating seal insertion jig (guide)

2. GENERAL A

47 mm (1.850 in.)

30 mm (1.181 in.)

71 mm (2.795 in.)

54 mm (2.126 in.)

8 mm (0.315 in.)

13 mm (0.512 in.)

M6 × 1

1 mm (0.0394 in.)

12. Ring gear disassembly jig Remove the ring gear of the HST motor with this jig. A

ϕ232.0 mm (ϕ9.134 in.)

ϕ195.8 mm (ϕ7.709 in.)

ϕ189.0 mm (ϕ7.441 in.)

ϕ197.3 mm (ϕ7.768 in.)

ϕ206.0 mm (ϕ8.110 in.)

20.0 mm (0.787 in.)

10.0 mm (0.394 in.)

6.0 mm (0.236 in.)

4.0 mm (0.157 in.)

6.5 mm (0.256 in.)

1.0 mm (0.0394 in.)

30 mm (1.181 in.)

11. Inner race extraction jig

10 mm (0.394 in.)

ϕ41 mm (ϕ1.614 in.)

Remove inner races of the HST pump with this jig.

ϕ20 mm (ϕ0.787 in.)

1 mm (0.0394 in.)

13. Seal ring insertion inner jig Install the seal ring of the hydraulic cylinder with this jig.

(1) Material: SS400

(2) t: 12 mm (0.472 in.)

(a) R20 to 30 (b) Paper puff finish 1.6

SVL97-2

2-45

KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 14. Seal ring insertion jig

2. GENERAL Lift arm cylinder/bucket cylinder A

ϕ75.7 mm ±0.25 (ϕ2.980 in. ±0.0098)

ϕ74.7 mm -0.3, -0 (ϕ2.941 in.+0.0118, -0)

ϕ65.7 mm (ϕ2.587 in.)

ϕ53 mm (ϕ2.087 in.)

82 mm (3.228 in.)

57.6 mm (2.268 in.)

25 mm (0.984 in.)

C0.5

0.5 mm (0.0197 in.)

R0.2

0.2 mm (0.00787 in.)

R0.3

0.3 mm (0.0118 in.)

1 mm (0.0394 in.)

R1.5

1.5 mm (0.0591 in.)

Material: S45C Surface processing: Hard chrome plating on full surface (hardness of HV800 or higher, thickness of 0.01 or more)

15. U-ring insertion inner jig Install the U-ring of the hydraulic cylinder with this jig.

(a) 30°

Lift arm cylinder A

53.5 mm (2.106 in.)

42 mm (1.654 in.)

14. Seal ring insertion jig

ϕ45 mm +0.050, -0.112 (ϕ1.772 in. +0.00197, -0.00441)

1 mm (0.0394 in.)

Install the seal ring of the hydraulic cylinder with this jig.

5 mm (0.197 in.)

Material: SGD400D Surface processing: MFZn8-D

Bucket cylinder

(a) 30°

(b) 1 to 3 mm

Lift arm cylinder/bucket cylinder A

ϕ77 mm ±0.2 (ϕ3.031 in. ±0.00787)

ϕ70 mm ±0.2 (ϕ2.756 in. ±0.00787)

ϕ74 mm ±0.2 (ϕ2.913 in. ±0.00787)

82 mm (3.228 in.)

20 mm (0.787 in.)

R0.2

0.2 mm (0.00787 in.)

59.5 mm (2.343 in.)

48 mm (1.890 in.)

ϕ40 mm +0.050, -0.112 (ϕ1.575 in. +0.00197, -0.00441)

1 mm (0.0394 in.)

5 mm (0.197 in.)

Material: SGD400D Surface processing: MFZn8-D

Material: Bakelite (threaded) Burrs, curl-ups, etc. must be completely removed.

2-46

SVL97-2 KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 16. U-ring insertion jig

16. U-ring insertion jig

2. GENERAL Bucket cylinder A

51.9 mm +0, -0.1 (2.043 in. +0, -0.00394)

48 mm +0.1, -0 (1.890 in. +0.00394, -0)

5 mm (0.197 in.)

30 mm (1.181 in.)

ϕ12 mm (ϕ0.472 in.)

18. Bushing punching jig

(a) 5 mm

Lift arm cylinder/bucket cylinder A

115 mm (4.528 in.)

10 mm (0.394 in.)

15 mm (0.591 in.)

ϕ53 mm (ϕ2.087 in.)

ϕ42.5 mm (ϕ1.673 in.)

2 mm (0.0787 in.)

1 mm (0.0394 in.)

5 mm (0.197 in.)

Material: Delrin

17. Wiper ring press-fit jig

Lift arm cylinder A

46.9 mm +0, -0.1 (1.846 in. +0, -0.00394)

32 mm (1.260 in.)

ϕ12 mm (ϕ0.472 in.)

Material: S45C-D

Bucket cylinder A

41.9 mm +0, -0.1 (1.650 in. +0, -0.00394)

38 mm (1.496 in.)

ϕ12 mm (ϕ0.472 in.)

Material: S45C-D

Lift arm cylinder A

56.9 mm +0, -0.1 (2.240 in. +0, -0.00394)

53 mm +0.1, -0 (2.087 in. +0.00394, -0)

5 mm (0.197 in.)

32 mm (1.260 in.)

ϕ12 mm (ϕ0.472 in.)

SVL97-2

2-47

KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 19. Bushing press-fit jig

2. GENERAL

19. Bushing press-fit jig

20. Handle

Lift arm cylinder

Lift arm cylinder/bucket cylinder

40 mm +0, -0.1 (1.575 in. +0, -0.00394)

ϕ30 mm (ϕ1.181 in.)

30 mm (1.181 in.)

M12 mm (M0.472 in.)

ϕ12 mm (ϕ0.472 in.)

100 mm (3.937 in.)

C0.3

0.3 mm (0.0118 in.)

20 mm (0.787 in.)

150 mm (5.906 in.)

3 mm (0.118 in.)

Material: S45C-D A

45 mm +0, -0.1 (1.772 in. +0, -0.00394)

30 mm (1.181 in.)

ϕ12 mm (ϕ0.472 in.)

C0.3

0.3 mm (0.0118 in.)

Material: S45C-D

21. Bearing press-in jig

Bucket cylinder A

40 mm +0, -0.1 (1.575 in. +0, -0.00394)

38 mm (1.496 in.)

ϕ12 mm (ϕ0.472 in.)

C0.3

0.3 mm (0.0118 in.)

Material: S45C-D A

45 mm +0, -0.1 (1.772 in. +0, -0.00394)

38 mm (1.496 in.)

ϕ12 mm (ϕ0.472 in.)

C0.3

0.3 mm (0.0118 in.)

60 mm (2.4 in.)

50 mm (2.0 in.)

ϕ14 mm (ϕ0.55 in.)

ϕ10 mm (ϕ0.39 in.)

Material: Resin

2-48

SVL97-2 KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 22. Piston pump dimension measuring jig

2. GENERAL

22. Piston pump dimension measuring jig Jig A

No.

Dimensions

ϕ150 mm (ϕ5.9 in)

ϕ72.2 mm (ϕ2.8 in)

52 mm (2.0 in)

87.9 mm (3.5 in)

80 mm (3.1 in)

7.9 mm (0.3 in)

40 mm (1.6 in)

62 mm (2.4 in)

ϕ52 mm (ϕ2.0 in)

ϕ113.6 mm (ϕ4.5 in)

ϕ129.8 mm (ϕ5.1 in)

No.

Dimensions

20 mm (0.8 in)

ϕ11 mm (ϕ0.4 in)

28 mm (1.1 in)

14 mm (0.6 in)

ϕ142 mm (ϕ5.6 in)

ϕ170 mm (ϕ6.7 in)

7 mm (0.3 in)

Jig C No.

Dimensions

ϕ71.5 mm (ϕ2.8 in)

57 mm (2.2 in)

14 mm (0.6 in)

43 mm (1.7 in)

ϕ40 mm (ϕ1.6 in)

Jig B

SVL97-2

2-49

KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 23. Piston ring correction jig

2. GENERAL Jig D

Lift arm cylinder/bucket cylinder

No.

Dimensions

ϕ51.7 mm (ϕ2.0 in)

22 mm (0.9 in)

14 mm (0.6 in)

23. Piston ring correction jig

(a) R20 to 30 (b) Paper puff finish 1.6

ϕ88 mm (ϕ3.465 in.)

ϕ87 mm (ϕ3.425 in.)

ϕ78 mm +0.1, -0 (ϕ3.071 in. +0.00394, -0)

ϕ75 mm +0.05, -0 (ϕ2.953 in. +0.00197, -0)

ϕ81.3 mm (ϕ3.201 in.)

88 mm (3.465 in.)

40 mm (1.575 in.)

33 mm (1.299 in.)

C0.5

0.5 mm (0.0197 in.)

1 mm (0.0394 in.)

2 mm (0.0787 in.)

Material: S45C Surface processing: Hard chrome plating on full surface (hardness of HV800 or higher, thickness of 0.01 or more)

24. Piston ring correction jig

(a) Paper buff finish 0.8a

(b) 5°

ϕ80 mm (ϕ3.150 in.)

ϕ63.5 mm +0.08, -0 (ϕ2.500 in. +0.00315, -0)

65 mm (2.559 in.)

35 mm (1.378 in.) laurette finish

15 mm (0.591 in.)

1 mm (0.0394 in.)

Material: S45C Hardening and tempering: HRC40 to 45

25. Manifold gauge Three functions for measuring the high and low pressure, vacuuming the refrigerant gas from the 2-50

SVL97-2 KiSC issued 09, 2021 A

SPECIAL JIGS AND TOOLS 26. Charging hoses

2. GENERAL

cooling circuit with a refrigerant gas vacuuming machine, and charging the refrigerant gas into the cooling circuit with a refrigerant gas canister.

27. Refrigerant gas vacuum machine

NOTE • Follow the manifold gauge manufacturer's manual for details when handling the manifold gauge.

Vacuums the refrigerant gas from the cooling circuit.

(1) Low pressure gauge (2) High pressure gauge (3) High pressure valve

IMPORTANT • Follow the refrigerant gas vacuum machine manufacturer's manual for details when handling the refrigerant gas vacuum machine.

(4) Air bleeding valve (5) Low pressure valve (1) Refrigerant gas vacuum machine

26. Charging hoses

28. Refrigerant gas leak tester

Three hoses which connect a manifold gauge to the cooling circuit, refrigerant gas vacuum machine or refrigerant gas canister.

Detects the leakage of the refrigerant gas.

(1) Red charging hose (to high pressure charging port) (2) Quick coupler (3) Yellow charging hose (to refrigerant gas vacuum machine or refrigerant gas canister)

NOTE • Follow the gas leak tester manufacturer's manual for details when handling the refrigerant gas leak tester.

(4) Blue charging hose (to low pressure charging port)

(1) Refrigerant gas leak tester

29. Refrigerant gas canister Charges refrigerant gas into the cooling circuit. NOTE the refrigerant gas canister • Follow manufacturer's manual when charging and storing. SVL97-2

2-51

KiSC issued 09, 2021 A

2. GENERAL

SPECIAL JIGS AND TOOLS

(1) Refrigerant gas canister

2-52

SVL97-2 KiSC issued 09, 2021 A

3. MAINTENANCE

KiSC issued 09, 2021 A

MAINTENANCE INTERVALS TABLE

3. MAINTENANCE

MAINTENANCE INTERVALS TABLE Hour meter indication No.

Check points

Measures

5 0

2 5 0

5 0 0

1 0 0 0

1 5 0 0

2 0 0 0

3 0 0 0

Intervals

Remarks

Reference

Coolant level *1

Check

Daily check

3-13

Fuel level *1

Check

Daily check

3-13

Engine oil level *1

Check

Daily check

3-14

DEF/AdBlue level

Check

Daily check

3-14

Hydraulic oil level *1*2

Check

Daily check

3-14

Lubrication point

Grease

Daily check

3-15

Radiator and oil cooler *1

Check

Daily check

3-15

Check

Daily check

3-16

Fan belt

Check

Daily check

3-16

Water separator

Drain

Daily check

3-16

Dust valve

Check

Daily check

3-17

Pre-cleaner

Check

Daily check

3-17

DPF muffler

Check

Daily check

3-18

Washer liquid level *1

Check

Daily check

3-18

Battery *1

Check

Daily check

3-18

Fuel tank cap

Clean

Daily check

3-21

Fuel tank

Drain

○

Every 50 h

3-23

Track tension

Check

○

Every 50 h

3-23

Air cleaner element *3

Clean

○

Every 50 h

Dust valve

Clean

○

Every 50 h

Air cleaner elements *3

Engine and engine electrical wire harnesses

Outer element

3-23 3-24

Outer element

Replace

○

Every 250 h

Inner element

Replace

○

Every 250 h

Radiator hoses and clamps *1

Check

○

Every 250 h

3-25

Fuel line *1*5

Check

○

Every 250 h

3-26

Intake air line *1

Check

○

Every 250 h

3-26

Main frame

Clean

○

Every 250 h

3-27

Fan belt *1

Adjust

○

Every 250 h

3-27

Engine oil

Replace

○

Every 500 h

3-29

Engine oil filter

Replace

○

Every 500 h

3-30

Water separator element *5

Replace

○

Every 500 h

3-31

Fuel filter *5

Replace

○

Every 500 h

3-25

3-31 (Continued)

SVL97-2

3-1

KiSC issued 09, 2021 A

3. MAINTENANCE Hour meter indication No.

Check points

Measures

5 0

2 5 0

5 0 0

1 0 0 0

1 5 0 0

2 0 0 0

3 0 0 0

Intervals

Remarks

Reference

HST motor gear oil

Replace

●

○

Every 500 h

3-32

Return filter

Replace

●

○

Every 500 h

3-32

Breather filter

Replace

○

Every 500 h

3-33

HST filter

Replace

○

Every 500 h

3-34

Front window roller [Closed cab specification only]

Clean

○

Every 500 h

3-34

Replace

○

Every 1000 h

3-37

Suction filter

Replace

○

Every 1000 h

3-37

Valve clearance

Adjust

○

Every 1000 h

3-38

Hydraulic oil

Replace

○

Every 1000 h

3-39

Injector

Check

○

Every 1500 h

3-41

Oil separator element

Replace

○

Every 1500 h

3-41

PCV valve

Check

○

Every 1500 h

EGR cooler

Check

○

Every 1500 h

DEF/AdBlue injector

Check

○

Every 1500 h

3-43

DEF/AdBlue hoses

Check

○

Every 1500 h

3-44

Starter motor

Check

○

Every 2000 h

3-45

Alternator

Check

○

Every 2000 h

3-45

EGR system

Check

○

Every 3000 h

3-47

Turbocharger *1

Check

○

Every 3000 h

3-48

DPF muffler *4

Clean

○

Every 3000 h

3-48

Filter in DEF/AdBlue pump

Replace

○

Every 3000 h

3-49

DEF/AdBlue injector

Check

○

Every 3000 h

3-49

Filter in DEF/AdBlue tank

Replace

○

Every 8000 h

3-53

Quality of DEF/AdBlue

Check

Every 3 months

3-55

Exhaust gas line *1

Check

Every 1 year

3-57

Intake air line *1

Check

Every 1 year

3-57

DPF muffler *4

Check

Every 1 year

3-57

EGR and EGR piping *1

Check

Every 1 year

3-58

CCV heater *1

Check

Every 1 year

3-58

Radiator hoses and clamps *1

Replace

Every 2 years

3-61

Fuel line *1*5

Replace

Every 2 years

3-61

Intake air line *1

Replace

Every 2 years

3-62

Coolant

Replace

Every 2 years

3-62

Oil separator rubber piping

Replace

Every 2 years

3-63

DPF differential pressure sensor *4 and rubber piping *1

Replace

Every 2 years

3-63

EGR cooler hose

Replace

Every 2 years

3-64

●

3-42 @

3-43

* The maintenance identified with ● must be carried out once the specified hours of operation after initial commissioning have been reached.

3-2

SVL97-2 KiSC issued 09, 2021 A

3. MAINTENANCE *1 Replace only if necessary. *2 When using a hydraulic breaker, change hydraulic oil and return filter according to the table on the operator's manual. *3 Clean and replace the air filter and the air cleaner element more frequently if used under dusty conditions. When the filter is very dirty due to dusty conditions, replace it. *4 Carry out this maintenance referring to "DPF HANDLING MANUAL (FOR COMPACT TRACK LOADER)". *5 Maintenance interval is half when using biodiesel fuel B6 to B20. (Maintenance interval is same as diesel fuel when using biodiesel fuel B0 to B5). •

IMPORTANT The items listed above (marked with @) are registered as emission-related critical parts by Kubota in the U.S.EPA non-road 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 refer to the warranty statement for detail.

Air conditioning Hour meter indication No.

Check points

Air conditioning belt *1

Air filters *3

Measures

5 0

2 5 0

Check

5 0 0

1 0 0 0

1 5 0 0

2 0 0 0

3 0 0 0

Intervals

Daily check

Remarks

Reference

3-65

Recirculation air filter

Clean

○

Every 250 h

Fresh air filter

Clean

○

Every 250 h

Condenser

Clean

○

Every 250 h

3-66

Air conditioning belt *1

Adjust

○

Every 250 h

3-67

Air filters *3

3-65

Recirculation air filter

Replace

○

Every 1000 h

Fresh air filter

Replace

○

Every 1000 h

Air conditioning and heater hoses

Check

Every 1 years

3-68

Air conditioning and heater hoses

Replace

Every 2 years

3-69

Refrigerant

Check

Perform maintenance as required

3-69

3-67

* The maintenance identified with ● must be carried out once the specified hours of operation after initial commissioning have been reached. *1 Replace only if necessary. *2 When using a hydraulic breaker, change hydraulic oil and return filter according to the table on the operator's manual. *3 Clean and replace the air filter and the air cleaner element more frequently if used under dusty conditions. When the filter is very dirty due to dusty conditions, replace it. *4 Carry out this maintenance referring to "DPF HANDLING MANUAL (FOR COMPACT TRACK LOADER)". *5 Maintenance interval is half when using biodiesel fuel B6 to B20. (Maintenance interval is same as diesel fuel when using biodiesel fuel B0 to B5). •

SVL97-2

3-3

KiSC issued 09, 2021 A

3. MAINTENANCE

3-4

SVL97-2 KiSC issued 09, 2021 A

LUBRICANT QUANTITY

3. MAINTENANCE

LUBRICANT QUANTITY Quantity

Remarks

Engine

11 L 2.9 U.S.gals

Including engine oil filter

Front idler

220 to 240 cc 13.4 to 14.6 in.3

Rear idler

125 to 135 cc 7.6 to 8.2 in.3

Track roller

170 cc 10.4 in.3

12.5 L 3.3 U.S.gals

Open cab

13 L 3.4 U.S.gals

Closed cab

Reserve tank

1.0 L 0.3 U.S.gals

At [FULL] mark

All hydraulic system

68.0 L 18.0 U.S.gals

Hydraulic oil tank

38.1 L 10.1 U.S.gals

At center of gauge

Fuel

Fuel tank

111 L 29.3 U.S.gals

Gear oil

HST motor

1.0 L 0.26 U.S.gals

DEF/AdBlue

13.0 L 3.4 U.S.gals

Refrigerant

Air conditioning system

650 to 700 g 1.4 to 1.5 lbs

Engine oil

Radiator Coolant

Hydraulic oil

SVL97-2

3-5

KiSC issued 09, 2021 A

3. MAINTENANCE

3-6

SVL97-2 KiSC issued 09, 2021 A

RECOMMENDED LUBRICANT

3. MAINTENANCE

RECOMMENDED LUBRICANT Recommendation

Engine oil

Ambient temperature conditions

Viscosity

Above 25 ℃ (77 ℉)

SAE 30 SAE 10W-30

0 to 25 ℃ (32 to 77 ℉)

SAE 20 SAE 10W-30

Below 0 ℃ (32 ℉)

SAE 10W SAE 10W-30

Grease

Filled at factory Quality standard

API CJ-4 or CK-4

Brand

Type

SHELL

Shell Alvania EP2

Note

Exxon Mobil

Mobilux EP2

Kubota

Hydraulic Fluid 46HD

KTC recommendation

Exxon Mobil

Mobil DTE 10 Excel 46

KCL recommendation

Hydraulic oil

Gear oil

All weather

SAE 90

API GL-4, GL-5

Above -5 ℃ (23 ℉)

ASTM D975 No.2-D S15

Below -5 ℃ (23 ℉)

ASTM D975 No.1-D S15

Use ultra low sulfur fuel [<0.0015% (15 ppm)]

Refrigerant

HFC-134a (R134a)

DEF/AdBlue

ISO 2241-1

Fuel

Engine oil and fuel grade Engine oil

API CJ-4 or CK-4

Fuel

Ultra low sulfur fuel < 0.0015% (15 ppm)

NOTE • Engine oil – Use the engine oil of suitable American-petroleum-institute (API) service classification and with proper SAE Engine oil standards according to the ambient temperatures. • Fuel – Use the ultra low sulfur diesel fuel only [below 0.0015% (15 ppm)] for the engine. – Cetane number of 45 is minimum. Cetane number greater than 50 is preferred, especially for temperature below -20 ℃ (-4 ℉) or elevations above 1500 m (5000 ft). – Diesel fuels conforming with EN 590 or ASTM D975 are recommended. – No.2-D is a distillate fuel with lower volatility for engines in industrial and heavy mobile service (SAE J313 JUN87). • Biodiesel fuel (BDF) – Allowable blended fuel is mineral oil diesel fuel blended with B100 (meaning, 100% BDF). The blended fuel ratio shall be less than 20% B100 and 80% or more diesel fuel. – Do not use BDF concentrations higher than 20% (namely, greater than B20). Engine performance and fuel consumption will be affected, and degradation of the fuel system components may occur. – Replace the fuel filter before using BDF.

SVL97-2

3-7

KiSC issued 09, 2021 A

3. MAINTENANCE IMPORTANT • If you use different fuel or engine oil, the cleaning efficiency of the DPF (3000 hours) will be reduced and the DPF longevity will be shorter than expected. Filters must trap fuel and lubricant sulfate additives (Zn, Pb, Na, K, Ca, Mg, Cu, Ba, P, etc.) as ash during combustion. You must control the fuel carefully to prevent the additives being mixed into fuel such as the fuel tank anti-oxidants, the water remover, the antifreeze, and so on.

3-8

SVL97-2 KiSC issued 09, 2021 A

HANDLING THE DEF/ADBLUE

3. MAINTENANCE

HANDLING THE DEF/ADBLUE About the DEF/AdBlue • The DEF/AdBlue, used as a reducing agent for the SCR system, is a 32.5% aqueous urea solution. • No qualification is needed for handling DEF/ AdBlue. In addition, DEF/AdBlue is not designated as a hazardous material. • Use DEF/AdBlue that conforms to ISO 22241. Handling the DEF/AdBlue

CAUTION • If DEF/AdBlue gets into your eyes, immediately rinse your eyes with a large amount of water for at least 15 minutes and consult a doctor. • Do not swallow DEF/AdBlue. If you have accidentally swallowed DEF/AdBlue, seek medical attention immediately. • If DEF/AdBlue gets on your skin, rinse immediately with water. In rare cases, DEF/ AdBlue may irritate the skin. • If DEF/AdBlue gets on your clothes or shoes, wash it off immediately. Simply wiping off or leaving DEF/AdBlue on clothes or shoes will leave a white residue. • If DEF/AdBlue gets heated due to a fire or the like, an irritating odor may be generated. • If you spill DEF/AdBlue, immediately rinse with clean water. If left untouched, DEF/AdBlue may rust metal parts or corrode painted surfaces. Also, resin and rubber parts may be deformed. • If you spill DEF/AdBlue, immediately rinse with clean water. If left untouched, DEF/AdBlue may rust metal parts or corrode painted surfaces. Also, resin and rubber parts may be deformed. Quality of the DEF/AdBlue IMPORTANT • If the DEF/AdBlue emits a strong ammonia odor, the quality of the fluid may have deteriorated. To check the quality of the DEF/AdBlue, check the odor of the DEF/AdBlue in the tank every 3 months. • If the DEF/AdBlue in the tank emits a strong ammonia odor, drain the all DEF/AdBlue. After draining the DEF/AdBlue, flush the inside of the tank with distilled water, then refill the tank with new or high-quality DEF/AdBlue. • When you do not use the machine for more than 3 months, drain the all DEF/AdBlue from the tank.

SVL97-2

• Purchasing DEF/AdBlue from a KUBOTA Dealer is recommended. The product is also available at gas stations, truck stops and specialty shops. Be sure to use an ISO 22241 compliant product. Using noncompliant products may lead to engine failure. • The appropriate environment for storing DEF/ AdBlue is between -5 ℃ to 30 ℃ (23 ℉ to 86 ℉). See the following table for more information about the storage life of DEF/AdBlue. Avoid storing in environments that exceed 30 ℃ (86 ℉) to avoid shortening the storage life of the DEF/AdBlue. • Do not dilute the DEF/AdBlue fluid. • DEF/AdBlue of deteriorated quality may cause a drop in engine output or an engine malfunction. Ambient temperature

Storage life

10 ℃ (50 ℉ ) or below

36 months

25 ℃ (77 ℉ ) or below

18 months

30 ℃ (86 ℉ ) or below

12 months

35 ℃ (95 ℉ ) or below

6 months

40 ℃ (104 ℉ ) or below

3 months

NOTE • If distilled water is not available for flushing the inside of the tank, rinse with clean water first, then rinse thoroughly with DEF/AdBlue again. Afterward, fill with new or high quality DEF/ AdBlue. • Be sure to turn the starter switch to [STOP] position when replacing the DEF/AdBlue. After stopping the engine • After stopping the engine, the SCR system automatically operates for up to about 25 minutes and returns DEF/AdBlue in the piping to the DEF/ AdBlue tank to prevent freezing and clogging. • The SCR system may generate operating sound after the engine has stopped, but this is not a malfunction. • Do not remove the battery terminal until the SCR system stops. This is to prevent damage to the system device. • Do not refill with DEF/AdBlue before the SCR system stops. Otherwise, DEF/AdBlue may overflow from the breather hose of the DEF/AdBlue tank.

3-9

KiSC issued 09, 2021 A

HANDLING THE DEF/ADBLUE 1. Checking, draining and refilling the DEF/AdBlue

3. MAINTENANCE

1. Checking, draining and refilling the DEF/AdBlue Checking NOTE • When the DEF/AdBlue level is low, the engine output is limited by about 50%. If operation is continued, the engine will be limited to idling.

(3) Drain cover

(1) DEF/AdBlue level gauge

(2) Low DEF/AdBlue level warning lamp

1. After starting the engine, check the remaining amount of DEF/AdBlue with the DEF/AdBlue gauge. 2. When the DEF/AdBlue level is low, the low DEF/ AdBlue level warning lamp turns on and the buzzer sounds. Draining IMPORTANT • Do not run the engine when the DEF/AdBlue tank is empty. • Do not use a power tool when reinstalling the drain plug. • When draining and refilling the DEF/AdBlue in the DEF/AdBlue tank, if the refilled amount is less than the drained amount, an SCR system error “E:9518” will be displayed. • When the error code “E:9518” is displayed, run the engine for 10 minutes in order to clear the error code.

3-10

(4) Drain plug

1. Turn the key switch to [STOP] position. 2. Remove the drain cover and the drain plug to drain the DEF/AdBlue. 3. Install the drain plug. Tightening torque (4) Drain plug

4.0 to 6.0 N⋅m 0.41 to 0.61 kgf⋅m 2.95 to 4.43 lbf⋅ft

Refilling IMPORTANT • Do not refill the DEF/AdBlue before the SCR system stops. • After stopping the engine, the SCR system continues to operate for up to about 25 minutes.

SVL97-2 KiSC issued 09, 2021 A

HANDLING THE DEF/ADBLUE

3. MAINTENANCE

(5) DEF/AdBlue tank cap (Blue tank cap)

1. Turn the key switch to [STOP] position. 2. Clean the area around the nozzle and supply port to prevent foreign matter such as soil and dust from entering. 3. Wait until the SCR system stops. 4. Refill the DEF/AdBlue to the DEF/AdBlue tank.

SVL97-2

3-11

KiSC issued 09, 2021 A

3. MAINTENANCE

3-12

HANDLING THE DEF/ADBLUE

SVL97-2 KiSC issued 09, 2021 A

DAILY CHECK 1. Checking the coolant level

3. MAINTENANCE

DAILY CHECK 1. Checking the coolant level Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

2. Checking the fuel level WARNING • Keep fire and flammable items away from the working area.

Checking 1. Check that the coolant level is between [FULL] and [LOW].

IMPORTANT • If the fuel is empty, do not start the engine to avoid mixing of the air into the fuel system. • Fully replenish the fuel into the fuel tank before parking overnight to prevent condensation in the fuel tank. • Do not add DEF/AdBlue to the fuel tank. Also, do not add diesel fuel to the DEF/AdBlue tank.

NOTE • Check the coolant level in the reserve tank after the engine has cooled down.

Preparing 1. Lower the front attachment to the ground, and stop the engine.

CAUTION • Check that the rear bonnet is securely locked.

Checking 1. Turn the starter switch to [RUN]. 2. Check the fuel level on the meter panel.

(1) Reserve tank (A) [FULL]

(B) [LOW]

2. Replenish the coolant into the reserve tank if necessary. IMPORTANT • Do not replenish the coolant exceeding [FULL]. • Do not mix the coolant with dirty or salt water. • In the case that the coolant level decreases soon after replenishing, there is a possibility of cooling system leakage. Repair the cooling system before starting the engine.

SVL97-2

(1) Fuel gauge (A) Full

(B) Empty

3. Replenish the fuel if necessary. Recommended oil Above -5 ℃ (23 ℉)

ASTM D975 No.2-D S15

Below -5 ℃ (23 ℉)

ASTM D975 No.1-D S15

Diesel fuel

3-13

KiSC issued 09, 2021 A

DAILY CHECK 3. Checking the engine oil level

3. MAINTENANCE

3. Checking the engine oil level IMPORTANT • If the oil level is too high or too low, the engine may be damaged during operation. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. Checking 1. Pull the engine oil gauge out of the engine and wipe the engine oil off.

4. Checking the DEF/AdBlue level NOTE • When the DEF/AdBlue level is low, the engine output is limited by about 50%. If operation is continued, the engine will be limited to idling. Preparing 1. Lower the front attachment to the ground, and stop the engine. Checking 1. After starting the engine, check the remaining amount of DEF/AdBlue with the DEF/AdBlue gauge. 2. When the DEF/AdBlue level is low, the low DEF/ AdBlue level warning lamp turns on and the buzzer sounds.

NOTE • Check the engine oil level 5 minutes after stopping the engine. 2. Fully insert the engine oil gauge into the dipstick port. 3. Pull the engine oil dipstick out of the engine again and check the engine oil level.

(1) DEF/AdBlue level gauge (A) Full (2) Low DEF/AdBlue level warn- (B) Empty ing lamp

5. Checking the hydraulic oil level (1) Oil filler port (2) Dipstick

(A) Correct oil level range

1. Operate the machine to the hydraulic oil checking position (lower the front attachment or quick hitch to the ground, and stop the engine).

4. Replenish the engine oil if necessary. Recommended oil

Engine oil

3-14

Above 25 ℃ (77 ℉)

API CJ-4 or CK-4 SAE 30 SAE 10W-30

0 to 25 ℃ (32 to 77 ℉)

API CJ-4 or CK-4 SAE 20 SAE 10W-30

Under 0 ℃ (32 ℉)

API CJ-4 or CK-4 SAE 10W SAE 10W-30

SVL97-2 KiSC issued 09, 2021 A

DAILY CHECK 6. Greasing the lubrication point 2. Check the hydraulic oil level with the level gauge while the temperature of the hydraulic oil is between 10 to 30 ℃ (50 to 86 ℉). NOTE • Make sure that the oil level is in between half and three-quarters on the level gauge.

(1) Hydraulic oil gauge

3. Replenish the hydraulic oil if necessary. IMPORTANT • Clean the surface of the hydraulic oil tank around the oil filler port before replenishing the hydraulic oil to avoid dust contamination. • Do not use or mix different oil.

3. MAINTENANCE Greasing 1. Grease each grease fitting. NOTE • Clean around the grease fittings before and after greasing. Lubrication points

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

Lift arm linkage Link 1 Bucket link pin Control link Lift arm cylinder boss

(6) Bucket cylinder boss (7) Quick hitch pin [A] Quick hitch model

Number of lubrication point (1) Lift arm linkage

(2) Link 1

(3) Bucket link pin

(4) Control link

(5) Lift arm cylinder boss

(6) Bucket cylinder boss

(7) Quick hitch pin

Total

7. Checking the radiator and oil cooler (2) Hydraulic oil tank cap

6. Greasing the lubrication point IMPORTANT • Grease the machine before working. • In the case of working the machine in water, grease again after finish working. Preparing 1. Lower the front attachment to the ground, and stop the engine.

SVL97-2

CAUTION • Wear eye protector when cleaning the radiator and oil cooler with compressed air. • Do not work soon after the engine has stopped. – Engine, fuel, muffler, radiator, and oil are extremely hot. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

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KiSC issued 09, 2021 A

3. MAINTENANCE

CAUTION • Check that the rear bonnet is securely locked. Checking 1. Check if the fins and ribs of the radiator and oil cooler are clogged.

DAILY CHECK 8. Checking the engine and electrical wiring Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator. Checking 1. Check the fan belt for crack and damage and replace it if necessary. 2. Push position (a) to check the fan belt tension.

(1) Radiator and oil cooler

2. Remove the dirt with compressed air if necessary. IMPORTANT • Pressure of compressed air must be under 205 kPa (2.1 kgf/cm2, 30 psi). 3. Check the radiator and oil cooler for damage and replace them if necessary. 4. Check the rubber hoses and replace them if necessary. 5. Check the bolts that fix the hose clamps for any looseness and tighten them if necessary.

(4) Alternator (5) Fan belt

(1) Bolt (2) Bolt (3) Adjuster bolt

3. Adjust the fan belt tension if necessary. Service specification

8. Checking the engine and electrical wiring 1. 2. 3. 4.

Check the function of the room light. Check the function of the worklight. Check the function of the blower motor. Check the tightness and condition of all accessible electrical wiring and connectors. 5. Repair or replace the damaged parts. 6. Check for the rust and dirt of the fuses and clean if necessary.

9. Checking the fan belt CAUTION • Stop the engine, remove the key, and hang a DO NOT OPERATE tag near the operator's seat when checking or adjusting the fan belt and air conditioning belt.

3-16

(a) Fan belt tension

4.0 to 5.0 mm 0.16 to 0.20 in.

Push with 50 to 60 N Push with 5 to 6 kgf Push with 11.0 to 13.5 lbf

10. Draining the water separator WARNING • Keep fire and flammable items away from the working area. IMPORTANT • Keep dust away from the working area. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

SVL97-2 KiSC issued 09, 2021 A

DAILY CHECK 11. Checking the dust valve

3. MAINTENANCE

CAUTION • Check that the rear bonnet is securely locked. Draining 1. Disconnect the water level sensor connector. 2. Turn the water separator lever to close the water separator. 3. Put a tray under the drain hose to receive the fuel. 4. Loosen the drain plug and drain the water. NOTE • Clean the cup with fuel if necessary.

(1) Dust valve

2. The dust valve can be removed to clean inside if necessary.

12. Checking the pre-cleaner IMPORTANT • If the engine runs with the pre-cleaner clogged with dust, the engine output may decrease or the engine oil may be consumed or degraded abnormally, resulting in engine trouble. • Ensure that no oil enters the dust collector. Otherwise, engine trouble may result. (1) (2) (3) (4) (5) (6)

Screw Cup Water separator lever Float Drain plug Water level sensor connector

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

Hose Close Open Loosen Tighten

5. Open the water separator lever. 6. Bleed the air from the fuel line. NOTE • Bleed the air for about 10 seconds after turning the starter switch to [RUN].

11. Checking the dust valve Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

Preparing 1. Lower the front attachment to the ground, and stop the engine. Checking 1. Check to see if the clamp is loose. If loose, retighten it up. 2. Check the appearance of the pre-cleaner for noticeable damage or cracks. In such a case, replace the pre-cleaner with new one. 3. Check to see if the pre-cleaner's suction and discharge ports are blocked with foreign matters. If so, remove such matters. 4. Check around the pre-cleaner for sand, mud, dust, snow and such deposits. Remove them as required.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. Checking 1. Open the dust valve to remove dust and dirt inside of the dust valve.

SVL97-2

3-17

KiSC issued 09, 2021 A

DAILY CHECK 13. Checking the DPF muffler

3. MAINTENANCE

NOTE • When replacing the DPF, sign up the code to KiSS.

14. Checking the washer liquid level (closed cab specification) Preparing 1. Lower the front attachment to the ground, and stop the engine. (1) Pre-cleaner (2) Clamp (A) Suction port

(B) Discharge port

13. Checking the DPF muffler

Checking 1. Check the washer liquid level. IMPORTANT • Do not turn on the washer motor when the washer tank is empty to avoid damaging the washer motor. 2. Replenish the washer tank if necessary.

CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, muffler, and oil are extremely hot. – Pressure in the engine oil line is high. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. Checking 1. Check if nothing flammable is deposited around the DPF muffler.

(1) Washer tank

Liquid quantity Washer liquid

0.8 L 0.2 U.S.gals

15. Checking the battery condition DANGER • In the case that the electrolyte level is below the lower level line, do not use or charge the battery to avoid battery explosion.

WARNING

(1) DPF muffler

3-18

• Do not remove the vent caps while the engine is running. • Keep electrolyte away from your eyes, hands, and clothing. Sulfuric acid in battery electrolyte is poisonous and it can burn your skin and

SVL97-2 KiSC issued 09, 2021 A

DAILY CHECK

3. MAINTENANCE

clothing and cause blindness. If you spill electrolyte on yourself, rinse yourself with water and get medical aid immediately. • Do not use metal tools when cleaning battery terminals. It may cause short circuit. • Do not open a maintenance-free battery.

CAUTION • Keep a fire (welding sparks, grinding sparks, cigarettes) away from the battery. The battery produces oxygen and hydrogen gases which are flammable. • Disconnect the negative (-) terminal first when removing the battery cable. • Connect the positive (+) terminal first when connecting the battery cable. IMPORTANT • For maintenance-free batteries, check of the level and density of electrolyte is not required. Check the battery condition with the indicator and replace the battery if necessary. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked.

(3) Battery

(4) Indicator

Battery condition (indicator color) Green

Black

White

Normal

Needs charging

Needs replacing

NOTE • Follow the battery manufacturer's manual for details when checking the battery indicator. Checking the electrolyte level 1. Check if the electrolyte level is in between the upper and lower level lines. 2. Replenish distilled water if necessary. IMPORTANT • Do not add distilled water exceeding the upper level line.

Checking the battery terminals 1. Check the condition of the battery terminals.

(A) Upper level line

(B) Lower level line

Checking the electrolyte density (1) Negative (-) terminal (2) Positive (+) terminal

(3) Battery

2. Clean the battery terminal, and grease with petroleum jelly if necessary. Checking the battery indicator 1. Check the battery condition with the battery indicator.

SVL97-2

CAUTION • Wear protective gloves, work clothing, and eye protector to protect your skin and eyes from sulfuric acid in battery electrolyte. 1. Remove the vent caps from the battery.

3-19

KiSC issued 09, 2021 A

DAILY CHECK

3. MAINTENANCE 2. Measure the density of electrolyte with a refractometer and charge the battery if necessary.

2. Check the electrolyte density in the case that the battery voltage is lower than the service specification. IMPORTANT • Replace a maintenance-free battery in the case that the battery voltage is lower than 12 V. Charging the battery

CAUTION • Do not charge maintenance-free batteries. • Wear protective gloves, work clothing, and eye protector to protect your skin and eyes from sulfuric acid in battery electrolyte. • When working indoors, make sure to ventilate the work area. 1. Check the electrolyte level and replenish distilled water if necessary. 2. Disconnect the battery cables from the battery. 3. Remove the vent caps. 4. Connect the battery to the charger. NOTE • Follow the battery charger manufacturer's manual for details when charging the battery. (C) Electrolyte density (D) Discharge (E) Normal

(F) Charging is required

Normal

Above 1.20

Charging is required

Less than 1.20

3. Install the vent caps. Checking the battery voltage 1. Check the battery voltage with a voltage tester.

5. Charge the battery. IMPORTANT • Charge the battery in normal speed. • Charge the battery in fast speed only for emergencies because fast speed charge may shorten the battery life. 6. Check the electrolyte level after charging and replenish distilled water if necessary. 7. Install the vent caps. 8. Connect the battery cables. Handling precautions after stopping the engine After stopping the engine, the SCR system automatically operates for up to about 25 minutes and returns the DEF/AdBlue in the piping to the DEF/ AdBlue tank to prevent freezing and clogging. The SCR system may generate operating noise after the engine has stopped, but this is not a malfunction.

(1) Negative (-) terminal

(2) Positive (+) terminal

Battery voltage

Higher than 12 V

3-20

IMPORTANT • Do not remove the battery terminal until the SCR system stops. This is to prevent damage to the system device. • Do not refill with DEF/AdBlue before the SCR system stops. Otherwise, DEF/AdBlue may overflow from the breather hose of the DEF/ AdBlue tank.

SVL97-2 KiSC issued 09, 2021 A

DAILY CHECK 16. Checking the fuel tank cap

3. MAINTENANCE

16. Checking the fuel tank cap WARNING • Keep fire and flammable items away from the working area. IMPORTANT • If the fuel tank cap is dirty, there is a risk to deform the fuel tank. • When cleaning the fuel tank cap, be careful not to allow dust or dirt into the fuel tank. Preparing 1. Lower the front attachment to the ground, and stop the engine. Cleaning 1. Remove the fuel tank cap.

(1) Fuel tank cap

2. Remove dust and dirt off the back of the fuel tank cap.

(2) Fuel tank cap (Back side)

3. Install the fuel tank cap.

SVL97-2

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KiSC issued 09, 2021 A

3. MAINTENANCE

3-22

DAILY CHECK

SVL97-2 KiSC issued 09, 2021 A

EVERY 50 HOURS 1. Draining the water from the fuel tank

3. MAINTENANCE

EVERY 50 HOURS 1. Draining the water from the fuel tank WARNING • Keep fire and flammable items away from the working area. Preparing 1. Lower the front attachment to the ground, and stop the engine.

Preparing 1. Remove foreign objects such as stones caught between the tracks and sprockets, track rollers, or front idlers. 2. Jack up the machine. Checking the rubber track tension 1. Check the track tension under the second track roller.

Draining 1. Put a tray under the drain plug to receive the water mixed fuel. 2. Remove the 4 bolts to remove the cover. 3. Remove the drain plug and drain the water-mixed fuel from the fuel tank.

(1) Second track roller (2) Drive sprocket (3) Idler

(a) Tension dimension (A) Front side of the machine

Service specification (a)

(1) Cover (2) Drain plug

(3) Bolt (M12 × 30) ×4

2. Checking the track tension CAUTION • Place the machine on the jack stands securely when jacking up the machine. • Do not work underneath when the machine is jacked up. • Keep hands and body away from the rotating track. IMPORTANT • Wear amount is increased if the tracks are too tight or loose. • The tracks may be thrown if the tracks are too loose.

SVL97-2

20 to 30 mm 0.8 to 1.2 in.

3. Cleaning the outer element of the air cleaner CAUTION • Wear an eye protector when cleaning the outer element with compressed air. IMPORTANT • In the case of using the machine in extremely dusty conditions, check and clean or replace the outer element more frequently. • In the case the air cleaner warning lamp on the meter panel lights up, check and clean or replace the outer element. • Do not start the engine without installing the filter elements. Preparing 1. Lower the front attachment to the ground, and stop the engine. 3-23

KiSC issued 09, 2021 A

EVERY 50 HOURS 4. Cleaning the dust valve

3. MAINTENANCE 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. Checking and cleaning 1. Open the clips and remove the cover.

7. Install the outer element and cover. IMPORTANT • Install the cover so that the top mark faces upwards.

4. Cleaning the dust valve Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. Cleaning 1. Remove the dust cover. 2. From behind the dust cover, remove foreign matters from the dust valve. (1) (2) (3) (4)

Inner element Outer element Cover Clamps

(5) Dust valve (6) Air cleaner case

2. Remove the outer element from the air cleaner case. 3. Check the outer element for damage and dirt, and replace it if necessary. 4. Clean the outer element with compressed air.

IMPORTANT • Pressure of the compressed air must be under 205 kPa (2.1 kg/cm2, 30 psi). • Blow with compressed air from the inside of the element to the outside. • Do not use any kind of fluid to clean the outer element. 5. Clean the air cleaner case and cover without removing the inner element. 6. Clean the dust valve. 3-24

(1) Dust valve (2) Dust cover

(A) Clean from behind

3. The dust valve can be removed to clean inside if necessary.

SVL97-2 KiSC issued 09, 2021 A

EVERY 250 HOURS 1. Replacing the air filter elements of the air cleaner

3. MAINTENANCE

EVERY 250 HOURS 1. Replacing the air filter elements of the air cleaner

2. Checking the radiator hoses and clamps

IMPORTANT • In the case of using the machine in extremely dusty conditions, replace the outer element more frequently.

• Do not work soon after the engine has stopped. – Coolant is extremely hot.

Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. Replacing 1. Open the clip and remove the cover.

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

Inner element Outer element Cover Clamps

CAUTION

• Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator. Checking 1. Check the radiator hoses and replace them if necessary. 2. Check the bolts that fix the hose clamps for any looseness and tighten them if necessary.

(5) Dust valve (6) Air cleaner case

2. Remove the outer element and inner element from the air cleaner case. 3. Clean the air cleaner case and dust valve. 4. Install a new inner and outer elements. 5. Install the cover. IMPORTANT • Install the cover so that the top mark faces upwards.

SVL97-2

3-25

KiSC issued 09, 2021 A

EVERY 250 HOURS 3. Checking the fuel line

3. MAINTENANCE

(1) Fuel hose

4. Checking the intake air line CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot.

(1) Radiator hose

(2) Hose clamp

3. Checking the fuel line CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. Checking 1. Check the intake air hoses and replace them if necessary. 2. Check the bolts that fix the hose clamps for any looseness and tighten them if necessary.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator. Checking 1. Check the fuel hoses and replace them if necessary. 2. Check the tightness of the hose clamps and tighten them if necessary.

3-26

SVL97-2 KiSC issued 09, 2021 A

EVERY 250 HOURS 5. Cleaning the main frame

3. MAINTENANCE 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator. Adjusting 1. Loosen the 2 bolts and the adjuster bolt to adjust the tension of the fan belt. 2. Move the alternator to the direction of the wide arrow, and tighten the 2 bolts and the adjustment bolt. 3. Push position (a) to check the fan belt tension.

(1) Intake air hoses

(2) Hose clamps

5. Cleaning the main frame IMPORTANT • Do not wash the machine while the engine is running. • Do not spray water into the electrical wiring or the air cleaner.

(1) Bolt (2) Bolt (3) Adjustment bolt

Service specification

(a) Fan belt tension

Preparing 1. Lower the front attachment to the ground, and stop the engine. Cleaning 1. Open the plates of the bottom of the main frame. 2. Remove mud, leaves, and any debris from the inside of the main frame.

(4) Alternator (5) Fan belt

4.0 to 5.0 mm 0.16 to 0.20 in.

Push with 50 to 60 N Push with 5 to 6 kgf Push with 11.0 to 13.5 lbf

4. Start the engine and check that the fan belt does not slip. IMPORTANT • The warning lamp may be displayed if running the engine with a loose belt.

6. Adjusting the fan belt CAUTION • Stop the engine, remove the key, and hang a DO NOT OPERATE tag near the operator's seat when checking or adjusting the fan belt. Preparing 1. Lower the front attachment to the ground, and stop the engine.

SVL97-2

3-27

KiSC issued 09, 2021 A

3. MAINTENANCE

3-28

EVERY 250 HOURS

SVL97-2 KiSC issued 09, 2021 A

EVERY 500 HOURS 1. Replacing the engine oil

3. MAINTENANCE

EVERY 500 HOURS 1. Replacing the engine oil WARNING • Keep fire and flammable items away from the working area.

CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, muffler, and oil are extremely hot. – Pressure in the engine oil line is high. IMPORTANT • Keep dust away from the working area. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Jack up the machine. Replacing 1. Remove the 4 bolts to remove the cover.

(1) Cover

(2) Bolt (M12 × 30) ×4

(3) Drain plug

NOTE • Remove the filler cap to drain the engine oil faster. 4. Install the drain plug again. 5. Tighten the 4 bolts to install the cover. 6. Fill the engine oil from the oil filler port up to the maximum level of the engine oil dipstick.

(4) Engine oil dipstick (5) Oil filler port

(a) Correct oil level range

2. Put a tray under the drain plug to receive the engine oil. 3. Remove the drain plug and drain all oil.

SVL97-2

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KiSC issued 09, 2021 A

EVERY 500 HOURS 2. Replacing the engine oil filter

3. MAINTENANCE Recommended oil Above 25 ℃ (77 ℉) API CJ-4 or CK-4 SAE 30 SAE 10W-30

Engine oil

11 L 2.9 U.S.gals

0 to 25 ℃ (32 to 77 ℉) API CJ-4 or CK-4 SAE 20 SAE 10W-30 Below 0 ℃ (32 ℉) API CJ-4 or CK-4 SAE 10W SAE 10W-30

7. Start the engine in idling speed and leave it for 5 minutes. 8. Replenish the engine oil if necessary.

(1) Cover

(2) Bolt (M12 × 30) ×4

2. Put a tray under the engine oil filter to receive the engine oil. 3. Remove the engine oil filter with a filter wrench.

2. Replacing the engine oil filter WARNING • Keep fire and flammable items away from the working area.

CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, muffler, and oil are extremely hot. – Pressure in the engine oil line is high. (3) Engine oil filter

IMPORTANT • Keep dust away from the working area. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION

4. Apply engine oil to the O-ring and install a new engine oil filter by hand tightening. IMPORTANT • Do not tighten the engine oil filter strongly with a filter wrench. 5. Tighten the 2 bolts to install the cover. 6. Check the engine oil level with the engine oil dipstick.

• Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator. Replacing 1. Remove the 4 bolts to remove the cover.

(4) Engine oil dipstick (5) Oil filler port

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(a) Correct oil level range

SVL97-2 KiSC issued 09, 2021 A

EVERY 500 HOURS 3. Replacing the water separator element

3. MAINTENANCE

Recommended oil Above 25 ℃ (77 ℉) API CJ-4 or CK-4 SAE 30 SAE 10W-30

Engine oil

11 L 2.9 U.S.gals

0 to 25 ℃ (32 to 77 ℉) API CJ-4 or CK-4 SAE 20 SAE 10W-30 Below 0 ℃ (32 ℉) API CJ-4 or CK-4 SAE 10W SAE 10W-30

7. Start the engine in idling speed and leave it for 5 minutes. 8. Replenish the engine oil if necessary.

3. Replacing the water separator element WARNING • Keep fire and flammable items away from the working area. (1) (2) (3) (4) (5) (6) (7) (8)

Preparing 1. Park the machine on the firm and level ground, lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

6. Tighten the cup. 7. Open the water separator lever. 8. Bleed the air from the fuel line.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator. Replacing 1. Disconnect the water level sensor connector. 2. Close the water separator lever. 3. Put a tray under the drain hose to receive fuel. 4. Loosen the drain plug and drain the water. 5. Loosen the cup and replace the water separator element.

SVL97-2

Water separator Cup Water separator lever Float Drain plug Water level sensor connector Head cover Water separator element

(9) O-ring (10) Hose (A) Close (B) Open (C) Loosen (D) Tighten

IMPORTANT • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. • Keep dust away from the working area. • Do not re-use removed O-rings for assembly to avoid oil leakage.

4. Replacing the fuel filter WARNING • Keep fire and flammable items away from the working area.

CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. IMPORTANT • Keep dust away from the working area. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position. 3-31

KiSC issued 09, 2021 A

EVERY 500 HOURS 5. Replacing the HST motor gear oil

3. MAINTENANCE

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator. Replacing 1. Remove the fuel filter with a filter wrench.

(3) Oil filler port

(1) Oil check port (2) Drain port

(1) Fuel filter

2. Apply fuel to the O-ring and install a new fuel filter by hand tightening. IMPORTANT • Do not tighten the filter strongly with a filter wrench. 3. Turn the starter switch to [RUN] to bleed the air from the fuel line. IMPORTANT • Check for fuel leakage from the fuel filter. If there is any leakage, tighten the filter slightly with a filter wrench.

5. Replacing the HST motor gear oil IMPORTANT • Perform the initial replacement 250 hours after starting using this machine. • Keep dust away from the working area. 1. Travel the machine for a while to warm up the gear oil. NOTE • It is difficult to drain the gear oil in the case that the gear oil is cold. 2. Travel the machine on the firm and level the ground so that the drain port is in the bottom position.

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3. Lower the front attachment to the ground, and stop the engine. 4. Put a tray under the drain port to receive the gear oil. 5. Remove the oil filler plug. 6. Remove the oil check plug. 7. Remove the drain plug and drain all gear oil. 8. Install the drain plug with a new O-ring. 9. Replenish gear oil from the oil filler port. Recommended lubricant Gear oil

1.0 L 0.3 U.S.gals

API GL-4, GL-5 SAE 90

10. Check the oil level from the oil check port. 11. Install the oil filler plug and oil check plug with a new O-ring.

6. Replacing the return filter WARNING • Keep fire and flammable items away from the working area.

CAUTION • The hydraulic devices and oil are extremely hot. Handle with care before preparation, measurement, and restoration. IMPORTANT • Perform the initial replacement 250 hours after starting using this machine. • Keep dust away from the working area. • Do not reuse removed O-rings for assembly to avoid oil leakage. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Release the residual pressure.

SVL97-2 KiSC issued 09, 2021 A

EVERY 500 HOURS 7. Replacing the breather filter

3. MAINTENANCE

3. Install a vacuum pump to the hydraulic tank and vacuum the hydraulic tank. 4. Tilt up the cab. Replacing 1. Put a tray under the return filter to receive the hydraulic oil. 2. Remove the 2 bolts and the cover. 3. Remove the drain plug and drain the hydraulic oil.

9. Install the 4 bolts and the cover. 10. Install the drain plug again. 11. Install the 2 bolts and the cover. 12. Fill hydraulic oil from the oil filler port up to the center of the gauge. IMPORTANT • Clean the surface of the hydraulic oil tank around the oil filler port before replenishing the hydraulic oil to avoid dust contamination. • Do not use mixed or different oil. Recommended lubricant Hydraulic oil

(1) Drain plug (2) Bolt (M8 × 20) ×2

(3) Cover

4. Remove the 4 bolts and the cover. 5. Remove the 2 bolts and the filter stopper. 6. Remove the return filter.

35 L 9.3 U.S.gals

13. Start the engine and move the control lever to the end and hold it for approximately 5 minutes to bleed air in the hydraulic circuit. 14. Operate the machine to the hydraulic oil level check position. 15. Check the hydraulic oil level and replenish it if necessary.

7. Replacing the breather filter WARNING • Keep fire and flammable items away from the working area.

CAUTION • The hydraulic devices and oil are extremely hot. Handle with care before preparation, measurement, and restoration. IMPORTANT • Keep dust away from the working area. (4) (5) (6) (7)

Breather filter Bolt (M10 × 20) ×4 Cover Bolt (M8 × 20) ×4

(8) Return filter (9) Filter stopper (10) Suction filter

7. Install a new return filter. NOTE • Apply hydraulic oil to the gasket of the new return filter. • Do not tighten the filter strongly with a filter wrench.

Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Install a vacuum pump to the hydraulic tank and vacuum the hydraulic tank. 3. Tilt up the cab. Replacing 1. Remove the bolt to remove the cover.

Tightening torque (8) Return filter

50.0 to 70.0 N⋅m 5.1 to 7.1 kgf⋅m 36.9 to 51.6 lbf⋅ft

8. Install the 2 bolts and the filter stopper. SVL97-2

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KiSC issued 09, 2021 A

EVERY 500 HOURS 8. Replacing the HST filter

3. MAINTENANCE Tightening torque

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

(1) HST filter

4. Fill the hydraulic oil from the oil filler port up to the center of the gauge. IMPORTANT • Clean the surface of the hydraulic oil tank around the oil filler port before replenishing the hydraulic oil to avoid dust contamination. • Do not use mixed or different oil. (1) Bolt (M8 × 12) (2) Cover

(3) Breather filter

2. Remove the breather filter and replace with a new one. 3. Tighten the bolt to install the cover.

9. Cleaning the front window roller

8. Replacing the HST filter

Preparing 1. Remove the bolts on the lock assembly. 2. Remove the bolts on the bracket.

WARNING • Keep fire and flammable items away from the working area. IMPORTANT • Perform the initial replacement 50 hours after starting using this machine. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Install a vacuum pump to the hydraulic tank and vacuum the hydraulic tank. 3. Tilt up the cab. Replacing 1. Put a tray under the HST filter to receive oil. 2. Remove the HST filter with a wrench.

(1) Lock, assembly (2) Bracket (roller) (3) Bolt

(4) Bolt

Cleaning 1. Clean the roller on the bracket.

(1) HST filter

3. Apply hydraulic oil to the O-ring of a new HST filter and install it.

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SVL97-2 KiSC issued 09, 2021 A

EVERY 500 HOURS

3. MAINTENANCE Tightening torque (3), (4) Bolt

(2) Bracket (roller)

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

(5) Roller

Recovering 1. Install the bracket with the bolts. 2. Install the lock assembly pm the bracket.

(a) Gap

(6) Pin

IMPORTANT • When installing the bracket, adjust it so that the gap between the roller and the rail is 6.0 mm (0.04 in.). • After tightening the bolts, check and make sure the front window opens and closes smoothly. • When installing the lock assembly, open the front window and lock the pin.

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3. MAINTENANCE

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EVERY 500 HOURS

SVL97-2 KiSC issued 09, 2021 A

EVERY 1000 HOURS 1. Replacing the front window roller

3. MAINTENANCE

EVERY 1000 HOURS 1. Replacing the front window roller Preparing 1. Remove the bolts on the lock assembly. 2. Remove the bolts on the bracket.

(1) Lock, assembly (2) Bracket (roller) (3) Bolt

(4) Bolt

Replacing 1. Replace the roller on the bracket.

(a) Gap

(6) Pin

(5) Roller

Recovering 1. Install the bracket with the bolts. 2. Install the lock assembly pm the bracket.

(3), (4) Bolt

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

2. Replacing the suction filter WARNING • Keep fire and flammable items away from the working area.

SVL97-2

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EVERY 1000 HOURS 3. Adjusting the engine valve clearance

3. MAINTENANCE

6. Install a new suction filter.

CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, muffler, and oil are extremely hot. – Pressure in the engine oil line is high.

NOTE • Apply hydraulic oil to the gasket of the new suction filter. • Do not tighten the filter strongly with a filter wrench.

IMPORTANT • Keep dust away from the working area. • Do not re-use removed O-rings for assembly to avoid oil leakage.

Tightening torque

Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Release the residual pressure. 3. Install a vacuum pump to the hydraulic tank and vacuum the hydraulic tank. 4. Tilt up the cab.

7. Install the 4 bolts and the cover. 8. Install the drain plug again. 9. Install the 2 bolts and the cover. 10. Fill the hydraulic oil from the oil filler port up to the center of the gauge.

Replacing 1. Put a tray under the suction filter to receive the hydraulic oil. 2. Remove the 2 bolts and the cover. 3. Remove the drain plug and drain the hydraulic oil.

(6) Suction filter

30.0 to 50.0 N⋅m 3.1 to 5.1 kgf⋅m 22.1 to 36.9 lbf⋅ft

IMPORTANT • Clean the surface of the hydraulic oil tank around the oil filler port before replenishing the hydraulic oil to avoid dust contamination. • Do not use mixed or different oil. Recommended lubricant Hydraulic oil

35 L 9.3 U.S.gals

11. Start the engine, and move the control lever to the end and hold it for approximately 5 minutes to bleed air in the hydraulic circuit. 12. Operate the machine to the hydraulic oil level check position. 13. Check the hydraulic oil level and replenish it if necessary.

(1) Drain plug (2) Bolt (M8 × 20) ×2

(3) Cover

4. Remove the 4 bolts and the cover. 5. Remove the suction filter.

3. Adjusting the engine valve clearance WARNING • Keep fire and flammable items away from the working area.

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(6) Suction filter

SVL97-2 KiSC issued 09, 2021 A

EVERY 1000 HOURS 4. Replacing the hydraulic oil

3. MAINTENANCE

Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Remove the cabin. 3. Remove the HST pump. 4. Remove the radiator. 5. Remove the intercooler. 6. Remove the pre-cleaner and air cleaner. 7. Remove the upper bonnet. 8. Remove the SCR muffler. 9. Remove the engine. 10. Remove the DPF muffler from the engine. 11. Remove the EGR cooler pipe. 12. Remove the cylinder head cover.

Adjustable cylinder location of piston

When No. 1 piston is at compression top dead center

Inlet

Exhaust

✓

4 1 When No. 1 piston is at overlap position

✓

Adjusting 1. Align the 1TC mark line on the flywheel and projection on the housing.

(1) Adjusting screw

(2) Lock nut

4. Install the removed parts. 2. Make sure that the No. 1 piston comes to the compression or overlap top dead center. 3. Check the subsequent valve clearance at the mark [1TC] with a feeler gauge. Valve clearance (cold)

Service specification

0.23 to 0.27 mm 0.0091 to 0.010 in.

NOTE • If the clearance is out of the service specifications, adjust with the adjusting screw (1). • Tighten the lock nut (2) of the adjusting screw (1).

Tightening torque

Injector clamp nut

23.5 to 27.5 N⋅m 2.40 to 2.80 kgf⋅m 17.4 to 20.2 lbf⋅ft

Overflow pipe joint screw

9.80 to 11.3 N⋅m 1.00 to 1.15 kgf⋅m 7.23 to 8.33 lbf⋅ft

Cylinder head cover screw

9.80 to 11.3 N⋅m 1.00 to 1.15 kgf⋅m 7.23 to 8.33 lbf⋅ft

Injection pipe retaining nut

22.6 to 36.3 N⋅m 2.31 to 3.70 kgf⋅m 16.7 to 26.7 lbf⋅ft

SCR mounting screw

49.0 to 55.9 N⋅m 5.00 to 5.70 kgf⋅m 36.2 to 41.2 lbf⋅ft

4. Replacing the hydraulic oil WARNING • Keep fire and flammable items away from the working area.

CAUTION • Do not work soon after the engine has stopped.

SVL97-2

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EVERY 1000 HOURS

3. MAINTENANCE – Engine, fuel, muffler, and oil are extremely hot. – Pressure in the engine oil line is high. IMPORTANT • Keep dust away from the working area. • Do not re-use removed O-rings for assembly to avoid oil leakage. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Release the residual pressure. 3. Install a vacuum pump to the hydraulic tank and vacuum the hydraulic tank. 4. Tilt up the cab. Replacing 1. Put a tray under the suction filter to receive the hydraulic oil. 2. Remove the 2 bolts and the cover. 3. Remove the drain plug and drain the hydraulic oil.

(1) Drain plug (2) Bolt (M8 × 20) ×2

(4) Hydraulic oil tank cap

Recommended lubricant Hydraulic oil

35 L 9.3 U.S.gals

7. Start the engine, and move the control lever to the end and hold it for approximately 5 minutes to bleed air in the hydraulic circuit. 8. Operate the machine to the hydraulic oil level check position. 9. Check the hydraulic oil level and replenish it if necessary.

(3) Cover

4. Install the drain plug again. 5. Install the 2 bolts and the cover. 6. Fill the hydraulic oil from the filling port up to the center of the gauge. IMPORTANT • Clean the surface of the hydraulic oil tank around the oil filler port before replenishing the hydraulic oil to avoid dust contamination. • Do not use mixed or different oil.

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SVL97-2 KiSC issued 09, 2021 A

EVERY 1500 HOURS 1. Checking the injector

3. MAINTENANCE

EVERY 1500 HOURS 1. Checking the injector Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Connect Diagmaster to the machine. Checking 1. Turn the starter switch to [RUN] position. 2. Start Diagmaster and select [Active Test]. 3. Select [#1, 2, 3 and 4 Cylinder Injector Injection Stop], then click [Proceed].

NOTE • Confirm that the each injector is injecting normally. • If it is injecting normally, the engine vibration and noise will increase and engine speed will fluctuate when the injector is stopped.

(8) [Send Specified Active Test Value]

7. Click the [Finish Active Test]. (1) [Active Test] button (2) [#1, 2, 3 and 4 Cylinder Injector Injection Stop]

(3) [Proceed] button

4. Select [#1, 2, 3 and 4 Cylinder Injector Injection Stop] from the [Select signal group]. 5. Click [Start Active Test], then click the [OK].

(9) [Finish Active Test]

2. Replacing the oil separator element (4) [Start Active Test] (5) [OK] (6) [#1, 2, 3 and 4 Cylinder Injector Injection Stop]

(7) [Select signal group]

6. Click the [Send Specified Active Test Value].

SVL97-2

CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. – Pressure in the fuel line is high. • Keep fire and flammable items away from the working area.

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KiSC issued 09, 2021 A

EVERY 1500 HOURS 3. Checking the positive crankcase ventilation valve

3. MAINTENANCE IMPORTANT • Install plugs or covers to the removed fuel hoses, radiator hoses, and air conditioning hoses to avoid dust contamination. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Tilt the radiator and oil cooler. 4. Remove the upper bonnet. Replacing 1. Remove the cover and the oil separator element. 2. Wipe off oil and carbon inside the case with a waste cloth. 3. Install a new oil separator element and a O-ring. 4. Tighten the cover until it comes in contact with the body.

(1) Oil separator (2) Body (3) Element

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(4) O-ring (5) Cover

3. Checking the positive crankcase ventilation valve CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. – Pressure in the fuel line is high. • Keep fire and flammable items away from the working area. IMPORTANT • Install plugs or covers to the removed fuel hoses, radiator hoses, and air conditioning hoses to avoid dust contamination. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Remove the oil separator case from the machine. Checking 1. Disassemble the oil separator.

(1) Cover (2) O-ring (3) Oil separator element

(4) Oil separator case

2. Press the positive crankcase ventilation valve and check if the valve moves smoothly.

SVL97-2 KiSC issued 09, 2021 A

EVERY 1500 HOURS 4. Checking the EGR cooler

3. MAINTENANCE

NOTE • If the valve does not move smoothly, replace the oil separator.

(1) EGR cooler (A) Test hose ×2

(B) Plug

5. Replace the EGR cooler if air leakage is found.

5. Checking the DEF/AdBlue injector tip

4. Checking the EGR cooler CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. – Pressure in the fuel line is high. • Keep fire and flammable items away from the working area. IMPORTANT • Install plugs or covers to the disconnected hoses to avoid fuel or oil leakage and dust contamination. • Do not reuse the used gasket of the EGR cooler.

CAUTION • Do not work soon after the engine has stopped as the engine is extremely hot. IMPORTANT • Do not apply excessive force when removing the DEF/AdBlue injector from the mixing pipe. • Do not reuse the gasket and clamp of the DEF/ AdBlue injector. Replace them with new ones after checking.

Preparing 1. Remove the EGR cooler from the engine. Checking 1. Attach the 2 test hoses to the coolant inlet and outlet. 2. Plug the test hose of the coolant outlet side. 3. Put the EGR cooler in a water. 4. Apply air pressure from the air hose and check for air leakage. NOTE • The air pressure should (2.5 kgf/cm2, 36 psi).

250

kPa

(1) DEF/AdBlue injector (2) DEF/AdBlue injector clamp

(3) Gasket

Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Leave the machine for about 25 minutes. NOTE • The SCR system cools down the DEF/ Adblue line and purges the remaining DEF/ AdBlue after stopping the engine, and this SVL97-2

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KiSC issued 09, 2021 A

EVERY 1500 HOURS 6. Checking the DEF/AdBlue hoses

3. MAINTENANCE process takes maximum.

about

minutes

3. Remove the intercooler. 4. Remove the DEF/AdBlue injector from the muffler pipe. Checking 1. Check the muffler pipe where the DEF/AdBlue was installed for any deposits, and clean as needed. 2. Check the connector of the DEF/AdBlue injector for damage and rust. NOTE • If rust or damage is found, replace the part. 3. Check the DEF/AdBlue injector for corrosion or deformation. 4. Check the DEF/AdBlue injector tip for DEF/AdBlue deposit.

6. Checking the DEF/AdBlue hoses CAUTION • Do not work soon after the engine has stopped as the engine is extremely hot. Preparing 1. Lower the front attachment to the ground, and stop the engine. Checking 1. Check the DEF/Adblue hoses for crack, damage, loose and DEF/Adblue leakage.

IMPORTANT • Clean with a soft sponge and clean water as needed. • Do not damage the injector tip while cleaning. NOTE • DEF/AdBlue can be crystallized and deposit on the injector tip as below picture. • A few drop of water can dissolve the crystals.

(A) DEF/AdBlue crystal deposit

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

Suction hose Delivery hose Return hose DEF/AdBlue tank

(5) DEF/AdBlue pump (6) SCR muffler (7) DPF muffler

(B) Normal condition

Installing Tightening torque (2) DEF/AdBlue injector clamp

3-44

3.7 to 4.0 N⋅m 0.38 to 0.40 kgf⋅m 2.8 to 2.9 lbf⋅ft

SVL97-2 KiSC issued 09, 2021 A

EVERY 2000 HOURS 1. Checking the starter motor

3. MAINTENANCE

EVERY 2000 HOURS 1. Checking the starter motor WARNING • Do not clamp the electrical wiring to fuel hoses.

CAUTION • Do not modify the electrical devices or wiring. Preparing 1. Lower the front attachment to the ground, and stop the engine. Checking the starter motor 1. Start the engine to check the starter motor. 2. If the starter motor does not operate, see the engine WSM to repair or replace the starter motor.

(1) Negative (-) terminal

Battery voltage

(2) Positive (+) terminal Engine stopped

Engine running

12.0 V

Approximately 14.0 V

2. Checking the alternator WARNING • Do not remove the vent caps while the engine is running. • Keep electrolyte away from your eyes, hands, and clothing. Sulfuric acid in the battery electrolyte is poisonous and it can burn your skin and clothing and cause blindness. If you spill electrolyte on yourself, rinse with water and get medical aid immediately. • Do not use metal tools when cleaning battery terminals. It may cause short circuit.

CAUTION • Keep a fire (welding sparks, grinding sparks, cigarettes) away from the battery. The battery produces oxygen and hydrogen gases which are flammable. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Check the battery condition. Checking 1. Check the battery voltage with a multimeter in each case when the engine is running and when it is stopped.

SVL97-2

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3. MAINTENANCE

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EVERY 2000 HOURS

SVL97-2 KiSC issued 09, 2021 A

EVERY 3000 HOURS 1. Checking the EGR valve

3. MAINTENANCE

EVERY 3000 HOURS 1. Checking the EGR valve Preparing 1. Warm up the engine until the coolant temperature is over 65 ℃/149 ℉. NOTE • The EGR is actuated when the coolant is warmer than the above temperature. 2. Connect Diagmaster to the machine. Checking 1. Start Diagmaster, then click the [Active Test]. 2. Select the [Exhaust Gas Recirculation (EGR) Valve ON/OFF Function], then click the proceed button

(4) [Start Active Test] button (5) [OK] button (6) [EGR Valve ON/OFF Function]

(7) [Select signal group]

5. Click the [Send Specified Active Test Value].

(1) [Active Test] button (2) [Exhaust Gas Recirculation (EGR) Valve ON/OFF Function]

(3) Proceed button

3. Select the [EGR Valve ON/OFF Function] from the [Select signal group]. 4. Click the [Start Active Test], then click the [OK].

(9) [Send Specified Active Test Value]

NOTE • The EGR target position and actual position can be checked by this function. • Check if the actual position changes in accordance with the target position. • Clean the EGR internal component if the actual position does not change correctly. 6. Click the [Finish Active Test].

SVL97-2

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EVERY 3000 HOURS 2. Checking the turbocharger

3. MAINTENANCE

(10) [Finish Active Test] button

(7) Compressor cover

2. Checking the turbocharger

2. Check the intake air hose for loose connections or crack.

CAUTION • Do not work soon after the engine has stopped as the engine is extremely hot. IMPORTANT • Do not reuse the used gasket of turbocharger and the exhaust manifold.

the

Turbine side 1. Check the exhaust port and air inlet port side of the turbine housing for exhaust gas leakage.

NOTE • If loose connections or crack is found, tighten the clamp or replace the hose. Radial clearance 1. Check the radial clearance between turbine wheel and housing. NOTE • If the wheel touches the housing, replace the turbocharger assembly with a new one.

NOTE • If gas leakage is found, tighten the bolts and nuts or replace the gasket with a new one.

3. Replacing the DPF muffler (1) Turbine housing (2) Gasket (3) Exhaust port

(4) Gasket (5) Inlet port (6) Gasket

Replacing 1. Refer to "DPF HANDLING MANUAL (FOR COMPACT TRACK LOADER)" for disassemble process of the DPF muffler.

Compressor side 1. Check the inlet hose of the compressor cover for air leakage. NOTE • If air leakage is found, change the clamp or the inlet hoses. 3-48

SVL97-2 KiSC issued 09, 2021 A

EVERY 3000 HOURS 4. Replacing the DEF/AdBlue pump filter

3. MAINTENANCE Replacing 1. Remove the cap. 2. Replace the filter with new one.

(1) DPF

Assembling 1. Refer to "DPF HANDLING MANUAL (FOR COMPACT TRACK LOADER)" to assemble the DPF muffler. Concluding 1. Perform the following tasks on the Diagmaster. • “DPF Soot Load Reset” • “Auto Regeneration Inhibit Time Reset” • “DPF Regeneration Interval Time Reset” • “DPF Manual Regeneration Request Function” 2. Click the following check boxes, input the hour meter, serviced date, and sign up to the K-ISS. • “Input of Clean and Return” • “Cleaning Completed DPF Component”

4. Replacing the DEF/AdBlue pump filter WARNING • Dispose of the used DEF/AdBlue properly in accordance with local regulations.

CAUTION • Do not work soon after the engine has stopped as the engine is extremely hot. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Leave the machine for about 25 minutes.

(1) Cap

(2) Filter

Installing Tightening torque DEF/AdBlue filter

9.0 to 11.0 N⋅m 0.9 to 1.1 kgf⋅m 6.6 to 8.1 lbf⋅ft

DEF/AdBlue pump mounting bolt

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

ACU mounting bolt

9.8 to 11.3 N⋅m 1.0 to 1.2 kgf⋅m 7.2 to 8.3 lbf⋅ft

5. Checking the DEF/AdBlue injector CAUTION • Do not work soon after the engine has stopped as the engine is extremely hot. IMPORTANT • Do not apply excessive force when removing the DEF/AdBlue injector from the mixing pipe. • Do not reuse the used gasket and clamp of the DEF/AdBlue injector.

NOTE • The SCR system cools down the DEF/ Adblue line and purges the remaining DEF/ AdBlue after stopping the engine, and this process takes about 25 minutes as maximum. 3. Remove the DEF/AdBlue pump.

SVL97-2

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KiSC issued 09, 2021 A

EVERY 3000 HOURS

3. MAINTENANCE

(1) DEF/AdBlue injector (2) Clamp

(3) Gasket

Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Leave the machine for about 25 minutes. NOTE • The SCR cools down the DEF/Adblue line and purges the remaining DEF/AdBlue after stopping the engine, and this process takes about 25 minutes as maximum.

(7) [Start Active Test] button (8) [OK] button (9) [Duty 80%] (10) [#DEF Injector Pump Test (ACU)]

(11) [Select signal group]

6. Set a container to receive the DEF/Adblue injected from the injector. 7. Set a weight scale to measure the weight of DEF/ AdBlue injected from the injector.

3. Remove the DEF/AdBlue injector from the muffler pipe. 4. Connect Diagmaster to the machine. Checking 1. Start Diagmaster and select [Active Test]. 2. Select [Injector Injection Control Function (ACU)], then click [Proceed].

(1) DEF/AdBlue injector (12) Container

(13) Weight scale

8. Click the [Send Specified Active Test Value] button. NOTE • If the DEF/AdBlue is injected in corn shape evenly, the injector is normal condition.

(4) [Active Test] button (5) [Injector Injection Control Function (ACU)]

(6) [Proceed] button

3. Select [#DEF Injector Pump Test (ACU)] from the [Select signal group]. 4. Select the [Duty 80%] as the duty for the DEF injector from [Specified Value]. 5. Click [Start Active Test], then click the [OK].

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SVL97-2 KiSC issued 09, 2021 A

EVERY 3000 HOURS

3. MAINTENANCE

(14) [Send Specified Active Test Value] button

9. Measure the wight of the DEF/AdBlue injected from the injector. Service specification Weight of DEF/AdBlue

80 to 120 g 0.18 to 0.26 lbs

NOTE • If the weight of the DEF/AdBlue collected does not meet evaluation criteria, perform the following corrective actions. – If the DEF/AdBlue pressure is unstable: leaking in of air is a possibility, so check the connection status of the DEF/AdBlue tube. – If DEF/AdBlue pressure is low: replace the filter in the DEF/AdBlue tank and the filter in the DEF/AdBlue pump. – If DEF/AdBlue pressure is high: this may be caused by a plugged DEF/AdBlue injector, so replace the DEF/AdBlue injector. – If DEF/AdBlue injection amount is low: wash the DEF/AdBlue injector hole. Installing Tightening torque (2) Clamp

SVL97-2

3.7 to 4.0 N⋅m 0.38 to 0.40 kgf⋅m 2.8 to 2.9 lbf⋅ft

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KiSC issued 09, 2021 A

3. MAINTENANCE

3-52

EVERY 3000 HOURS

SVL97-2 KiSC issued 09, 2021 A

EVERY 8000 HOURS 1. Replacing the filter in the DEF/AdBlue tank

3. MAINTENANCE

EVERY 8000 HOURS 1. Replacing the filter in the DEF/AdBlue tank CAUTION • Do not work soon after the engine has stopped as the engine is extremely hot. Preparing 1. Tilt the radiator. 2. Remove the DEF/AdBlue header unit from the DEF/ AdBlue tank. Replacing 1. Replace the filter with a new one.

(1) Filter

SVL97-2

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KiSC issued 09, 2021 A

3. MAINTENANCE

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EVERY 8000 HOURS

SVL97-2 KiSC issued 09, 2021 A

EVERY 3 MONTHS 1. Checking quality of DEF/AdBlue

3. MAINTENANCE

EVERY 3 MONTHS 1. Checking quality of DEF/ AdBlue IMPORTANT • Do not run the engine when the DEF/AdBlue tank is empty. • Do not use a power tool when reinstalling the drain plug. • When draining and refilling the DEF/AdBlue in the DEF/AdBlue tank, if the refilled amount is less than the drained amount, an SCR system error “E:9518” will be displayed. • When the error code “E:9518” is displayed, run the engine for 10 minutes in order to clear the error code.

(3) Drain cover

Preparing 1. Lower the front attachment to the ground, and stop the engine. Checking 1. Turn the key switch to [STOP] position. 2. Open the cover and then remove the DEF/AdBlue tank cap (The cap is colored in blue).

(4) Drain plug

3. Install the drain plug. Tightening torque (4) Drain plug

(1) Cover

4.0 to 6.0 N⋅m 0.41 to 0.61 kgf⋅m 2.95 to 4.43 lbf⋅ft

(2) DEF/AdBlue tank cap

3. Check the odor of the DEF/AdBlue in the DEF/ AdBlue tank. IMPORTANT • If the DEF/AdBlue emits a strong ammonia odor, the quality of the fluid may have deteriorated. replace the DEF/AdBlue. Draining 1. Turn the key switch to [STOP] position. 2. Remove the drain cover and the drain plug to drain the DEF/AdBlue.

SVL97-2

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3. MAINTENANCE

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EVERY 3 MONTHS

SVL97-2 KiSC issued 09, 2021 A

EVERY 1 YEAR 1. Checking the exhaust gas line

3. MAINTENANCE

EVERY 1 YEAR 1. Checking the exhaust gas line CAUTION • Do not work soon after the engine has stopped as the engine is extremely hot. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator and oil cooler. Checking 1. Check the bolts and nuts for any looseness and tighten them if necessary. 2. Apply gas leak detection solution to the exhaust manifold. 3. Start the engine to check for exhaust gas leakage and replace the damaged parts or gaskets if necessary.

– Engine, fuel, and oil are extremely hot. – Pressure in the fuel line is high. Preparing 1. Lower the front attachment to the ground, and stop the engine. Checking 1. Make sure the 4 intake air hoses are securely connected. NOTE • If the hose is loose, insert the hose securely and tighten the hose clamp. 2. Apply gas leak detection solution to the 4 intake air hoses. 3. Start the engine to check for intake air leakage and replace the damaged parts if necessary. 4. Check the air flow sensor, intake air temperature sensor, and boost sensor, and replace them if necessary. 5. Check the bolts that fix the sensors for any looseness and tighten them if necessary. 6. Check the wire harnesses and replace them if necessary.

(1) Intake air hose ×4 (2) Air flow sensor (3) Boost sensor

(1) Exhaust manifold

2. Checking the intake air line CAUTION • Do not work soon after the engine has stopped.

SVL97-2

(4) Intake air temperature sensor

3. Checking the DPF muffler CAUTION • Do not work soon after the engine has stopped as the engine is extremely hot. Preparing 1. Open the rear bonnet and insert the pin into the lock position. 3-57

KiSC issued 09, 2021 A

EVERY 1 YEAR 4. Checking the EGR and EGR pipes

3. MAINTENANCE

CAUTION • Check that the rear bonnet is securely locked. 2. Open the upper bonnet. 3. Tilt the radiator and oil cooler. Checking 1. Check the DPF differential pressure pipe for crack, gas leakage and loose mounting nut. NOTE • If crack is found, change the DPF differential pressure pipe. • If gas leakage is found, remove the DPF differential pressure pipe and wipe off the anti-seize and lubricating compound. 2. Apply an anti-seize and lubricating compound again, then tighten the DPF differential pressure pipe to the specified torque. 3. Check the DPF differential pressure hose for crack and gas leakage. NOTE • If crack or gas leakage is found, change the DPF differential pressure pipe.

• Keep fire and flammable items away from the working area. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Tilt the radiator and oil cooler. Checking 1. Check the EGR cooler and EGR pipes for crack or gas leakage. NOTE • If crack is found, replace the EGR cooler. • If gas leakage is found, tighten the bolts or replace the gasket with a new one. 2. Start the engine to check for the exhaust gas leakage, and replace the damaged parts or gaskets if necessary.

(1) EGR cooler

(2) EGR pipe

(1) DPF differential pressure hose

5. Checking the CCV heater

(2) DPF differential pressure pipe (3) DPF differential pressure pipe

4. Checking the EGR and EGR pipes

CAUTION • Do not work soon after the engine has stopped as the engine is extremely hot. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. – Pressure in the fuel line is high. 3-58

SVL97-2 KiSC issued 09, 2021 A

EVERY 1 YEAR

3. MAINTENANCE

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. Checking 1. Turn the starter switch to the [RUN] position and leave it for 1 minute. 2. Turn the starter switch to the [STOP] position. 3. Touch the CCV heater cases. See the figure below for the touching area. NOTE • If the CCV heaters are working, the temperature inside the cases rise to approximately 70 ℃ (158 ℉), and the heater cases become warm. • In case that the CCV heater cases are not warm, do not start the engine in cold condition (below the freezing point).

(1) CCV heater

(A) Touch area

4. Check the CCV heaters for crack and gas leakage and replace them if necessary. For KTC (Kubota Tractor Corporation)

(1) CCV heaters

For KCL (Kubota Canada Ltd)

(1) CCV heaters

SVL97-2

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KiSC issued 09, 2021 A

3. MAINTENANCE

3-60

EVERY 1 YEAR

SVL97-2 KiSC issued 09, 2021 A

EVERY 2 YEARS 1. Replacing the radiator hoses and clamps

3. MAINTENANCE

EVERY 2 YEARS 1. Replacing the radiator hoses and clamps

Coolant quantity Open cab

12.5 L 3.3 U.S.gals

Closed cab

13 L 3.4 U.S.gals

Radiator

WARNING • Do not open the radiator cap soon after the engine has stopped. There is a possibility of serious burn injury due to the coolant blowing out from the radiator.

CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. Preparing 1. Park the machine on the firm and level ground, lower the bucket to the ground, and stop the engine. Replacing 1. Drain the coolant. 2. Replace the radiator hoses and hose clamps.

Reserve tank

50% antifreeze

1.0 L 0.26 U.S.gals

4. Start the engine in idle speed and leave it for 5 minutes. 5. Check for leakage of the coolant. 6. Check the coolant level.

2. Replacing the fuel line CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator. Replacing 1. Replace the fuel hoses.

(1) Fuel hose (1) Radiator hose

(2) Hose clamp

3. Replenish the new coolant. SVL97-2

2. Turn the starter switch to [RUN] to bleed the air from the fuel line. 3-61

KiSC issued 09, 2021 A

EVERY 2 YEARS 3. Replacing the intake air line

3. MAINTENANCE IMPORTANT • Check for fuel leakage from the fuel hoses. If there is any leakage, tighten the hose clamps.

3. Replacing the intake air line CAUTION • Do not work soon after the engine has stopped as the engine is extremely hot. IMPORTANT • Work at clean space with clean tools to avoid dust contamination. • Plug the engine and turbocharger after removing the hoses to avoid dust entry. Preparing 1. Lower the front attachment to the ground, and stop the engine. Replacing 1. Replace the hoses and hose clamps.

4. Changing the coolant CAUTION • Do not work soon after stopped the engine. – Engine, fuel, and oil are extremely hot. – Pressure in the fuel line is high. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. Changing 1. Tilt the radiator and oil cooler. 2. Set an oil pan under the drain plug. 3. Loosen the radiator cap and remove the drain plug to drain the coolant completely.

(1) Drain plug

(2) Radiator cap

4. Dispose of the coolant in the reserve tank.

(1) Hoses

(5) Hose clamps

(3) Reserve tank (A) [FULL]

(B) [LOW]

5. Clean the inside of the radiator with water.

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SVL97-2 KiSC issued 09, 2021 A

EVERY 2 YEARS 5. Replacing the oil separator hoses

3. MAINTENANCE

IMPORTANT • Do not apply excessive pressure to the radiator to avoid the radiator burst. The coolant pressure inside the radiator must be below 0.9 kgf/cm2. 6. Close the drain plug and fill up the radiator with coolant for flushing. 7. Install the radiator cap. 8. Start the engine and keep it idle to flush the coolant circuit.

2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Tilt the radiator and oil cooler. Replacing 1. Replace the 4 hoses and 8 hose clamps with new ones.

NOTE • Warm up the coolant until the thermostat opens. • In the case of the A/C specification, activate the heater. 9. Drain the coolant and fill the radiator with new coolant to flush again. 10. Repeat flushing several times until the drained coolant becomes clean. 11. Close the drain plug and fill up the radiator with new coolant. IMPORTANT • Do not fill the reserve tank with the coolant exceeding the [FULL] level. • Do not mix the coolant with dirty or salt water. • Do not operate the machine without coolant. Coolant quantity Open cab

12.5 L 3.3 U.S.gals

Closed cab

13 L 3.4 U.S.gals

Radiator

Reserve tank

50% antifreeze

1.0 L 0.26 U.S.gals

5. Replacing the oil separator hoses CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. • Keep fire and flammable items away from the working area. IMPORTANT • Install plugs or covers to the removed hoses to avoid dust contamination. Preparing 1. Lower the front attachment to the ground, and stop the engine.

SVL97-2

(1) Oil separator (2) Hose ×4 (3) Hose clamp ×8

(A) To the intake air line (B) From the engine

6. Replacing the DPF differential pressure sensor rubber hoses CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and coolant are extremely hot. – Pressure in the fuel line is high. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

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KiSC issued 09, 2021 A

EVERY 2 YEARS 7. Replacing the EGR cooler hose

3. MAINTENANCE

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. Replacing 1. Replace the 2 hoses and 4 clamps with new ones.

(1) Differential pressure sensor (2) Hose ×2

(3) Hose clamp ×4

7. Replacing the EGR cooler hose CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and coolant are extremely hot. – Pressure in the fuel line is high. Preparing 1. Lower the front attachment to the ground, and stop the engine. Replacing 1. Remove the 2 cooler hoses, 4 clamps and an Oring with new ones.

(1) EGR cooler (2) Cooler hose ×3 (3) Hose clamp ×4

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(4) O-ring

SVL97-2 KiSC issued 09, 2021 A

MAINTENANCE FOR A/C SPECIFICATION 1. Daily check

3. MAINTENANCE

MAINTENANCE FOR A/C SPECIFICATION 1. Daily check

Service specification

1.1 Checking the air conditioning belt

(a) Air conditioning belt tension

7.0 to 9.0 mm 0.27 to 0.35 in.

Push with 50 to 60 N Push with 5 to 6 kgf Push with 11.0 to 13.5 lbf

CAUTION • Stop the engine, remove the key, and hang a DO NOT OPERATE tag near the operator's seat when checking or adjusting the fan belt and air conditioning belt. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator. Checking 1. Check the fan belt for any crack and damage of the fan belt and replace it if necessary. 2. Push position (a) to check the air conditioning belt tension.

2. Every 250 hours 2.1 Cleaning the air filters CAUTION • Wear an eye protector when cleaning the air filter with compressed air. IMPORTANT • In the case of using the machine in extremely dusty conditions, check and clean or replace the air filter more frequently. • Do not hit the air filter. If the air filter becomes deformed, dust may enter into the air conditioning system, which may cause damage and malfunction of the machine. • Do not use gasoline, thinner, or similar chemicals to clean the air filter as they can damage the filter. Preparing 1. Lower the front attachment to the ground, and stop the engine. Cleaning 1. Remove the 2 screws to remove the inner air filter.

(1) Air conditioning belt (2) Tension pulley (3) Compressor

(4) Pulley (5) Tension bolt

3. Adjust the air conditioning belt tension if necessary. (1) Cover

(2) Screw ×2

2. Clean the inner air filter with compressed air from the direction opposite of the intake air flow.

SVL97-2

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MAINTENANCE FOR A/C SPECIFICATION 2. Every 250 hours

3. MAINTENANCE IMPORTANT • Pressure of the compressed air must be under 205 kPa (2.1 kg/cm2, 30 psi).

(A) Intake air flow

2.2 Checking the condenser

(A) Intake air flow

3. Install the inner air filter.

CAUTION • Wear an eye protector when cleaning the air filter with compressed air. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

CAUTION • Check that the rear bonnet is securely locked. (1) Cover (2) Screw ×2

(3) Air filter

3. Open the upper bonnet.

4. Remove the fresh air filer.

Checking 1. Check the condenser and clean it if necessary.

(4) Fresh air filter

(1) Condenser

5. Clean the inner air filter with compressed air from the direction opposite of the intake air flow. IMPORTANT • Pressure of the compressed air must be under 205 kPa (2.1 kg/cm2, 30 psi).

3-66

IMPORTANT Cleaning the condenser • Pressure of the compressed air must be under 20h5 kPa (2.1 kg/cm2, 30 psi).

SVL97-2 KiSC issued 09, 2021 A

MAINTENANCE FOR A/C SPECIFICATION 2. Every 250 hours

(1) Condenser

(A) Intake air flow

2.3 Adjusting the air conditioning belt CAUTION • Stop the engine, remove the key, and hang a DO NOT OPERATE tag near the operator's seat when checking or adjusting the fan belt. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

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

Air conditioning belt Tension pulley Compressor Pulley Tension bolt

(A) Deflection of the belt (B) Press the belt (C) Shift

5. Start the engine and check that the air conditioning belt does not slip. IMPORTANT • The inside of the cab may not be cooled down if running the engine with a loose belt.

3. Every 1000 hours 3.1 Replacing the air filters CAUTION • Wear an eye protector when cleaning the air filter with compressed air.

CAUTION • Check that the rear bonnet is securely locked. 3. Open the upper bonnet. 4. Tilt the radiator. Adjusting 1. Loosen the tension bolt to adjust the tension of the air conditioning belt. 2. Shift the tension pulley to adjust the tension. 3. Push position (B) to check the tension of the air conditioning belt. Service specification Air conditioning belt tension

3. MAINTENANCE

7.0 to 9.0 mm 0.27 to 0.35 in.

IMPORTANT • In the case of using the machine in extremely dusty conditions, check and clean or replace the air filter more frequently. Preparing 1. Lower the front attachment to the ground, and stop the engine. Replacing 1. Remove the 2 screws to replace the inner air filter with a new one.

Push with 50 to 60 N Push with 5 to 6 kgf Push with 11.0 to 13.5 lbf

4. Tighten the tension bolt.

SVL97-2

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KiSC issued 09, 2021 A

MAINTENANCE FOR A/C SPECIFICATION 4. Every 1 year

3. MAINTENANCE

4. Every 1 year 4.1 Checking the air conditioning and heater hoses CAUTION • Wear gloves, work clothing and eye protector to protect your skin and eyes. The liquid refrigerant may cause the frostbite hazard due to evaporation. • Keep fire and flammable items away from the working area. • Do not wash the cooling circuit with water. The residual water in the cooling circuit may cause corrosion.

(1) Cover (2) Screw ×2

(3) Air filter

NOTE • Do not damage the air filter to avoid dust contamination which may cause damage and malfunction of the air conditioning system.

IMPORTANT • Work at the clean and dry work space with clean and dry tools. • Install plugs to the disconnected hoses, pipes, and devices to avoid infiltration of the water and dust contamination. • Use the refrigerant and parts specified by R134a. Mixing with other refrigerants or using parts which are not specified by R134a may cause leakage, performance decrement, and so on. • Apply compressor oil to every O-ring to avoid damage when installing. Checking the air conditioning and heater hoses 1. Check the air conditioning hoses, and replace them if necessary.

2. Remove the fresh air filter to replace with a new one.

(1) Air conditioning hoses

(4) Fresh air filter

3-68

2. Check the heater pipes and hoses, and replace them if necessary.

SVL97-2 KiSC issued 09, 2021 A

MAINTENANCE FOR A/C SPECIFICATION 5. Every 2 years

(2) Heater hoses

Concluding 1. Charge the cooling circuit with the refrigerant. 2. Refill the radiator with the coolant.

3. MAINTENANCE

(1) Air conditioning hoses

2. Replace the heater hoses with new ones.

5. Every 2 years 5.1 Replacing the air conditioning and heater hoses CAUTION • Wear gloves, work clothing and eye protector to protect your skin and eyes. The liquid refrigerant may cause the frostbite hazard due to evaporation. • Keep fire and flammable items away from the working area. • Do not wash the cooling circuit with water. The residual water in the cooling circuit may cause corrosion. IMPORTANT • Work at the clean and dry work space with clean and dry tools. • Install plugs to the disconnected hoses, pipes, and devices to avoid infiltration of the water and dust contamination. • Use the refrigerant and parts specified by R134a. Mixing with other refrigerants or using parts which are not specified by R134a may cause leakage, performance decrement, and so on. • Apply compressor oil to every O-ring to avoid damage when installing. Preparing 1. Vacuum the refrigerant from the cooling circuit. 2. Drain the coolant. Replacing the air conditioning and heater hoses 1. Replace the air conditioning hoses with new ones.

SVL97-2

(2) Heater hoses

Concluding 1. Charge the cooling circuit with the refrigerant. 2. Refill the radiator and reserve tank with the coolant.

6. Service as required 6.1 Checking the refrigerant CAUTION • Use protective gloves and goggles when removing the hose from the charging valve. NOTE • Always use the R134a refrigerant and the compressor oil for the R134a refrigerant. Preparing 1. Lower the front attachment to the ground, and stop the engine. Checking 1. Start the engine, and turn on the air conditioning. 2. Set the engine speed to 1500 rpm, and set an air flow of the air conditioner to the maximum. 3. Check the flow of the refrigerant from the sight glass.

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MAINTENANCE FOR A/C SPECIFICATION 6. Service as required

3. MAINTENANCE

(1) Sight glass

(A)

Suitable charge

Almost no air bubbles in the flow. If the engine speed is raised gradually from idle to 1500 rpm, the air bubbles disappear and the flow becomes transparent.

(B)

Undercharged

Air bubbles flow past constantly.

(C)

Overcharged

No air bubbles at all in the flow. Both high and low pressure sides are at high pressure and the cooling is ineffective.

4. If refrigerant is low, charge the refrigerant gas.

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SVL97-2 KiSC issued 09, 2021 A

4. MACHINE BODY

KiSC issued 09, 2021 A

SERVICING 1. Machine layout

4. MACHINE BODY

SERVICING 1. Machine layout

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

Bucket Bucket cylinder AUX outlet Travel motor Cabin Front work light

SVL97-2

(7) Lift arm stopper (8) Rear work light (9) Lift arm (10) DEF/AdBlue tank (11) Fuel tank cap (12) Rear idler

(13) Track roller (14) Front idler (15) Lift arm cylinder (16) Hydraulic oil tank cap (17) Crawler (18) Left pilot lever

(19) Right pilot lever (20) Armrest (21) Seat (22) Power socket

4-1

KiSC issued 09, 2021 A

SERVICING 2. Cabin

4. MACHINE BODY

2. Cabin 2.1 Removing/Installing cabin

2. Remove four bolts, cover, and drain plug, and drain the coolant from the engine.

CAUTION • There is a risk of burns. Cool down the hydraulic equipments and oil when working and checking • There is a risk of burns. Wait until the coolant cools down when working. • The cab may drop. When raising the cab, hold it securely with a stopper pin. • The cab may drop. Do not enter underneath the cab when it is being raised or lowered.

2.1.1 Collecting the refrigerant gas

(4) Bolt (M12 × 30) ×4 (5) Cover

(6) Drain plug

Air conditioner model only. 1. Collect the refrigerant gas.

2.1.3 Removing the cabin 1. Insert two shackles to cab and attach the sling. 2. Hoist the cab and hold it up. IMPORTANT • Check the engagement mechanism of the damper.

(1) Hose (discharge)

the

latch

(2) Hose (suction)

2.1.2 Draining the coolant 1. Remove three bolts, and drain the coolant with tilting the radiator.

(1) Bolt (M14 × 40) × 3 (2) Drain plug

4-2

(1) Shackle

(2) Nylon sling

(3) Gas cylinder

(4) Latch mechanism

(3) Radiator cap

SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Cabin

4. MACHINE BODY

3. Remove three wire harness relay connectors.

6. Remove the β pin and cotter pin of the damper, and remove the pins and damper.

(5) Connector

4. Disconnect every quick couplers for pilot valve, and plug the adapter and pilot hose. (12) Pin (13) Damper

(14) Pin

7. Release the cabin lock, gently lower the cab with crane NOTE • Ensure that the hose and wire harness are not caught by the cab. 8. Insert four shackles to cabin, and suspend the cab temporarily with crane. (6) Quick coupler

(15) Shackle

(7) Quick coupler

(16) Nylon sling

5. Disconnect the cooler hose and heater hose, and remove the hoses and clamps from the bracket.

(8) Cooler hose (9) Heater hose (10) Clamp

SVL97-2

(11) Bracket

4-3

KiSC issued 09, 2021 A

4. MACHINE BODY

SERVICING 2. Cabin

9. Lift the cabin gently and remove the pin.

(17) Pin

(18) Cabin

4-4

SVL97-2 KiSC issued 09, 2021 A

SERVICING 3. Armrest

4. MACHINE BODY

3. Armrest 3.1 Armrest parts drawing

(1) Left armrest guard holder (2) Bushing ×2 (3) Left armrest (4) Collar (5) Shaft circlip (6) Spring (7) Headed pin (8) Split pin (9) Left armrest switch (10) Machine screw with washer

(11) Flange nut (12) Magnet (13) Bolt (M5 × 10) (14) Bolt (M8 × 25) (15) Nut (M8) (16) Bolt (M10 × 25) ×3 (17) Right armrest guard holder (18) Bushing ×2 (19) Right armrest (20) Collar

Machine screw with washer (10) (26)

SVL97-2

Tightening torque

(21) Shaft circlip (22) Spring (23) Headed pin (24) Split pin (25) Right armrest switch (26) Machine screw with washer (27) Flange nut (28) Magnet (29) Bolt (M5 × 10) (30) Bolt (M8 × 25)

(31) Nut (M8) (32) Bolt (M10 × 25) ×3 (a) Lock release range 20 ± 5° (b) Apply grease (c) 16.5 mm, 0.65 in. (Reference value) (d) The bushing must not protrude from the armrest guard holder (e) 3 mm (0.12 in.)

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

4-5

KiSC issued 09, 2021 A

SERVICING 4. Seat and seat belt

4. MACHINE BODY

4. Seat and seat belt

Gap dimension

4.1 Seat and seat belt parts drawing

(a) (b) (c) A:

125 mm (4.921 in.) 40 mm (1.575 in.) 90 mm (3.543 in.) Right

B: C:

Bottom Left

2. Install the cushion to the frame temporarily.

(1) Seat (2) Seat mounting bolt Seat mounting bolt (2)

(3) Seat belt

Tightening torque

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

5. Front window

(2) Stopper cushion

3. Install the front left and right to the frame temporarily.

5.1 Assembling the front window 5.1.1 Assembling window parts 1. Apply primer to the top, left and right of the frame. NOTE • Apply Primer24 (Sunrise MSI) or equivalent.

(3) Front right lock

(1) Frame

(4) Front left lock

4-6

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Front window

4. MACHINE BODY

4. Install the rubber seal and left and right cables to the frame.

(11) Roller (12) Handle (13) Nut (5) Left cable (6) Clip (7) Rubber seal

(d) 31 ± 0.5 (1.22 ± 0.02 in.)

(8) Right cable Nut (13)

Tightening torque

Enlarged view of left side

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

7. Install grommets to the glass.

(4) Front left lock

(9) Bolt

5. Install the left and right handrails to the frame.

(14) Glass

(15) Grommet

8. Install plate to the glass.

(10) Handrail

6. Install the roller to handle assembly.

SVL97-2

(16) Plate

4-7

KiSC issued 09, 2021 A

SERVICING 5. Front window

4. MACHINE BODY 9. Install plate and handrail to the glass.

(25) Wiper motor (17) Plate

(26) Nut

(18) Handrail

10. Install handle, packing, and collar to the glass.

Nut (26)

Tightening torque

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

13. Affix stickers to the top, bottom, left and right of the glass.

(19) Handle (20) Packing (21) Collar

(22) Collar

11. Install plate and handle to the glass.

(23) Handle

(24) Plate

12. Install wiper motor to the glass.

(27) Seal (28) Seal (29) Seal (D) Top (E) Right (F) Left (G) Bottom

(e) (f) (g) (h) (i) (j)

152.5 mm (6.00 in.) 515 mm (20.28 in.) 780 mm (30.71 in.) 121 mm (4.764 in.) 765 mm (30.12 in.) 27.5 mm (1.083 in.)

NOTE • Tool : 22 mm spanner

4-8

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Front window

4. MACHINE BODY

14. Apply primer to the outside of each sticker. NOTE • Primer35 (Sunrise MSI) or equivalent

(7) Rubber seal

(14) Glass

18. After installing the left and right cables to the handles, install the cover to the glass. (27) Seal

(28) Seal

15. Apply SR sealant along the seal.

NOTE • Tool : 10 mm socket wrench

NOTE • SR seal U90 (Sunrise MSI) or equivalent

(5) Left cable (8) Right cable (29) Cover (k) Right (l) Left (m) Top

(n) Bottom

16. Install glass to frame. NOTE • Tool : Plastic pliers

(o) 5.0 mm (0.197 in.)

17. Fit the glass in the rubber seal.

Bolt (30)

Tightening torque

1.47 to 1.96 N⋅m 0.15 to 0.20 kgf⋅m 1.09 to 1.44 lbf⋅ft

19. Install the blade and arm to the wiper motor. NOTE • Tool : 10 mm socket wrench

(31) Blade (32) Arm

Nut (33)

SVL97-2

(30) Bolt

(33) Nut

Tightening torque

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

4-9

KiSC issued 09, 2021 A

SERVICING 5. Front window

4. MACHINE BODY

5.1.2 Assembling the front window linkage 1. Install left and right stopper cushions and strikers to the front of the cabin. NOTE • Tool : 12 mm spanner

(8) Bushing (9) Bolt (10) Linkage

Bolt (9)

(1) Stopper cushion

Striker (2)

(2) Striker

Tightening torque

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

(11) Linkage left-side bracket

Tightening torque

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

5. Install the damper to linkage. NOTE • Tool : 12 mm spanner

2. Install the cushion to rear of the cabin with adjusting left and right nuts. 3. Install the striker temporally. NOTE • Adjust so the gap with the cushion is approx.12 mm (0.472 in.).

(10) Linkage (12) Stud

(13) Damper

Enlarged view

(3) (4) (5) (6)

Flat metal washer Nut Cushion Striker

(7) Bolt (a) Approx.12 mm (0.472 in.)

4. Install the bushing and brackets to the linkage. NOTE • Tool : 14 mm socket wrench

(12) Stud

Stud (12)

4-10

Tightening torque

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

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Front window

4. MACHINE BODY

6. Install the bracket and damper to the cabin. NOTE • Tool : 12 mm socket wrench

(4) Bolt

Bolt (4) (10) Linkage (13) Damper (14) Nut Nut (14) Bolt (16)

(15) Right linkage bracket (16) Bolt

Tightening torque

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

(5) Roller left bracket

Tightening torque

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

3. After installing the lock to the frame, adjust the lock and striker at the front of the cabin. NOTE • Tool: 14 mm socket wrench

5.1.3 Assembling the front window frame 1. Install the frame to the linkage. NOTE • Tool: 12 mm socket wrench

(6) Striker (7) Lock

Bolt (8)

(1) Linkage (2) Frame

Bolt (3)

(8) Bolt

Tightening torque

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

(3) Bolt

Tightening torque

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

2. After installing the bracket on the frame, adjust the front window. NOTE • Tool: 12 mm socket wrench • Open and close the front window, and adjust the left- and right-side play until the window moves smoothly.

SVL97-2

4-11

KiSC issued 09, 2021 A

SERVICING 5. Front window

4. MACHINE BODY 4. Tighten the striker at the rear of the cabin. NOTE • Tool: 12 mm socket wrench

(14) Stopper cushion (15) Right rear stopper (16) Bolt

(9) Striker (10) Bolt

Bolt (10)

(11) Lock

Tightening torque

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

5. Close the front window, and adjust the clearance between the stopper cushion and cabin bracket. NOTE • Tool: 12 mm spanner

(12) Stopper cushion (13) Nut (a) Bracket

Nut (13)

(b) 0 mm (0 in.)

Tightening torque

17.7 to 20.6 N⋅m 1.8 to 2.1 kgf⋅m 13.0 to 15.2 lbf⋅ft

Bolt (16)

Tightening torque

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

7. Install the left and right locks at the front of the cabin. NOTE • Tool: 12 mm socket wrench • Check if the locks can be enabled. • When the windshield is open and in the locked position, check and make sure there is no rattling up and down.

(17) Lock

Bolt (18)

(18) Bolt

Tightening torque

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

6. Install the left and right rear stopper. NOTE • Tool: 14 mm socket wrench

4-12

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Front window

4. MACHINE BODY

8. Attach lock assembly to frame with adjusting it. NOTE • Tool: 10 mm socket wrench

(19) Bolt (20) Bolt (21) Lock (22) Lock (d) There must be no slack in the cables.

(e) The cable must be in contact with the stopper

Bolt (19) Tightening torque Bolt (20)

SVL97-2

7.8 to 9.3 N⋅m 0.8 to 0.95 kgf⋅m 5.8 to 6.9 lbf⋅ft 4.0 to 6.0 N⋅m 0.41 to 0.61 kgf⋅m 3.0 to 4.4 lbf⋅ft

4-13

KiSC issued 09, 2021 A

4. MACHINE BODY

SERVICING 5. Front window

5.2 Front window components

4-14

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Front window (1) Flat metal washer (2) Nut (3) Cushion (4) Stopper cushion (5) Flange nut (6) Blade assembly (7) Arm assembly (8) Blade (9) Machine screw with washer (10) Handrail (11) Glass (12) Handle (13) Seal (14) Seal (15) Plate (16) Grommet (17) Wiper motor (18) Packing

SVL97-2

4. MACHINE BODY (19) Collar (20) Plate (21) Nut (22) Roller (23) Handle (24) Self-tapping screw (25) Collar (26) Machine screw with washer (27) Seal (28) Striker (29) Bolt (M8 × 16) (30) Striker (31) Lock (32) Cushion (33) Bolt (M10 × 25) (34) Bolt (M6 × 16) (35) Bushing (36) Bolt (M6 × 16)

(37) Bolt (M10) (38) Right cable (39) Clip (40) Roller (41) Bolt (M8 × 20) (42) Right roller bracket (43) Clip (44) Stud (45) Damper (46) Right linkage bracket (47) Bolt (M8 × 20) (48) Linkage (49) Left linkage bracket (50) Lock (51) Left cable (52) Cover (53) Bolt (M6) (54) Frame

(55) Left roller bracket (56) Rubber seal (57) Nut ×2 (58) Right rear stopper (59) Left rear stopper (60) Bolt (M10 × 25) (61) Lock (62) Lock (63) Bolt (M10 × 25) (64) Lock (65) Spring (66) Pin (67) Lever (68) Grip (69) Lock

4-15

KiSC issued 09, 2021 A

SERVICING 6. Upper window

4. MACHINE BODY

6. Upper window 6.1 Removing/Installing the upper window 6.1.1 Removing the upper window 1. Use a utility knife to open a hole in the sticker and adhesive. 2. Insert piano wire into the hole, and cut out the adhesive from the whole circumference. 3. After removing the glass, remove the seal and adhesive. (1) (2) (3) (a)

Seal Glass Adhesive 10 mm (0.39 in.)

(b) 8 mm (0.31 in.) (c) 12 mm (0.47 in.)

4. Apply primer around the whole circumference of the flange of the cab frame. 5. Attach the glass to the cab frame.

(1) Cabin frame (2) Glass (3) Utility knife

(4) Adhesive (5) Piano wire

(d) 30 mm (1.18 in.)

6. Secure the glass and wait until it is fixed.

(2) Glass (4) Adhesive

(6) Seal

6.1.2 Installing the upper window 1. Clean dust, oil, and so on. 2. Affix a seal to the glass. 3. Apply an adhesive to the outer circumference of the seal.

(4) Window suction pad (5) Glass (6) Adhesive

(7) Spacer

NOTE • Use Sekisui Super Sealer 21 or equivalent agent

4-16

SVL97-2 KiSC issued 09, 2021 A

SERVICING 7. Rear window

4. MACHINE BODY

7. Rear window 7.1 Removing/Installing the rear window 7.1.1 Installing the rear window trim 1. Install H rubber to the frame.

(1) H rubber (2) Glass (3) Window suction plate

(4) Glass holding plate (A) Mark

2. Pass the linkage through the rubber core insertion jig. 3. Use the jig to insert the rubber core into the H rubber. NOTE • Jig: Rubber core insertion jig

(1) H rubber

H rubber fitting direction

(1) H rubber (5) Ring (6) Rubber core (a) Top (b) Cabin exterior (c) Bottom

(d) Cabin interior

(a) Rubber core insertion jig

4. Install the ring in the assembly position. Linkage installing position

7.1.2 Installing the glass for rear window 1. Insert the glass into the groove of the H rubber. NOTE • Tool : Flat tip screwdriver • Assemble so that the mark is on the bottom right of the window.

(1) (5) (6) (b)

H rubber Ring Rubber core Bolt hole position

5. Rotate the rubber core once, and then cut it off.

SVL97-2

4-17

KiSC issued 09, 2021 A

SERVICING 8. Side window

4. MACHINE BODY 6. Apply adhesive to the joint. NOTE • Adhesive: ThreeBond 1521C

(5) Collar

3. Remove seven bolts and remove the sash.

(d) Joint

8. Side window 8.1 Removing/Installing the side window 8.1.1 Removing the side window 1. Remove six nuts, protective rubber, plain washer and side glass.

(4) Nut

(1) Side glass (2) Protective rubber (3) Flat metal washer

Nut (4)

(6) Sash

Tightening torque

4.0 to 6.0 N⋅m 0.4 to 0.6 kgf⋅m 3.0 to 4.4 lbf⋅ft

2. Remove the collar.

4-18

SVL97-2 KiSC issued 09, 2021 A

SERVICING 8. Side window

4. MACHINE BODY

8.2 Side window parts drawing

(1) Left sash (2) Right sash (3) Left side glass

SVL97-2

(4) Right side glass (5) Bolt (M8 × 16) × 14 (6) Protective rubber ×12

(7) Flat metal washer ×12 (8) Nut ×12 (9) Collar ×12

4-19

KiSC issued 09, 2021 A

SERVICING 9. Lift arm/linkage

4. MACHINE BODY

9. Lift arm/linkage 9.1 Removing/Installing the lift arm / linkage CAUTION • The machinery may suddenly move. Stop the engine and lower the working equipment to the ground when removing/disconnecting the hydraulic equipments/hoses. • There is a risk of burns. Cool down the hydraulic equipments and oil when working and checking • There is a risk of injury to fingers. Keep your finger out from the pin hole when aligning the pin.

(1) β pin

(2) Pin

9.1.4 Removing the lift arm 1. Remove the left and right hose clamps connected to the lift arm.

9.1.1 Removing the cabin 1. Dismount the cabin.

9.1.2 Installing the vacuum pump 1. Plug the breather hose, and attach the vacuum pump.

9.1.3 Rear bonnet lock 1. Lock the rear bonnet.

4-20

SVL97-2 KiSC issued 09, 2021 A

SERVICING 9. Lift arm/linkage

4. MACHINE BODY

2. Disconnect all of the hydraulic hoses connected to the lift arm, and plug the piping and hydraulic hoses.

(7) Nylon sling

(1) Hydraulic hoses (2) Hose clamp

(3) Hose clamp

(A) Front section

4. Remove the self-locking nut from the head side of the left and right lift arm cylinder, and remove the left and right bolt and pin. NOTE • Place a block, etc., in the gap between linkage 2 and the body.

(8) Bolt (M10 × 100)

(9) Self-locking nut (M10)

5. Remove the pin of the left and right lift arm cylinder. NOTE • Place a block, etc., in the gap between the lift arm cylinder and body.

(4) Hydraulic hoses (5) Hose clamp

(6) Hydraulic hoses

3. Attach a nylon sling to the rear bar and front section of the lift arm, and suspend the lift arm temporarily. NOTE • If the nylon sling is contacting any parts, etc., protect the parts with a rag.

(10) Bolt (M10 × 16) (11) Pin (12) Pin

SVL97-2

(13) Linkage 2 (14) Lift arm cylinder

4-21

KiSC issued 09, 2021 A

SERVICING 9. Lift arm/linkage

4. MACHINE BODY 6. Remove the self-locking nut and bolt of left and right linkage 1, and remove the pin.

(4) Nylon sling

3. Remove the self-locking nut, and remove the bolt. (15) Bolt (M10) (16) Self-locking nut (M10)

(17) Pin

7. Lift up the lift arm assembly and remove it.

(18) Lift arm Lift arm weight (bucket-less)

SVL95-2s SVL97-2

493 kg 1087 lbs

9.1.5 Removing the linkage 1 1. Remove the bolt, and the hose guide. (5) Bolt (M10) (6) Pin (7) Self-locking nut (M10)

(8) DEF/AdBlue hose (9) DEF/AdBlue hose heater

4. Remove the pin, and lift up linkage 1 to remove. Linkage 1 weight

(1) Linkage 1 (2) Bolt (M10)

SVL95-2s SVL97-2

63 kg 139 lbs

(3) Hose guide

2. Attach a nylon sling to linkage 1, and support with a crane.

4-22

SVL97-2 KiSC issued 09, 2021 A

SERVICING 10. Quick hitch

4. MACHINE BODY

10. Quick hitch 10.1 Quick hitch parts drawing 10.1.1 Mechanical quick hitch parts drawing

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

Quick hitch Handle (LH) Handle (RH) Spring ×2 Flat metal washer ×2 Bolt (M12 × 25) × 2 Pin ×2

SVL97-2

(8) Spring ×2 (9) Linkage ×2 (10) Stopper ×2 (11) Bolt (M12 × 25) × 2 (12) Self-locking nut (M12) ×2 (13) Bolt (M10 × 45) × 2 (14) Grease nipple × 2

(15) Self-locking nut (M10) ×2 (a) Contacts with the bolt head and hitch groove to suppress rotation (b) The bolt head must not protrude from the end face of the hitch

4-23

KiSC issued 09, 2021 A

SERVICING 10. Quick hitch

4. MACHINE BODY

10.1.2 Hydraulic quick hitch parts drawing

(1) (2) (3) (4) (5) (6) (7) (8)

Hydraulic quick hitch Hydraulic hitch LH arm Hydraulic hitch RH arm Spring ×2 Flat metal washer ×2 Bolt (M12 × 25) × 2 Pin ×2 Spring ×2

4-24

(9) Linkage ×2 (10) Stopper ×2 (11) Bolt (M12 × 25) × 2 (12) Self-locking nut (M12) ×2 (13) Bolt (M10 × 45) × 2 (14) Grease nipple × 2 (15) Quick hitch cylinder (16) Bolt (M12 × 25) × 2

(17) Clamp (18) Collar (19) Bolt (M8 × 45) (20) Self-locking nut (M10) ×2 (a) Contacts with the bolt head and hitch groove to suppress rotation

(b) The bolt head must not protrude from the end face of the hitch (c) Clearance: 0.5 to 1.5 mm (0.02 to 0.059 in.) (d) Spring set length: 83 to 84 mm (3.27 to 3.3 in.)

SVL97-2 KiSC issued 09, 2021 A

SERVICING 11. Accelerator pedal

4. MACHINE BODY

11. Accelerator pedal

11.2 Accelerator pedal parts drawing

11.1 Removing/Installing the accelerator pedal 11.1.1 Removing the accelerator pedal 1. Remove the mat.

(1) (2) (3) (4) (5) (6) (7) (8)

(1) Mat

2. Remove three bolts.

Linkage Bolt (M10 × 20) × 3 Accelerator pedal Accelerator pedal rod Rod end right screw Nut Snap pin Spring washer

(9) Nut (10) Headed pin (11) Snap pin (12) Spring (13) Accelerator pedal sensor (14) Machine screw with washer (15) Flat metal washer

12. Rear bonnet/rear cover 12.1 Removing/Installing the rear bonnet/rear cover 12.1.1 Removing the rear bonnet 1. Open the bonnet and cover.

(2) Bolt (M10 × 20) × 3

3. Remove the accelerator potentiometer connector and the accelerator pedal assembly.

(1) Rear bonnet

(3) Accelerator potentiometer connector

SVL97-2

(4) Accelerator pedal assembly

4-25

KiSC issued 09, 2021 A

SERVICING 12. Rear bonnet/rear cover

4. MACHINE BODY 2. Remove the back buzzer connector, and take the harness off from bonnet.

1. Collect the refrigerant gas.

(1) Hose (discharge) (2) Back buzzer (3) Connector

(2) Hose (suction)

(4) Harness

12.1.3 Removing the rear cover

3. Support the bonnet with a crane.

1. Remove four bolts, and cover.

(5) Bonnet

(6) Nylon sling

4. Remove four bolts, and remove the bonnet slowly with a crane. NOTE • During assembly, tighten tightening bolts from the top.

(1) Bolt (M10 × 20) ×4

the

bonnet

(2) Cover

2. Remove the connector for the electromagnetic fan, and take the harness off from cover.

(7) Bolt (M16 × 50) × 4

Bonnet mass

70.2 kg 154.8 lbs

(3) Condenser (4) Electromagnetic fan

(5) Connector

12.1.2 Collecting the refrigerant gas Air conditioner model only. 4-26

SVL97-2 KiSC issued 09, 2021 A

SERVICING 12. Rear bonnet/rear cover

4. MACHINE BODY

3. Remove two snap pins.

(6) Snap pin

4. Remove the gas damper from the rear cover, and remove the rear cover.

(7) Snap pin

SVL97-2

(8) Gas damper

4-27

KiSC issued 09, 2021 A

SERVICING 12. Rear bonnet/rear cover

4. MACHINE BODY

12.2 Rear bonnet parts drawing

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

Rear bonnet Stopper Sponge ×4 Nut ×4 Bolt (M14 × 110) × 2 Hinge ×2

Bolt (7)

4-28

(7) Bolt (M16 × 50) × 4 (8) Flat metal washer ×4 (9) Headed pin (10) Cushion ×2 (11) Nut ×2 (12) Cushion

Tightening torque

(13) Lever (14) Lever (15) Snap pin (16) Torsion spring (a) Align the ends

(b) Cushion squeeze margin 1.0 mm (0.04 in.) (c) Face the lip section upwards (d) Tighten the bolts from the top side (e) 16 mm (0.63 in.)

196.1 to 225.6 N⋅m 20 to 23 kgf⋅m 144.7 to 166.3 lbf⋅ft

SVL97-2 KiSC issued 09, 2021 A

SERVICING 12. Rear bonnet/rear cover

4. MACHINE BODY

12.3 Rear cover parts drawing 12.3.1 Rear cover parts drawing (Open cab model)

(1) Rear bonnet (2) Snap pin

SVL97-2

(3) Rod (4) Snap pin

(5) Rubber seat support ×2 (6) Nut ×2

(a) 14 mm (0.55 in.)

4-29

KiSC issued 09, 2021 A

SERVICING 12. Rear bonnet/rear cover

4. MACHINE BODY

12.3.2 Rear cover parts drawing (Closed cab model)

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

Rear cover Electromagnetic fan Flange bolt (M6) ×4 Condenser Thrust collar × 4

(6) Grommet ×4 (7) Bolt (M8 × 35) ×4 (8) Bracket ×4 (9) Bolt (M6 × 12) ×8 (10) Cushion ×2

Bolt (9)

4-30

(16) Rubber seat support ×2 (17) Nut ×2 (a) 6 mm (0.24 in.)

4.0 to 6.0 N⋅m 0.4 to 0.6 kgf⋅m 3.0 to 4.4 lbf⋅ft

Flange bolt (3)

Bolt (7)

(11) Pin (12) Damper (13) Snap pin ×2 (14) Headed pin (15) Snap pin

Tightening torque

10.0 to 12.5 N⋅m 1.0 to 1.3 kgf⋅m 7.4 to 9.2 lbf⋅ft 3.9 to 6.9 N⋅m 0.4 to 0.7 kgf⋅m 3.0 to 5.2 lbf⋅ft

SVL97-2 KiSC issued 09, 2021 A

SERVICING 13. Radiator

4. MACHINE BODY

13. Radiator 13.1 Removing/Installing the radiator CAUTION • There is a risk of burns. Cool down the hydraulic equipments and oil when working and checking • There is a risk of burns. Wait until the coolant cools down when working. 2. Firstly remove the (-) cable, and the (+) cable next.

13.1.1 Draining the coolant 1. Remove three bolts, and drain the coolant with tilting the radiator.

(1) (-) cable

(2) (+) cable

3. Remove two self-locking nuts, battery retainer, battery cover, and battery.

(1) Bolt (M14 × 40) × 3 (2) Drain plug

(3) Radiator cap

2. Remove four bolts, cover, and drain plug, and drain the coolant from the engine.

(3) Battery retainer (4) Battery cover (5) Battery

Self-locking nut (6)

(4) Bolt (M12 × 30) ×4 (5) Cover

(6) Self-locking nut

Tightening torque

4.0 to 5.0 N⋅m 0.41 to 0.51 kgf⋅m 3.0 to 3.7 lbf⋅ft

(6) Drain plug

13.1.2 Removing the battery 1. Open the rear cover and bonnet.

SVL97-2

4-31

KiSC issued 09, 2021 A

SERVICING 13. Radiator

4. MACHINE BODY

13.1.3 Installing the vacuum pump 1. Plug the breather hose, and attach the vacuum pump.

(4) Oil cooler hose

(5) Oil cooler hose

4. Suspend the radiator with a crane temporarily, and remove the stopper.

CAUTION

13.1.4 Removing the radiator

• Do not tilt the radiator, as it may fall.

1. Remove the radiator hose. • Tool: 10 mm spanner

• Tools: 14 mm, 17 mm socket wrench

(6) Radiator stopper

5. Remove the radiator slowly with a crane. (1) Radiator hose

(2) Radiator hose

2. Remove the hose guide of the oil cooler. • Tool: 12 mm socket wrench

(7) Radiator (3) Guide

3. Disconnect the oil cooler hose, and plug the adapter to hose. • Tool: 36 mm spanner

4-32

Radiator weight

SVL95-2s SVL97-2

70.5 kg 155 lbs

SVL97-2 KiSC issued 09, 2021 A

SERVICING 13. Radiator

4. MACHINE BODY

13.2 Radiator parts drawing

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

Radiator Trim ×2 Elbow pipe joint Pipe joint (45L, G6, G6) Radiator mount rubber ×4 Fan surround

SVL97-2

(7) Bolt (M8 × 25) × 4 (8) Trim (9) Stay (10) Bolt (M10 × 25) × 4 (11) Stay (12) Grommet

(13) Bolt (M14 × 40) × 3 (14) Roller ×2 (15) Snap pin × 2 (16) Stopper (17) Bolt (M12 × 30) (18) Stopper

(19) Bracket (20) Bolt (M12 × 30) × 2 (a) 15° (b) 10° (c) Mounting orientation of snap pin

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KiSC issued 09, 2021 A

SERVICING 13. Radiator

4. MACHINE BODY

(21) Top radiator hose (22) Hose clamp (23) Hose clamp (24) Bottom radiator hose (25) Hose clamp (26) Hose clamp

4-34

(27) Hose guide (28) Bolt (M8 × 20) × 2 (29) Reserve tank (30) Drain hose (31) Pipe band (32) Headed pin

(33) Hose clamp (d) No less than 11 mm (0.43 in.) (e) Tubing should be higher than the guide. (f) Pass through the guide

(g) Insert the hose as far as the frame (h) 45° (i) 10 mm (0.39 in.)

SVL97-2 KiSC issued 09, 2021 A

SERVICING 13. Radiator

H: I:

Open model Closed model

SVL97-2

4. MACHINE BODY

(34) Hose guide (35) Bolt (M8 × 25) × 4

(36) Bolt (M8 × 20) × 4 (37) AC belt cover

4-35

KiSC issued 09, 2021 A

SERVICING 14. Rubber crawler

4. MACHINE BODY

14. Rubber crawler 14.1 Removing/Installing the rubber crawler CAUTION • Keep your hands or body away from the crawler while it is rotating. • The grease cylinder is filled with high-pressure grease, so there is a risk of grease spurting out. • Keep your face and body away from front of the grease nipple when loosening it. • Do not fit the crawler in wrong direction. • Do not work with your hands or feet under the machine when jerking up.

(3) Grease nipple

5. Slide the rubber crawler from the front idler to remove.

14.1.1 Removing the rubber crawlers 1. Jack up the machine, and set the machine on the jack stand. 2. Lower the lift arm cylinder to the stroke end, and place the quick hitch on the ground.

(4) Front idler

(5) Rubber crawler

3. Remove two bolts, and cover.

(1) Bolt (M12 × 30) × 2

(2) Cover

4. Loosen the grease nipple slowly.

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 14. Rubber crawler

4. MACHINE BODY

6. Use a bar to remove the rubber crawler from the sprocket, and remove it from the machine.

14.2 Rubber crawler parts drawing

(6) Sprocket

Assembling direction for rubber crawlers (1) (2) (3) (4)

Sprocket Idler (Front) Idler (Rear) Track roller

(a) Front of machine (b) Tension dimension of the rubber crawler

• The orientation of the rubber crawler is as indicated in the above diagram. Tension dimension of the rubber crawler (b)

Factory spec

20 to 30 mm 0.79 to 1.18 in.

15. Front idler, tension spring, and grease cylinder (a) Front of machine Rubber crawler weight

SVL95-2s SVL97-2

212 kg 514 lbs

15.1 Front idler, tension spring, and grease cylinder parts drawing

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

Front idler Tension spring Grease cylinder Grease fitting

Preset length of spring

SVL97-2

(5) Bolt (M12 × 50) (a) Preset length (b) Front of machine

SVL95-2s SVL97-2

224 ± 1 mm 8.82 ± 0.04 in.

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KiSC issued 09, 2021 A

SERVICING 15. Front idler, tension spring, and grease cylinder

4. MACHINE BODY

15.2 Front idler components

Tightening torque 77.5 to 90.2 N⋅m 7.9 to 9.2 kgf⋅m 52.1 to 66.5 lbf⋅ft

Bolt (5)

NOTE • Apply a threadlock (Loctite® 271) to the female screw side. Dimensions

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

Idler Shaft Bracket Bracket Bushing

(6) Floating seal (7) O-ring (8) Parallel pin (9) Circlip (10) Plug

15.3 Tension spring components

Service specifications (6) Idler outer diameter

ϕ356 mm ϕ14.0 in.

(7) Guide width

96 mm 3.8 in.

(8) Idler width

204 mm 8.0 in.

(9) Shaft outer diameter

ϕ46 mm ϕ1.81 in.

Service limits (6) Idler outer diameter

ϕ348 mm ϕ13.7 in.

(7) Guide width

104 mm 4.1 in.

(8) Idler width

(9) Shaft outer diameter

ϕ45 mm ϕ1.77 in.

(1) Bolt (2) Spring (3) Yoke

(4) Slotted nut (5) Cotter pin

15.4 Grease cylinder components

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

Cylinder tube Rod Dust seal O-ring

(5) Backup ring (6) Grease fitting (a) Backup ring mating surface

• Apply oil (New UDT, M80B or equivalent) when assembling the dust seal, O-ring, and backup ring.

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 16. Track roller

4. MACHINE BODY

• Grease after the rod is pushed in to (A) so that the air will not be mixed in. • The mating surface of the backup ring faces the 90° range on the side. Grease fitting (6)

Tightening torque

Service specifications

98 to 108 N⋅m 9.0 to 11 kgf⋅m 65 to 79.5 lbf⋅ft

16. Track roller 16.1 Track roller parts drawing

(4) Outer diameter

ϕ200 mm ϕ7.9 in.

(5) Track roller width

212 mm 8.3 in.

(6) Guide width 1

88 mm 3.5 in.

(7) Guide width 2

30 mm 1.2 in.

(8) Shaft outer diameter

ϕ40 mm ϕ1.6 in.

Service limits

(1) Track roller (2) Bolt (M16 × 45) ×2

Bolt (2)

(3) Flat metal washer ×2 (a) Plug facing out side Tightening torque

(4) Outer diameter

ϕ192 mm ϕ7.6 in.

(5) Track roller width

(6) Guide width 1

96 mm 3.8 in.

(7) Guide width 2

(8) Shaft outer diameter

ϕ39 mm ϕ1.5 in.

16.2 Track roller components

344 to 403 N⋅m 35.1 to 41.1 kgf⋅m 254 to 297 lbf⋅ft

NOTE • Apply the thread locking compound to the female threads. Dimensions

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

Bracket Shaft Track roller Bushing ×2 Bracket Floating seal ×2

(7) O-ring ×2 (8) Jig circlip ×2 (9) Pin (10) Plug (R1/8) (a) Set the R side against the bracket

Apply a threadlock (Loctite® 271) to the female screw side.

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 17. Rear idler

4. MACHINE BODY

17. Rear idler

Service limits

17.1 Rear idler parts drawing

(4) Idler outer diameter

ϕ322 mm ϕ12.7 in.

(5) Guide width

51 mm 2.0 in.

(6) Idler width

(7) Shaft outer diameter

ϕ45 mm ϕ1.77 in.

17.2 Rear idler components (1) Rear idler (2) Bolt (M16 × 45) ×2

(3) Flat metal washer ×2

Tightening torque

Bolt (2)

344 to 403 N⋅m 35.1 to 41.1 kgf⋅m 254 to 297 lbf⋅ft

NOTE • Apply a threadlock (Loctite® 271) to the female screw side. (1) (2) (3) (4) (5) (6)

Dimensions

Idler Shaft Bracket Bracket Bushing ×2 Floating seal ×2

(7) O-ring ×2 (8) Circlip ×2 (9) Plug (10) Parallel pin ×2 (11) Parallel pin ×2

Service specifications (4) Idler outer diameter

ϕ330 mm ϕ13.0 in.

(5) Guide width

59 mm 2.3 in.

(6) Idler width

140 mm 5.5 in.

(7) Shaft outer diameter

ϕ46 mm ϕ1.81 in.

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 18. Pin, bushing

4. MACHINE BODY

18. Pin, bushing 18.1 Pins, bushing and shims list

(1) Frame - Linkage (2) Linkage - Arm [Left and right] (3) Frame - Arm cylinder (bottom) [Left and right] (4) Arm cylinder (Rod) - Arm [Left and right]

SVL97-2

(5) Frame - Control linkage [Left (8) Arm - Bucket cylinder (bottom) (c) Bushing I.D and right] [Left and right] (d) Bushing O.D (6) Control linkage - Arm [Left and (9) Bucket cylinder (Rod) - Hitch (e) Bushing length right] [Left and right] (7) Arm - Hitch [Left and right] (a) Pin diameter (b) Pin length

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KiSC issued 09, 2021 A

4. MACHINE BODY

4-42

SERVICING 18. Pin, bushing

SVL97-2 KiSC issued 09, 2021 A

SERVICING 18. Pin, bushing

4. MACHINE BODY

Pin dimensions [1]

Bushing dimensions [2]

Collar dimensions [3] Shim dimensions [5]

Shim insertion position

Cylinder bushing dimensions [4]

I.D. × Length

I.D. × O.D. × Length

I.D. × O.D. × Thickness

I.D. × O.D. × Length

(1)

Frame - Linkage

50 × 264.5 mm

50 × 60 × 50

53.8 × 57 × 70

(2)

Linkage - Arm [Left and right]

50 × 245 mm

50 × 60 × 50

53.8 × 57 × 59

(3)

Frame - Arm cylinder (bottom) [Left and right]

45 × 249.5 mm

45 × 55 × 60

(4)

Arm cylinder (Rod) Arm [Left and right]

45 × 142 mm

45 × 55 × 50

(5)

Frame - Control linkage [Left and right]

45 × 94 mm

45 × 55 × 36

46 × 90 × 2

(6)

Control linkage - Arm [Left and right]

45 × 75 mm

45 × 55 × 36

Top side

(7)

Arm - Hitch [Left and right]

50 × 238 mm

50 × 60 × 99

51 × 94 × 2 × 2.3 × 3.0 × 3.5 × 4.0

(8)

Arm - Bucket cylinder (bottom) [Left and right]

45 × 228 mm

46 × 80 × 0.5 × 1.0 × 1.5 × 2.0

Top side

45 × 55 × 60

(9)

Bucket cylinder (Rod) Hitch [Left and right]

46 × 80 × 0.5 × 1.0 × 1.5 × 2.0

Top side Bottom side

45 × 55 × 40

SVL97-2

45 × 123 mm

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KiSC issued 09, 2021 A

5. ENGINE

KiSC issued 09, 2021 A

MECHANISM 1. Engine device layout

5. ENGINE

MECHANISM 1. Engine device layout

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

Intercooler SCR muffler DPF muffler Rail Intake throttle valve Supply pump

SVL97-2

(7) Oil pan (8) Engine oil filter (9) Fan (10) Air cleaner (11) Oil separator (12) Air conditioner belt

(13) Starter motor (14) Fan belt (15) Alternator (16) Drain plug (17) Fan pulley (18) Compressor

(19) Intake air heater (20) Flywheel (21) Turbocharger (22) Pre-cleaner

5-1

KiSC issued 09, 2021 A

MECHANISM

5. ENGINE

(23) ACU (24) DEF/AdBlue pump

5-2

(25) Engine ECU (26) DEF/AdBlue tank

(27) Coolant valve (28) Water separator

(29) Fuel pump (30) Fuel filter

SVL97-2 KiSC issued 09, 2021 A

MECHANISM

(31) DPF outlet exhaust temperature sensor (T2) (32) DPF inlet exhaust temperature sensor (T1) (33) DOC inlet exhaust temperature sensor (T0) (34) Pressure discharge valve (35) EGR valve

5. ENGINE

(36) Intake temperature sensor (37) Suction control valve (SCV) (38) Rail pressure sensor (39) Intake pressure sensor (40) Injector (41) Air flow sensor (42) CCV heater

(43) CCV heater* (Serial number : from 49832) (44) Pre-NOx sensor (45) Post-NOx sensor (46) DEF/AdBlue injector (47) SCR inlet temperature sensor (48) Intake throttle valve (49) DEF/AdBlue header unit

(50) Camshaft position sensor (51) Crank position sensor (52) Engine oil pressure switch (53) Coolant temperature sensor (54) Ground (55) Differential pressure sensor (56) CCV pressure switch*1

*1 Only for Kubota Canada Ltd. or with an additional CCV heater specification.

SVL97-2

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KiSC issued 09, 2021 A

5. ENGINE

MECHANISM

(57) Crankcase relief valve*2

*2 The crankcase relief valve is installed from serial number 65679 only for Canadian market. The relief valve setting pressure is 12.5 kPa (0.13 kgf/cm2, 1.8 psi).

5-4

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 2. Engine specifications

5. ENGINE

2. Engine specifications Specifications Engine model name

V3800-TIEF4-L

Number of cylinders

Cylinder I.D × Stroke

100 × 120 mm (3.94 × 4.72 in.)

Total displacement

3796 cm3 (231.7 cu.in.)

Maximum speed

2480 min-1

Idling RPM

1150 min-1

Rated output/rotating speed

Maximum torque

Net (ISO3046-1 2002)

Net (SAE J1349 JUN95)

64.9 KW / 2400 min-1 87.1 HP / 2400 min-1

Gross SAE J1995 JUN95

71.9 KW / 2400 min-1 96.4 HP / 2400 min-1

Net (ISO3046-1 2002)

Net (SAE J1349 JUN95)

337.8 N⋅m / 1500 min-1 34.45 kgf⋅m / 1500 min-1 249.2 lbf⋅ft / 1500 min-1

Gross SAE J1995 JUN95

352.2 N⋅m / 1500 min-1 35.91 kgf⋅m / 1500 min-1 259.7 lbf⋅ft / 1500 min-1

Machine dimensions Length × Width × Height

961 × 615 × 1168 mm (37.9 × 24.2 × 46.0 in.)

Dry weight

414 kg (913 lbs)

Valve clearance

0.25 mm (0.01 in.)

Combustion chamber

Re-entrant, 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

Fuel injection order

1-3-4-2

Compression ratio

17 2.95 to 3.13 MPa 30.0 to 32.0 kgf/cm2 427 to 455 psi

Compression pressure

Fuel consumption rate

Engine oil pressure (at rated RPM)

Gross SAE J1995 JUN95

220.0 g/kWh 161.8 g/PSh 0.361 lbs/HPh 196 to 392 kPa 2.00 to 3.99 kgf/cm2 28.5 to 56.8 psi

Engine oil consumption (at rated RPM)

0.55 g/kWh 0.40 g/PSh

Alternator

12 V, 1380 W

Starter

12 V, 3.0 kW

SVL97-2

5-5

KiSC issued 09, 2021 A

MECHANISM 3. Engine dimensions

5. ENGINE

3. Engine dimensions

V3800-TIEF4-L

5-6

961 mm 37.8 in.

615 mm 24.2 in.

1168 mm 46.0 in.

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 4. Engine performance curve

5. ENGINE

4. Engine performance curve Net

A: B:

SI Unit Industrial unit of the United States

SVL97-2

(a) Engine speed (rpm) (b) Output (kW) (c) Torque (N⋅m)

(d) Torque (N⋅m) (e) Output (HP) (f) Torque (ft⋅lb)

(g) Fuel consumption (g/HP⋅h)

5-7

KiSC issued 09, 2021 A

MECHANISM

5. ENGINE Gross

A: B:

5-8

SI Unit Industrial unit of the United States

(a) Engine speed (rpm) (b) Output (kW) (c) Torque (N⋅m)

(d) Fuel consumption (g/kW⋅h) (e) Output (HP) (f) Torque (ft⋅lb)

(g) Fuel consumption (g/HP⋅h)

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 5. Engine control system

5. ENGINE

5. Engine control system 5.1 Engine control system general description

SVL97-2

5-9

KiSC issued 09, 2021 A

MECHANISM 5. Engine control system

5. ENGINE (1) Engine oil switch (2) Charging switch (3) Fuel sensor (4) DPF inhibit switch (5) Hand accelerator sensor (6) Foot accelerator sensor (7) +B (8) Key switch ON signal (9) Starter switch ON signal (10) CAN communication (high) (11) CAN communication (low) (12) Suction control valve (13) Supply pump

5-10

(14) Rail pressure sensor (15) Rail (16) Pressure limiter (17) Injector (18) Intercooler (19) EGR DC motor (20) EGR lift sensor (21) Intake throttle sensor (22) Intake air heater (23) Intake pressure sensor (24) Intake temperature sensor (25) Coolant temperature sensor (26) Crank position sensor

(27) Cam position sensor (28) DPF muffler (29) Temperature sensor (DPF outlet exhaust temperature) (T2) (30) Differential pressure sensor (differential pressure between the DPF inlet and outlet) (31) Temperature sensor (DPF inlet exhaust temperature) (T1) (32) Temperature sensor (DOC inlet exhaust temperature) (T0) (33) Air flow sensor (34) Coolant valve

(35) DEF/AdBlue tank (36) DEF/AdBlue tube heater (37) DEF/AdBlue pump (38) DEF/AdBlue injector (39) SCR muffler (40) Pre-NOx sensor (41) SCR inlet temperature sensor (42) Post-NOx sensor (A) To fuel tank (a) Main ECU (b) Meter panel (c) Engine ECU (d) ACU

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 6. Common rail system

5. ENGINE

6. Common rail system 6.1 Common rail system general description The supply pump is used to store pressurized fuel on the rail, and the fuel is injected by the injector at the appropriate pressure, amount and timing. This system suppresses PM generated with incomplete combustion of fuel.

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

Supply pump Pressure limiter Rail High-pressure pipe Rail pressure sensor

(6) Suction control valve (SCV) (7) Fuel camshaft (8) Engine ECU (9) CAN communication (10) Main ECU

(11) Each sensors (12) Injector (13) Fuel filter (14) Fuel tank (15) Water separator

(16) Fuel pump (17) Check valve (a) High-pressure circuit (b) Low-pressure circuit

• The supply pump pressurizes the fuel and stores it on the rail. • The injector controlled by the engine ECU injects fuel into the cylinder at the appropriate pressure, amount, and timing. • Any fuel remaining in the injector returns from the overflow pipe to the tank via the fuel cooler.

SVL97-2

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KiSC issued 09, 2021 A

MECHANISM 7. EGR system

5. ENGINE

7. EGR system Exhaust Gas Recirculation (EGR)

7.1 EGR system general description This system reduces temperature inside the combustion chamber to reduce nitrogen oxide (NOx) in exhaust gas. The combustion temperature is reduced with recirculating the exhaust gas.

(1) (2) (3) (4) (5) (6) (7) (8)

Air cleaner Air flow sensor Turbocharger EGR cooler EGR Pipe EGR lift sensor EGR DC motor Injector

• • • •

Some of the exhaust gas that passes through exhaust manifold enters the EGR cooler. Exhaust gas is cooled down by coolant which is passing through the EGR cooler. The EGR valve controlled by the engine ECU optimally adjusts the recirculating amount of exhaust gas. The exhaust gas that passes through the EGR valve is mixed with the intake air and enters the combustion chamber.

5-12

(9) Intercooler (10) Intake pressure sensor (11) Intake throttle valve (12) Intake manifold (13) Coolant temperature sensor (14) Crank position sensor (15) Exhaust manifold (16) Cam position sensor

(17) Reed valve (18) Temperature sensor (DOC inlet exhaust temperature) (T0) (19) Temperature sensor (DPF inlet exhaust temperature) (T1) (20) Differential pressure sensor (differential pressure between the DPF inlet and outlet)

(21) Temperature sensor (DPF outlet exhaust temperature) (T2) (22) Intake temperature sensor (A) Exhaust gas leakage (B) Intake air flow

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 8. Supercharger system

5. ENGINE

8. Supercharger system Compresses the intake air and sends it to the engine for improved fuel efficiency.

8.1 Supercharger system general description This system improves combustion efficiency with sending compressed intake air to engine.

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

Air cleaner Turbocharger Compressor wheel Turbine wheel Injector Intercooler EGR valve

(8) Intake pressure sensor (9) Intake temperature sensor (10) DPF muffler (A) Intake air flow (B) Compressed air flow (C) Exhaust gas leakage

• The turbine wheel rotated by the exhaust gas rotates with the compressor wheel. • The compressor wheel compresses the intake air and sends it to the intercooler. • The intercooler cools the hot compressed air. • The cooled compressed air flows to the combustion chamber. • Compressed air has a high oxygen level, that increases combustion efficiency and engine output.

SVL97-2

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KiSC issued 09, 2021 A

MECHANISM 9. DPF

5. ENGINE

9. DPF Diesel Particulate Filter (DPF)

9.1 DPF general description Collects and burns the PM (particulates) contained in the exhaust gas.

(1) Injector (2) PM (particulate) (3) Diesel oxidation catalyst (DOC)

(4) (5) (a) (b)

Diesel particulate filter (DPF) Unburned fuel Post injection Exhaust gas leakage

(A) Collecting (B) Regenerating

Collect PM • The PM in the exhaust gas is collected in a honeycomb-shaped filter. Regeneration • When a specified amount of PM has been collected, the injector begins post injection. • The fuel enters the DOC (Diesel oxidation catalyst) via the combustion chamber. • The unburned fuel is combusted by the DOC, and oxidizes HC (hydrocarbon) and NO (nitric oxide). • Oxidation heats the DPF to approx. 600 ℃, and it burns the collected PM.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 9. DPF

5. ENGINE

9.2 DPF output limit and warning lamp Engine output limit and warning (lamp, error) according to the amount of PM deposits (deposit level)

Deposit level

DPF regeneration inhibit switch ON: Inhibit

Engine speed

Engine output

Level 0

Lit

OFF

Lit

...Pi, Pi, Pi...

Every 60 sec.

Blink

...Pi, Pi, Pi...

Continuous

1800 rpm or more

Lit

...Pi, Pi, Pi...

Every 30 sec.

1800 rpm or less

Lit

Blink

E:9000

...Pi, Pi, Pi...

Every 60 sec.

50%

Blink

E:9007

Pi...Pi

Continuous

1800 rpm or more

50%

Lit

Blink

E:9002

Pi...Pi

Continuous

1800 rpm or less

50%

Lit

Blink

E:9001

Pi...Pi

Continuous

50%

Blink

E:9003

Pi, Pi, Pi, Pi

Continuous

OFF

50%

Blink

E:9003

Pi, Pi, Pi, Pi

Continuous

50%

Blink

E:9004

Pi, Pi, Pi, Pi

Continuous

OFF

50%

Blink

E:9004

Pi, Pi, Pi, Pi

Continuous

Level 1

Level 2 OFF

ON Level 3 OFF

Warning lamp

Error Buzzer

Level 4

Level 5

Level 2 • DPF is regenerated at 1800 rpm or higher • The speed increase lamp blinks and an error is displayed when the speed is at 1800 rpm or less (E:9000) Level 3 • Engine output limit: 50% • DPF is regenerated at 1800 rpm or higher, and an error is displayed (E:9002) • The speed increase lamp blinks and an error is displayed when the speed is at 1800 rpm or less (E:9001) Level 4 • Engine output limit: 50% • There is an excessive amount of PM deposits, or DPF regeneration is not possible, and an error is displayed (E:9003) • Use the engine diagnostic tool for forced regeneration only Level 5 • Engine output limit: 50% • There is an excessive amount of PM deposits, or DPF regeneration / forced regeneration is not possible, and an error is displayed (E:9004) • Clean / replace DPF

SVL97-2

5-15

KiSC issued 09, 2021 A

MECHANISM 10. SCR system

5. ENGINE

10. SCR system Selective Catalytic Reduction (SCR)

10.1 SCR system general description The nitrogen oxide (NOx) in the exhaust gas is neutralized by the Diesel Exhaust Fluid (DEF/AdBlue).

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

DPF muffler Pre-NOx sensor SCR inlet temperature sensor Post-NOx sensor

• • • • •

The pre NOx sensor detects the amount of NOx included in the exhaust gas. The DEF/AdBlue injector injects the optimum amount of urea for the amount of NOx. Urea is hydrolyzed into water vapor and ammonia by the heat of exhaust gas. Ammonia reacts with NOx at the SCR catalyst, and degraded to water vapor and nitrogen. Unreacted ammonia is degraded to nitrogen and water vapor at ASC (Ammonia Slip Catalyst).

5-16

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

SCR catalyst ASC (Ammonia Slip Catalyst) ACU Engine ECU

(9) CAN communication (10) DEF/AdBlue injector (11) DEF/AdBlue pump (12) Coolant valve

(13) DEF/AdBlue tank (14) DEF/AdBlue tube (suction) (15) DEF/AdBlue tube (delivery) (16) DEF/AdBlue tube (return)

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 10. SCR system

5. ENGINE

10.2 SCR output limit and warning lamp 10.2.1 Diesel Exhaust Fluid (DEF/AdBlue) level in SCR Engine output limit and warning (lamp, error) according to the amount of DEF/AdBlue level. Warning lamp

Error

DEF/ AdBlue water level

Time

Engine output, speed

(1)

Normal

(2)

15% or less

Lit

Blink

E:9503

Every 60 sec.

0 to 45 min.

Limit

Lit

Blink

E:9503 E:9601

Pi···Pi

Every 20 sec.

45 min. or more

Idling

Lit

Blink

E:9503 E:9602

Pi···Pi

Every 10 sec.

(3)

(4)

5% or less

(1) Normal state (2) Diesel Exhaust Fluid (DEF/ AdBlue) level: 15% or less

Buzzer

(3) Diesel Exhaust Fluid (DEF/ (4) Diesel Exhaust Fluid (DEF/ AdBlue) level: 5% or less (0 to AdBlue) level: 5% or less (45 45 min.) min. or more) (a) Engine output, speed

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

Time 100% Limit Idling

Diesel Exhaust Fluid (DEF/AdBlue) level: 15% or less • DEF/AdBlue warning lamp lit, warning lamp blinks (yellow) • Error code display: E:9503 Diesel Exhaust Fluid (DEF/AdBlue) level: 5% or less (0 to 45 min.) • Engine output, speed: Limited • DEF/AdBlue warning lamp lit, warning lamp blinks (red), SCR system warning lamp blinks (yellow) • Error code display: E:9503, E:9601 Diesel Exhaust Fluid (DEF/AdBlue) level: 15% or less (45 min. or more) • Engine output, speed: Idling • DEF/AdBlue warning lamp lit, warning lamp blinks (red), SCR system warning lamp blinks (yellow) • Error code display: E:9503, E:9602

SVL97-2

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KiSC issued 09, 2021 A

MECHANISM 10. SCR system

5. ENGINE

10.2.2 DEF/AdBlue concentration and quality Engine output limit and warning (lamp, error) due to detection of a change in concentration and quality of DEF/AdBlue

(1)

DEF/ AdBlue concentration and quality

Time

Engine output, speed

Normal

0 to 195 min.

Lit

Blink

E:9520

Every 60 sec.

195 to 240 min.

Limit

Lit

Blink

Lit

Blink

E:9520 E:9601

Pi···Pi

Every 20 sec.

240 min. or more

Idling

Lit

Blink

Lit

Blink

E:9520 E:9602

Pi···Pi

Every 10 sec.

Warning lamp

(2)

(3)

(4)

Error

(1) Normal state (2) 0 to 195 min. (3) 195 to 240 min.

Error

Buzzer

(4) 240 min. or more (a) Engine output, speed (b) Time

(f)

Idling

Diesel Exhaust Fluid (DEF/AdBlue) concentration, quality error detected (0 to 195 min.) • DEF/AdBlue warning lamp lit, DEF/AdBlue quality warning lamp lit, DEF/AdBlue system warning lamp blinks (yellow) • Error code display: E:9520 Diesel Exhaust Fluid (DEF/AdBlue) concentration, quality error detected (195 to 240 min.) • Engine output, speed: Limited • DEF/AdBlue warning lamp lit, DEF/AdBlue quality warning lamp lit, DEF/AdBlue system warning lamp blinks (yellow), warning lamp blinks (red) • Error code display: E:9520, E:9601 Diesel Exhaust Fluid (DEF/AdBlue) concentration, quality error detected (240 min. or more) • Engine output, speed: Idling • DEF/AdBlue warning lamp lit, DEF/AdBlue quality warning lamp lit, DEF/AdBlue system warning lamp blinks (yellow), warning lamp blinks (red) • Error code display: E:9520, E:9602

5-18

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 10. SCR system

5. ENGINE

10.2.3 SCR defrost control Engine output limit and warning (lamp, error) due to DEF/AdBlue defrost control Warning lamp

Error

Control

Time

Engine output, speed

(1)

Normal

(2)

Defrost control

0 to 70 min.

Limit

Lit

(1) Normal state (2) 0 to 70 min.

Buzzer

(a) Engine output, speed (b) Time

(e) Limit

DEF/AdBlue defrost detection • When freezing of the DEF/AdBlue is detected, defrost control is performed for up to 70 minutes. • Engine output, speed: Idling • DEF/AdBlue defrost lamp is lit

SVL97-2

5-19

KiSC issued 09, 2021 A

MECHANISM 10. SCR system

5. ENGINE

10.2.4 DEF/AdBlue pump (Tampering) Engine output limit and warning (lamp, error) due to defective DEF/AdBlue pump (Tampering) Warning lamp

(1)

State

Time

Normal

0 to 195 min.

Limit

Blink

E:9517 E:9600

Every 60 sec.

195 to 240 min.

Limit

Blink

E:9517 E:9601

Pi···Pi

Every 20 sec.

240 min. or more

Idling

Blink

E:9517 E:9602

Pi···Pi

Every 10 sec.

(2)

(3)

(4)

Error

Engine output, speed

DEF/ AdBlue pump error

(1) Normal state (2) 0 to 195 min. (3) 195 to 240 min.

Buzzer

(4) 240 min. or more (a) Engine output, speed (b) Time

(e) Limit (f) Limit (g) Idling

DEF/AdBlue pump error detection (0 to 195 min.) • Engine output, speed: Limited • SCR system warning lamp blinks (red), warning lamp blinks (red) • Error code display: E:9517, E:9600 DEF/AdBlue pump error detected (195 to 240 min.) • Engine output, speed: Limited • SCR system warning lamp blinks (red), warning lamp blinks (red) • Error code display: E:9517, E:9601 DEF/AdBlue pump error detected (240 min or longer) • Engine output, speed: Idling • SCR system warning lamp blinks (red), warning lamp blinks (red) • Error code display: E:9517, E:9602

5-20

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 10. SCR system

5. ENGINE

10.2.5 SCR system error (Tampering) Engine output limit and warning (error, lamp) due to failure (tampering) of DEF/AdBlue pump, CAN communication, DEF/AdBlue tank, electrical equipment except 5 V power. Warning lamp

(1)

State

Time

Normal

0 to 195 min.

Blink

Every 60 sec.

195 to 240 min.

Limit

Blink

Pi···Pi

Every 20 sec.

240 min. or more

Idling

Blink

Pi···Pi

Every 10 sec.

(2) SCR system errors

(3)

(4) *1

Error

Engine output, speed

Buzzer

E:9601 *1

E:9602

E9500, 9505, 9508, 9509, 9510, 9518, 9519, 9521, 9522, 9523, 9525, 9527

(1) Normal state (2) 0 to 195 min. (3) 195 to 240 min.

(4) 240 min. or more (a) Engine output, speed (b) Time

(f)

Idling

SCR system error detected (0 to 195 min.) • SCR system warning lamp blinks (red), warning lamp blinks (red) SCR system error detected (195 to 240 min.) • Engine output, speed: Limited • SCR system warning lamp blinks (red), warning lamp blinks (red) SCR system error detected (240 min or longer) • Engine output, speed: Idling • SCR system warning lamp blinks (red), warning lamp blinks (red)

SVL97-2

5-21

KiSC issued 09, 2021 A

MECHANISM 10. SCR system

5. ENGINE

10.2.6 SCR system error (Derating) Engine output limit and warning (error, lamp) due to failure (tampering) of DEF/AdBlue pump, CAN communication, flash ROM, electrical equipment for 5 V power.

State

Engine output, speed

(1)

Normal

(2)

SCR system errors

0 or more

(1) Normal state (2) 0 minutes or longer

Warning lamp

Error Buzzer

Idling

(a) Engine output, speed (b) Time

Blink

E:9502 E:9504 E:9507 E:9526 E:9602

Pi···Pi

Every 10 sec.

(e) Idling

SCR system error detected • Engine output, speed: Idling • SCR system warning lamp blinks (red), warning lamp blinks (red) • Error code display: E:9502, E:9504, E:9507, E:9507, E:9526, E:9602

5-22

SVL97-2 KiSC issued 09, 2021 A

SERVICING 1. Intercooler

5. ENGINE

SERVICING 1. Intercooler

Mass

1.1 Removing and installing the intercooler CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. IMPORTANT • Install plugs or covers to the removed hoses, intake air line and engine to avoid dust contamination.

Intercooler

Approximately 4.7 kg Approximately 10.4 lbs

Installing IMPORTANT • In case that the hose is inserted too deep or shallow, the hose may come off. • Install the clamp at the specified position as shown in the following pictures.

Removing 1. Remove the 2 hose clamps and 2 hoses.

(6) Hose (to the intake manifold) (8) Clamp (7) Intake manifold (9) Bulge of the intake manifold

(1) Hose clamp x2

(2) Hose x2

2. Remove the 13 bolts and muffler cover. 3. Remove the intercooler with the cover.

(10) Hose (to the turbocharger) (11) Turbocharger outlet surface

(12) Clamp (13) Bulge of the turbocharger

Hose clamp position Hose clamp position

(3) Bolt (4) Muffler cover

SVL97-2

(a)

15 mm 0.6 in.

(b)

13 mm 0.5 in.

(5) Cover

5-23

KiSC issued 09, 2021 A

SERVICING 1. Intercooler

5. ENGINE Tightening torque (8), (12) Clamp

4.9 to 5.9 N⋅m 50 to 60 kgf⋅m 3.7 to 4.4 lbf⋅ft

IMPORTANT • In case that the hose is inserted too deep or shallow, the hose may come off. • Install the clamps parallel to the white line.

(14) Hose (intercooler side) (15) Clamp

(16) White line (c) 0 to 1 mm (0 to 0.04 in.)

(17) Hose (turbocharger side) (18) Clamp

(19) White line (d) 0 to 1 mm (0 to 0.04 in.)

IMPORTANT • The hoses have white and yellow marks as below. Install the hoses so that the marks faces downward (engine side). – White mark: hose between intercooler and intake manifold. – Yellow mark: hose between turbocharger and intercoole. Tightening torque (15), (18) Clamp

4.9 to 5.9 N⋅m 50 to 60 kgf⋅m 3.7 to 4.4 lbf⋅ft

(3) Bolt

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

5-24

SVL97-2 KiSC issued 09, 2021 A

SERVICING 1. Intercooler

5. ENGINE

1.2 Intercooler parts drawing

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

Intercooler Flange bolt (M6 × 10) ×4 Hose clamp ×4 Hose Hose

(6) (7) (a) (b)

Stay (c) Install the hose so that the yel- (f) White mark Bolt ×2 low mark faces downwards (g) Install the clamp at the lower Parallel (d) Install the hose so that the end of the white mark Install the intercooler with it white mark faces downwards pushed up against the cushion (e) 13 mm (0.5 in.) 7.8 to 9.3 N⋅m 0.8 to 1.0 kgf⋅m 5.7 to 6.9 lbf⋅ft

Flange bolt (2)

Hose clamp (3)

Stay (6)

SVL97-2

Tightening torque

4.9 to 5.9 N⋅m 0.5 to 0.6 kgf⋅m 3.6 to 4.4 lbf⋅ft 23.5 to 27.5 N⋅m 2.4 to 2.8 kgf⋅m 17.3 to 20.3 lbf⋅ft

5-25

KiSC issued 09, 2021 A

SERVICING 1. Intercooler

5. ENGINE

(8) Intercooler cover (9) Flange bolt (M10 × 16) ×10 (10) Cushion ×2 (11) Cushion

5-26

(12) Cushion (13) Cover (14) Flange bolt (M10 × 16) ×4 (15) Muffler cover

(16) Bolt ×3 (h) Do not leave clearance in the join section (i) Line up with the end face

(j)

Line up with the end face of the opening

SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Air cleaner

5. ENGINE

2. Air cleaner 2.1 Air cleaner parts drawing

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

Air cleaner Bolt (M8 × 20) ×4 Bracket Indicator

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

Hose clamp Bolt (M10 × 20) ×2 Inlet hose Hose clamp

(9) Hose clamp (10) Air flow sensor (11) Pan head machine screw (a) Parallel

Indicator (4)

1.0 to 2.0 N⋅m 0.1 to 0.2 kgf⋅m 0.74 to 1.48 lbf⋅ft

Hose clamp (5)

2.0 to 2.4 N⋅m 0.20 to 0.24 kgf⋅m 1.5 to 1.8 lbf⋅ft

Tightening torque Hose clamp (8)

2.8 to 3.2 N⋅m 0.29 to 0.33 kgf⋅m 2.1 to 2.4 lbf⋅ft

Hose clamp (9)

4.9 to 5.9 N⋅m 0.5 to 0.6 kgf⋅m 3.6 to 4.4 lbf⋅ft

SVL97-2

(b) 10 mm or longer (0.39 in. or longer)

5-27

KiSC issued 09, 2021 A

SERVICING 3. SCR muffler

5. ENGINE

3. SCR muffler

Installing

3.1 Removing/Installing the SCR muffler

IMPORTANT • In case that the hose is inserted too deep or shallow, the hose may come off. • Install the clamp at the specified position as shown in the following pictures.

3.1.1 Removing and installing the intercooler CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. IMPORTANT • Install plugs or covers to the removed hoses, intake air line and engine to avoid dust contamination. Removing 1. Remove the 2 hose clamps and 2 hoses.

(6) Hose (to the intake manifold) (8) Clamp (7) Intake manifold (9) Bulge of the intake manifold

(1) Hose clamp x2

(2) Hose x2

2. Remove the 13 bolts and muffler cover. 3. Remove the intercooler with the cover.

(10) Hose (to the turbocharger) (11) Turbocharger outlet surface

(12) Clamp (13) Bulge of the turbocharger

Hose clamp position Hose clamp position (a)

15 mm 0.6 in.

(b)

13 mm 0.5 in.

Tightening torque (8), (12) Clamp (3) Bolt (4) Muffler cover

5-28

(5) Cover

Mass Intercooler

4.9 to 5.9 N⋅m 50 to 60 kgf⋅m 3.7 to 4.4 lbf⋅ft

Approximately 4.7 kg Approximately 10.4 lbs

IMPORTANT • In case that the hose is inserted too deep or shallow, the hose may come off. • Install the clamps parallel to the white line.

SVL97-2 KiSC issued 09, 2021 A

SERVICING 3. SCR muffler

5. ENGINE NOTE • Use the cover to prevent contaminants from entering the DEF/AdBlue hose and DEF/ AdBlue injector.

(14) Hose (intercooler side) (15) Clamp

(16) White line (c) 0 to 1 mm (0 to 0.04 in.)

(1) DEF/AdBlue injector (2) DEF/AdBlue delivery hose

(3) DEF/AdBlue return hose

2. Disconnect the SCR intake temperature sensor connector, and then remove all of the clamps on the wire harness side.

(17) Hose (turbocharger side) (18) Clamp

(19) White line (d) 0 to 1 mm (0 to 0.04 in.)

(4) Connector

3. Remove the bolt.

Tightening torque (15), (18) Clamp

4.9 to 5.9 N⋅m 50 to 60 kgf⋅m 3.7 to 4.4 lbf⋅ft

(3) Bolt

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

3.1.2 Removing the SCR muffler 1. Remove the DEF/AdBlue injector connector, DEF/ AdBlue delivery hose, DEF/AdBlue return hose and clamp. (5) Bolt

SVL97-2

5-29

KiSC issued 09, 2021 A

SERVICING 3. SCR muffler

5. ENGINE 4. Remove the flange clamp.

IMPORTANT • When removing the SCR muffler, always remove it together with the bracket.

(6) Flange clamp

5. Remove two connectors. 6. Remove two bolts, and pre-NOx sensor module. 7. Remove two bolts, and remove the bracket and after-NOx sensor module together.

(14) SCR muffler

3.1.3 Installing the SCR muffler IMPORTANT • Replace the flange clamp and gasket with new parts. 1. Loosen the hook mounting bolts.

(7) Connector (8) Bolt (9) Pre-NOx sensor module (10) Bolt

(11) Bracket (12) After-NOx sensor module

8. Remove four bolts. (1) Hook

(13) Bolt

9. Remove the SCR muffler.

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 3. SCR muffler

5. ENGINE

2. Assemble the inlet pipe.

(2) Bolt (M10 × 25) × 4

Bolt (2)

(3) Inlet pipe

Tightening torque

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

3. Mount the SCR muffler on the bracket. 4. Match the inlet pipe and SCR muffler connection after matching hole positions.

(4) (5) (6) (a)

SCR muffler SCR muffler bracket Flange clamp Hole position

(b) Inlet pipe and SCR muffler connection

5. Tighten the flange clamp temporarily. 6. Check if SCR is mounted securely with rotating the flange clamp.

SVL97-2

(7) Flange clamp (8) Gasket (9) Gasket

(10) Flange clamp

5-31

KiSC issued 09, 2021 A

SERVICING 3. SCR muffler

5. ENGINE 7. Final tighten four SCR mounting bolts.

10. Tighten the hook mounting bolts.

(11) Flange bolt

(1) Hook

Flange bolt (11)

(12) Flat metal washer

Tightening torque

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

8. Final tighten the flange clamp. 9. Check if it is fixed securely with shaking the pipe, and double check the tightening torque.

Flange bolt (13)

(13) Bolt

Tightening torque

11. Adjust the position of the flange clamp bolt between the stay and bolt. 12. After tightening the flange clamp, tighten the bolt with the flange. 13. Final tighten the flange clamp. 14. Check if it is fixed securely with shaking the pipe, and double check the tightening torque.

(14) Stay (15) Flange clamp (16) Flat metal washer (17) Bolt

Flange clamp (15) Tightening torque Bolt (17) (7) Flange clamp (10) Flange clamp (c) Reference surface Flange clamp (7) Flange clamp (10)

5-32

(d) Assemble the clamp bolt below the reference surface

Tightening torque

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

12.0 to 17.0 N⋅m 1.2 to 1.7 kgf⋅m 8.9 to 12.5 lbf⋅ft 48.1 to 55.9 N⋅m 4.9 to 5.7 kgf⋅m 35.5 to 41.2 lbf⋅ft

12.0 to 17.0 N⋅m 1.2 to 1.7 kgf⋅m 8.9 to 12.5 lbf⋅ft

SVL97-2 KiSC issued 09, 2021 A

SERVICING 3. SCR muffler

5. ENGINE

3.2 SCR muffler pipe parts drawing

(1) SCR muffler pipe (2) Band (3) Muffler cover

Band (2)

(a) Do not mount on welding beads.

(b) Allow a clearance of 15 mm (0.6 in.) or more for the whole circumference between the SCR pipe and muffler cover. 23.1 to 26.9 N⋅m 2.4 to 2.7 kgf⋅m 17.0 to 19.8 lbf⋅ft

Tightening torque

4. DPF muffler 4.1 Removing/Installing the DPF muffler IMPORTANT • If the DPF is dropped or suffers an impact, it cannot be reused even if visually undamaged, therefore it must be replaced with a new part. • Use a claw-foot wrench to loosen the temperature sensor fixing nuts or differential pressure pipe fixing nuts so as to avoid damaging the sensor or pipe. If it is difficult to loosen the nuts, spray some lubricant oil on to the thread and allow it to lubricate the nuts. NOTE • The DPF muffler remains hot immediately after the engine is stopped, therefore, allow it to cool before carrying out the work. • Do not allow contaminants to enter the opening when carrying out work. • The DPF muffler has a ceramic filter installed, therefore, take care not to drop the muffler or allow it to suffer an impact. • Before removing the DPF muffler, connect a diagnostic tool (Diagmaster) to investigate the

SVL97-2

•

• •

breakdown history of the muffler, and save the work data. When the DPF is cleaned, the machine running time, engine serial number, comp filter (DPF) parts numbers, comp filter (DPF) serial number, catalyst (DOC) parts numbers, and engine operation time is recorded. (Preparation work for the DPF cleaning instructions is required) When mounting or removing the DPF muffler, ensure that the temperature sensor, differential pressure sensor, and differential pressure pipe do not come into contact with surrounding parts. Replace the gasket with a new part. If the differential pressure tube is damaged or cracked, replace it.

4.1.1 Removing and installing the intercooler CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot.

5-33

KiSC issued 09, 2021 A

SERVICING 4. DPF muffler

5. ENGINE IMPORTANT • Install plugs or covers to the removed hoses, intake air line and engine to avoid dust contamination. Removing 1. Remove the 2 hose clamps and 2 hoses.

(6) Hose (to the intake manifold) (8) Clamp (7) Intake manifold (9) Bulge of the intake manifold

(1) Hose clamp x2

(2) Hose x2

2. Remove the 13 bolts and muffler cover. 3. Remove the intercooler with the cover.

(10) Hose (to the turbocharger) (11) Turbocharger outlet surface

(12) Clamp (13) Bulge of the turbocharger

Hose clamp position Hose clamp position

(3) Bolt (4) Muffler cover

15 mm 0.6 in.

(b)

13 mm 0.5 in.

(5) Cover

Tightening torque

Mass

(8), (12) Clamp Intercooler

Approximately 4.7 kg Approximately 10.4 lbs

Installing IMPORTANT • In case that the hose is inserted too deep or shallow, the hose may come off. • Install the clamp at the specified position as shown in the following pictures.

5-34

(a)

4.9 to 5.9 N⋅m 50 to 60 kgf⋅m 3.7 to 4.4 lbf⋅ft

IMPORTANT • In case that the hose is inserted too deep or shallow, the hose may come off. • Install the clamps parallel to the white line.

SVL97-2 KiSC issued 09, 2021 A

SERVICING 4. DPF muffler

5. ENGINE

(14) Hose (intercooler side) (15) Clamp

(16) White line (c) 0 to 1 mm (0 to 0.04 in.)

(1) SCR muffler

4.1.3 Removing the DPF muffler 1. Disconnect the DPF temperature sensor connector and DPF differential pressure sensor connector, and remove two bolts.

(17) Hose (turbocharger side) (18) Clamp

(19) White line (d) 0 to 1 mm (0 to 0.04 in.)

(1) Connector

(2) Bolt

2. Remove three bolts and the bracket.

Tightening torque (15), (18) Clamp

4.9 to 5.9 N⋅m 50 to 60 kgf⋅m 3.7 to 4.4 lbf⋅ft

(3) Bolt

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

4.1.2 Removing the SCR muffler 1. Remove the SCR muffler.

SVL97-2

(3) Bolt

(4) Bracket

5-35

KiSC issued 09, 2021 A

SERVICING 4. DPF muffler

5. ENGINE 3. Remove five bolts.

Bolt (7) Nut (8)

Tightening torque

124 to 147.1 N⋅m 12.6 to 15.0 kgf⋅m 91.2 to 108.5 lbf⋅ft

6. Remove two bolts.

(5) Bolt

4. Remove four nuts for the exhaust manifold and DPF muffler flange. (9) Bolt

7. Remove four bolts for the DPF bracket.

(6) Nut

Nut (6)

Tightening torque

49 to 55 N⋅m 5.0 to 5.7 kgf⋅m 37 to 41 lbf⋅ft

5. Remove two bolts and nuts for the right SCR bracket, and slide the right SCR bracket toward the left of the machine.

(10) Bolt

Bolt (10)

(7) Bolt

5-36

Tightening torque

49 to 55 N⋅m 5.0 to 5.7 kgf⋅m 37 to 41 lbf⋅ft

(8) Nut

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE

8. Remove six bolts so that the bracket can be moved.

2. Firstly remove the (-) cable, and the (+) cable next.

(11) Bolt

(12) Bracket

9. While moving the bracket, turn the DPF muffler vertically so it can be removed.

(1) (-) cable

(2) (+) cable

3. Remove two self-locking nuts, battery retainer, battery cover, and battery.

(13) DPF muffler

5. Engine 5.1 Removing/Installing the engine 5.1.1 Removing the cabin 1. Dismount the cabin.

(3) Battery retainer (4) Battery cover (5) Battery

Self-locking nut (6)

(6) Self-locking nut

Tightening torque

4.0 to 5.0 N⋅m 0.41 to 0.51 kgf⋅m 3.0 to 3.7 lbf⋅ft

5.1.2 Removing the battery 1. Open the rear cover and bonnet.

SVL97-2

5-37

KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE

5.1.3 Draining fuel 1. Remove four bolts, and the cover.

(3) Guide

(1) Bolt (M12 × 30) ×4

(2) Cover

3. Disconnect the oil cooler hose, and plug the adapter to hose. • Tool: 36 mm spanner

2. Remove the drain plug, and drain the fuel.

(4) Oil cooler hose (3) Drain plug

(5) Oil cooler hose

4. Suspend the radiator with a crane temporarily, and remove the stopper.

5.1.4 Removing the radiator 1. Remove the radiator hose. • Tool: 10 mm spanner

CAUTION • Do not tilt the radiator, as it may fall. • Tools: 14 mm, 17 mm socket wrench

(6) Radiator stopper (1) Radiator hose

(2) Radiator hose

2. Remove the hose guide of the oil cooler. • Tool: 12 mm socket wrench

5-38

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE

5. Remove the radiator slowly with a crane.

5.1.6 Removing and installing the intercooler CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. IMPORTANT • Install plugs or covers to the removed hoses, intake air line and engine to avoid dust contamination. Removing 1. Remove the 2 hose clamps and 2 hoses.

(7) Radiator

Radiator weight

SVL95-2s SVL97-2

70.5 kg 155 lbs

5.1.5 Removal of the air cleaner 1. Remove the hose clamp.

(1) Hose clamp x2

(2) Hose x2

2. Remove the 13 bolts and muffler cover. 3. Remove the intercooler with the cover.

(1) Hose clamp

(2) Inlet hose

2. Remove two bolts, and then remove the air cleaner with the inlet hose.

(3) Bolt (4) Muffler cover

(5) Cover

Mass Intercooler

Approximately 4.7 kg Approximately 10.4 lbs

Installing (3) Bolt

SVL97-2

(4) Air cleaner

IMPORTANT • In case that the hose is inserted too deep or shallow, the hose may come off. 5-39

KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE • Install the clamp at the specified position as shown in the following pictures.

(14) Hose (intercooler side) (15) Clamp

(16) White line (c) 0 to 1 mm (0 to 0.04 in.)

(17) Hose (turbocharger side) (18) Clamp

(19) White line (d) 0 to 1 mm (0 to 0.04 in.)

(6) Hose (to the intake manifold) (8) Clamp (9) Bulge of the intake manifold (7) Intake manifold

(10) Hose (to the turbocharger) (11) Turbocharger outlet surface

(12) Clamp (13) Bulge of the turbocharger

Hose clamp position Hose clamp position (a)

15 mm 0.6 in.

(b)

13 mm 0.5 in.

Tightening torque (8), (12) Clamp

4.9 to 5.9 N⋅m 50 to 60 kgf⋅m 3.7 to 4.4 lbf⋅ft

(3) Bolt

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

IMPORTANT • In case that the hose is inserted too deep or shallow, the hose may come off. • Install the clamps parallel to the white line.

5-40

(15), (18) Clamp

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE

5.1.7 Removing the HST pump 1. Remove the HST pump.

(1) Connector (2) Hose (3) Bolt

(4) Oil separator

3. Remove three bolts and the bracket.

5.1.8 Removing the SCR muffler 1. Remove the SCR muffler.

(5) Bolt

(6) Bracket

4. Remove the engine oil guide. (1) SCR muffler

5.1.9 Removing the engine 1. Disconnect two connectors and all of the oil separator hoses, and plug the hoses. 2. Remove two bolts, and the oil separator.

(7) Engine oil guide

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE 5. Remove two bolts and the bracket.

(13) Coolant hose (8) Bolt

(9) Bracket

9. Remove the fuel hose, and plug the hose.

6. Remove the A/C hose from the compressor, and cover the hose and compressor.

(14) Fuel hose

10. Remove all connectors. (10) A/C hose

Flange bolt (11)

(11) Flange bolt

Tightening torque

7.9 to 11.8 N⋅m 0.8 to 1.2 kgf⋅m 1.8 to 2.7 lbf⋅ft

7. Remove the ground cable.

(12) Ground cable

8. Remove the coolant hose, and plug the hose.

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE

11. Remove three engine stopper bolts and self-locking nuts. NOTE • Apply a threadlock (Loctite® 271) to the stud bolts. • Apply a threadlock (Loctite® 271) to the bolts.

(a) Suspension position of jig (b) Engine suspension jig

13. Remove the engine slowly. NOTE • Ensure that the hose and wire harness are not caught. (15) Bolt (16) Stud bolt (17) Flat metal washer

(18) Self-locking nut

196.1 to 225.6 N⋅m 20.0 to 23.0 kgf⋅m 144.6 to 166.4 lbf⋅ft

Bolt (15)

Stud bolt (16)

Self-locking nut (18)

Tightening torque

98 to 113 N⋅m 10.0 to 11.5 kgf⋅m 72.8 to 83.4 lbf⋅ft 98 to 113 N⋅m 10.0 to 11.5 kgf⋅m 72.8 to 83.4 lbf⋅ft

12. Set the jig on the SCR bracket.

(d) Suspension position when removing the engine

IMPORTANT • Only when removing the engine, insert a pin at the front. • Check that the jig is mounted on the SCR bracket.

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE

5.2 Engine parts drawing 5.2.1 Engine mount parts drawing

(1) Bracket (2) Bracket

(3) Bolt (M12 × 30) ×8 (4) Washer

Bolt (3) Bolt (6)

Tightening torque

(5) Bracket (6) Bolt (M12 × 45) ×6

(7) Washer

103.0 to 117.7 N⋅m 10.5 to 12.0 kgf⋅m 76.0 to 86.8 lbf⋅ft

Apply a threadlock (Loctite® 271) to the bolts (3) (6).

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Engine

(8) Anti-vibration rubber (9) Stud bolt

5. ENGINE

(10) Washer (11) Self-locking nut

(14) Bolt (M16 ×75) (a) 8 mm (0.31 in.)

98 to 113 N⋅m 10.0 to 11.5 kgf⋅m 72.8 to 83.4 lbf⋅ft

Stud bolt (9)

Self-locking nut (11)

(12) Collar (13) Bolt (M16 × 90) ×2

Tightening torque

Bolt (13) Bolt (14)

166.7 to 191.2 N⋅m 17.0 to 19.5 kgf⋅m 123.0 to 141.0 lbf⋅ft 196.1 to 225.6 N⋅m 20.0 to 23.0 kgf⋅m 144.6 to 166.4 lbf⋅ft

Apply a threadlock (Loctite® 271) to the stud bolts (9). Apply a threadlock (Loctite® 271) to the bolts (13) (14).

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE

5.2.2 Oil separator parts drawing

(1) Oil separator (2) Bracket (3) Flange bolt (M8 × 20) ×7 (4) Tube (5) Hose clamp (6) Hose clamp (8) Hose clamp (9) Tube (10) Clamp

5-46

(11) Cord band (12) Tube (13) Hose clamp (14) Heater (a) Insert the tube until it is in contact with the oil separator and heater (b) Insert the tube until it is in contact with the engine

(c) Do not allow the clamp to contact the intercooler hose (d) Insert the tube until it is in contact with the engine (e) Pass the tube through the engine long hole and tie it up (f) Insert the tube until it reaches the end

(g) Insert the tube until it is in contact with the heater (h) Black tape (i) Yellow tape (j) Assemble with the connector facing the left side of the body and horizontal (k) Bind together with the tube (l) Mount the clamp as figure (6 clamps)

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE

5.2.3 Muffler bracket parts drawing

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

Base Flange bolt (M14 × 55) ×2 Flange nut (M14) Base Flange bolt (M14 × 55) ×3 Flange nut (M14)

(7) Stay (8) Flange bolt (M10 × 25) ×6 (9) Flange bolt (M10 × 35) ×2 (10) Flat metal washer (11) Washer (12) Stay

Flange bolt (2) (5)

(13) Flange bolt (M10 × 25) ×2 (14) Stay (15) Flange bolt (M10 × 25) ×3 (16) Flat metal washer (17) Oiling flange (18) O-ring

(19) Stay (20) Bolt (M8 × 25) ×2 (21) Oil supply port plug (a) Assemble without oil supply port plug

123.6 to 147.1 N⋅m 12.6 to 15.0 kgf⋅m 91.2 to 108.5 lbf⋅ft

Flange nut (3) (6) Flange bolt (8) Flange bolt (9) Flange bolt (13)

Tightening torque

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

Flange bolt (15) Bolt (20)

SVL97-2

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

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KiSC issued 09, 2021 A

SERVICING 5. Engine

5. ENGINE

5.3 Removing/Installing the fuel tank 5.3.1 Cabin lock 1. Tilt-up the cabin, and lock it.

(1) Mat

2. Remove three bolts.

5.3.2 Draining fuel 1. Remove four bolts, and the cover.

(2) Bolt (M10 × 20) × 3

3. Remove the accelerator potentiometer connector and the accelerator pedal assembly. (1) Bolt (M12 × 30) ×4

(2) Cover

2. Remove the drain plug, and drain the fuel.

(3) Drain plug

(3) Accelerator potentiometer connector

(4) Accelerator pedal assembly

5.3.3 Removing the step 1. Remove the mat.

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SERVICING 5. Engine

5. ENGINE

4. Remove three bolts and the step.

(12) Bolt (M10 × 20) × 3 (5) Bolt (M10 × 20) × 3

(6) Step

(13) Step

8. Remove two bolts and the bracket.

5. Remove ten bolts and the plate.

(14) Bolt (M10 × 20) × 2 (7) Bolt (M10 × 20) × 7 (8) Bolt (M10 × 20) × 3

(15) Bracket

(9) Step

6. Remove two bolts and the plate.

5.3.4 Removing the fuel tank 1. Remove two mounting bolts for the fuel supply port.

(1) Bolt (10) Bolt (M10 × 25) × 2

(11) Plate

7. Remove three bolts and the step.

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SERVICING 5. Engine

5. ENGINE 2. Remove the connector, nut, two bolts, and remove the band and plate.

(5) Band (6) Plate

(2) Connector (3) Nut (M10) (4) Bolt (M10)

3. Remove two hose clamps. 4. Remove two fuel hoses, and plug the fuel tank and fuel hoses.

(7) Drain hose

(8) Delivery hose

5. Remove the hose clamp, fuel hose, and fuel tank. NOTE • Do not slide the fuel tank from side to side while carrying out this work, as this could damage the fuel tank.

(9) Hose clamp

Fuel tank mass

5-50

(10) Fuel hose SVL95-2s SVL97-2

7.3 kg 16.1 lbs

SVL97-2 KiSC issued 09, 2021 A

SERVICING 6. Fuel tank

5. ENGINE

6. Fuel tank 6.1 Fuel tank parts drawing

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Fuel tank Cap Fuel pump Fuel hose Hose clamp Fuel sensor Screw with washer Bolt (M10 × 25) ×2 Plate

(10) Cushion (11) Bolt (M10 × 25) ×2 (12) Flat metal washer (13) Band (14) Cushion (15) Self-locking nut (16) Cushion (17) Cushion (18) Cushion

(19) Cushion (20) Cushion (21) Plate (22) Cushion (23) Bolt (M10 × 25) ×2 (24) Band (25) Cushion (26) Self-locking nut (a) Adjust the holes to the bolts.

Hose clamp (Tank side) (5)

2.9 to 3.9 N⋅m 0.3 to 0.4 kgf⋅m 2.1 to 2.9 lbf⋅ft

Hose clamp (Pipe side) (5)

4.9 to 5.9 N⋅m 0.5 to 0.6 kgf⋅m 3.6 to 4.4 lbf⋅ft

Tightening torque Screw with washer (7)

3.0 to 4.0 N⋅m 0.3 to 0.4 kgf⋅m 2.21 to 2.95 lbf⋅ft

Bolt (11)

48 to 56 N⋅m 4.9 to 5.7 kgf⋅m 35.4 to 41.3 lbf⋅ft

SVL97-2

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

Parallel 5 to 10 mm (0.2 to 0.4 in.) 10 to 15 mm (0.4 to 0.6 in.) 68 mm (2.7 in.) 78 mm (3.0 in.) 150 mm (5.9 in.) 115 mm (4.5 in.) 495 mm (19.4 in.) 33 mm (1.3 in.)

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KiSC issued 09, 2021 A

SERVICING 6. Fuel tank

5. ENGINE

6.2 Fuel pump parts drawing

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

Bracket Bolt (M10 × 20) ×2 Water separator Fuel hose Bolt (M8 × 70)

5-52

(6) Fuel tube (7) Fuel pump (8) Bolt (M6 × 30) ×2 (9) Fuel tube (10) Fuel filter

(11) Pipe joint (12) Packing (13) Joint (14) Packing (15) Coupling bolt

(16) Bolt (M10 × 30) ×2 (a) 15° (b) Parallel (c) Drain water

SVL97-2 KiSC issued 09, 2021 A

SERVICING 6. Fuel tank

5. ENGINE

6.3 Fuel hose route CAUTION • • • •

Do not contact the fuel hoses to sharp edges, high temperature parts, and rotating parts. Do not stretch the fuel hoses excessively. Do not clamp with electrical wiring. Do not flatten the fuel hoses by the clamps.

A: B:

Engine Fuel tank

C: D:

Fuel return port Supply pump

E: F:

Fuel filter Fuel feed pump

Water separator

Fuel tube length

Protective tube length

(1)

1800 mm (70.9 in.)

1660 mm (65.4 in.)

(2)

1800 mm (70.9 in.)

1660 mm (65.4 in.)

(3)

250 + 35 mm (9.84 + 1.4 in.)

(4)

500 mm (19.7 in.)

380 mm (15.0 in.)

(5)

495 mm (19.5 in.)

380 mm (15.0 in.)

(6)

280 mm (11.0 in.)

(7)

Molded hose

(8)

180 mm (7.1 in.)

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 7. DEF/AdBlue tank

5. ENGINE

7. DEF/AdBlue tank 7.1 Removing the DEF/AdBlue tank CAUTION • Do not work soon after the engine has stopped. – Engine, fuel, and oil are extremely hot. – Pressure in the fuel line is high. • Keep fire and flammable items away from the working area. Preparing 1. Lower the front attachment to the ground, and stop the engine. 2. Open the rear bonnet and insert the pin into the lock position.

(3) Drain plug

3. Open the DEF/AdBlue tank cover and remove the DEF/AdBlue tank cap.

CAUTION • Check that the rear bonnet is securely locked. 3. Tilt the radiator and oil cooler. Removing 1. Remove four bolts and the bottom cover.

(4) Bolt

(5) Cover

4. Remove the 3 connectors, 2 DEF/AdBlue hoses and coolant hoses.

(1) Bolt

(2) Cover

2. Remove the drain plug and drain the DEF/AdBlue. NOTE • The DEF/AdBlue corrodes metal, so place the DEF/AdBlue in a plastic container.

(6) Connector (7) DEF/AdBlue hose

(8) Coolant hose

5. Remove the 6 bolts to remove the fan.

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 7. DEF/AdBlue tank

(9) Bolt x6

5. ENGINE

(10) Fan

6. Remove the DEF/AdBlue tank band, and then remove the DEF/AdBlue tank.

(11) Band (12) DEF/AdBlue tank

(13) Bolt

Installing Tightening torque (3) Drain plug

4.0 to 6.0 N⋅m 0.41 to 0.61 kgf⋅m 2.95 to 4.43 lbf⋅ft

(13) Bolt

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

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 7. DEF/AdBlue tank

5. ENGINE

7.2 DEF/AdBlue hose routing

(1) Return hose (2) Delivery hose

5-56

(3) Suction hose (4) DEF/AdBlue tank

(5) DEF/AdBlue pump (6) SCR muffler

(7) DEF/AdBlue injector

Hose

Length

Tape color

(1)

Injector to tank

1260 mm 50 in.

Blue

(2)

Pump to injector

510 mm 20 in.

None

(3)

Tank to pump

860 mm 34 in.

Red

SVL97-2 KiSC issued 09, 2021 A

SERVICING 8. DEF/AdBlue pump

5. ENGINE

8. DEF/AdBlue pump 8.1 DEF/AdBlue pump parts drawing

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

DEF/AdBlue delivery hose DEF/AdBlue return hose DEF/AdBlue suction hose Bracket

SVL97-2

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

DEF/AdBlue pump Bolt (M8 × 35) × 4 ACU Flange bolt (M6 × 30) × 4

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KiSC issued 09, 2021 A

SERVICING 9. Coolant valve

5. ENGINE

9. Coolant valve 9.1 Coolant valve parts drawing 9.1.1 Coolant valve parts drawing (Open cab model)

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

Coolant valve Bolt (M8 × 65) ×3 Bracket Bolt (M10 × 20) ×2

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

Bolt (2)

Heater hose Heater hose Heater hose Heater hose

(9) Heater hose (a) Insert the hose until it is in contact with the valve (b) Bind heater hoses (5) and (9)

9.8 to 11.3 N⋅m 1.00 to 1.15 kgf⋅m 7.2 to 8.3 lbf⋅ft

Tightening torque

9.1.2 Coolant valve parts drawing (Closed cab model)

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

Coolant valve Bolt (M8 × 65) ×3 Bracket Bolt (M10 × 20) ×2

Bolt (2)

5-58

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

Heater hose Heater hose Heater hose Heater hose

Tightening torque

(9) Heater hose (10) Heater hose (a) Insert the hose until it is in contact with the valve

(b) Bind heater hoses (5) and (9) (c) Bind heater hoses (7) and (8)

9.8 to 11.3 N⋅m 1.00 to 1.15 kgf⋅m 7.2 to 8.3 lbf⋅ft

SVL97-2 KiSC issued 09, 2021 A

6. HYDRAULIC SYSTEM

KiSC issued 09, 2021 A

MECHANISM 1. Hydraulic equipment layout

6. HYDRAULIC SYSTEM

MECHANISM 1. Hydraulic equipment layout

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

HST pump Piston pump Gear pump Control valve HST motor Pilot Valve (travel)

SVL97-2

(7) Pilot Valve (front attachment) (8) Unload valve (travel speed shift, parking brake and hydraulic unlock) (9) Proportional solenoid valve (anti-stall and AUX)

(10) Hydraulic oil tank (11) Forced lift arm lowering valve (12) Breather filter (13) HST filter (14) Oil cooler (15) AUX outlet port

(16) Lift arm cylinder (17) Bucket cylinder (18) Hydraulic quick hitch cylinder

6-1

KiSC issued 09, 2021 A

MECHANISM 2. HST pump

6. HYDRAULIC SYSTEM

2. HST pump 2.1 HST Pump specifications

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

Port A (high-pressure port) Port B (high-pressure port) Port C (high-pressure port) Port D (high-pressure port) Port M5 (control port)

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

Port M14 (control port) Port M4 (control port) Port M15 (control port) Port M6 (charge port)

(10) Port L1 (engine stop prevention) (11) Port L2 (drain) (12) High pressure relief valve (13) Charge relief valve

(14) Max swash-plate adjustment bolt (15) Neutral adjustment bolt (a) Body front - Gear pump side (b) Engine side (c) Body top

Specifications Manufacturer Rotation direction

DAIKIN SAUER DANFOSS LTD. Right turn as seen from the engine side (input shaft)

Rated RPM

2900 rpm

Max displacement

94 c/rev 5.7 in3

High pressure relief valve setting pressure

32.5 MPa 331 kgf/cm2 4710 psi

Charge relief valve setting pressure

2.4 MPa 24 kgf/cm2 350 psi

6-2

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 2. HST pump

6. HYDRAULIC SYSTEM

2.2 HST Pump functions and structures 2.2.1 HST pump working principles The HST pump and travel motor are connected in the closed circuit, and switching of travel operations (neutral, forward, reverse, travel speed) is variable.

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

Piston Retainer plate Shoe Swash-plate

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

Cylinder block Valve plate Discharge port Suction port

(9) A: B: C:

Shaft Discharge side Suction side Gear pump side

Engine side

• • • •

The cylinder block is splined to the shaft, which is rotated by the engine. One end of the cylinder block is in contact with the valve plate, and is connected to the Suction/Discharge port. When the cylinder block is rotated, the piston moves in a reciprocating motion, guided by the swash-plate. The reciprocating motion changes the capacity inside the cylinder, performing a pumping action (suction/ discharge). • When the swash plate angle changes, the stroke of the piston changes, which in turn, changes the pump discharge quantity. Zero discharge rate (the travel motor is stopped)

(1) Servo cylinder (2) Servo piston

(3) M5 port (4) M4 port

(5) Swash-plate (6) A-port

(7) B port (a) Engine side

• The swash-plate is in the neutral position (swash plate angle 0 ), so the HST pump will not discharge oil.

SVL97-2

6-3

KiSC issued 09, 2021 A

MECHANISM 2. HST pump

6. HYDRAULIC SYSTEM Discharge from B port (the travel motor is in "Forward")

(1) Servo cylinder (2) Servo piston

• • • •

(3) M5 port (4) M4 port

(5) Swash-plate (6) A-port

(7) B port (a) Engine side

The oil from the gear pump flows to the M5 port. Oil that flows to the M5 port pushes the servo piston. The servo piston tilts the swash-plate, discharging high pressure oil from B port. The oil returned from the travel motor enters the HST pump from A-port.

Discharge from A-port (the travel motor is in "Reverse")

(1) Servo cylinder (2) Servo piston

(3) M5 port (4) M4 port

(5) Swash-plate (6) A-port

(7) B port (a) Engine side

When the travel motor is in "reverse", the workings are the opposite to those of "forward".

6-4

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 3. Piston pump

6. HYDRAULIC SYSTEM

3. Piston pump 3.1 Piston pump specifications

(1) A1 port (2) B1 port

(3) P1 port (4) PL port

(5) Drain port

Specification Manufacturer

Kawasaki Heavy Industries, Ltd

Model

K3VLS65-1ARBBM-LXA-T048

Rotation direction Rated RPM

To the right as seen from the shaft end 2600 min-1

Max displacement

65 cm3 4.0 in3

Rated pressure

28 MPa 286 kgf/cm2 4060 psi

Peak pressure

35 MPa 357 kgf/cm2 5075 psi

SVL97-2

6-5

KiSC issued 09, 2021 A

MECHANISM 3. Piston pump

6. HYDRAULIC SYSTEM

3.2 Piston pump functions and structures

3.2.2 Piston pump "Regulator" functions and structures

3.2.1 Piston pump working principles

The difference in pressure is used to control the swash plate angle of the piston pump.

Rotation of the shaft causes the piston to move in a reciprocating motion inside the cylinder, which produces oil suction and discharge.

(1) Shaft (2) Cylinder block (3) Piston

(4) Swash-plate (5) Valve plate

• The cylinder block is splined to the shaft, which is rotated by the engine. • The rotation of the cylinder block causes the piston to move in a reciprocating motion, guided by the swash-plate. • The reciprocating motion changes the capacity inside the cylinder, performing a pumping action. • The pump discharge rate is controlled by the swash plate angle.

(1) Spring (2) Spool (3) Orifice

(4) Piston pump (5) Gear pump

Gain control The flow rate of the piston pump is proportionally controlled with the engine speed. • The oil discharged from the gear pump flows to the regulator from the PI port. • The oil from the PI port flows to the PA port via an orifice. • When the engine speed changes, the pressure of the oil that flows from the PI port changes. • This increases/reduces the pressure before and after the orifice and switches the position of the spool. • The hydraulic oil from the Pd port passes through the spool, and determines the flow rate of the piston pump. LS differential pressure The difference in pressure between PPS and PLS controls the flow rate of the piston pump. • The pressurized oil (PPS) from the piston pump flows to the regulator from the Pd port, and the load pressure (PLS) flows to the regulator from the PL port. • The pressure difference between PPS and PLS + Spring determines the position of spool inside the regulator.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 3. Piston pump

6. HYDRAULIC SYSTEM

• The hydraulic oil from the Pd port passes through the spool, and determines the flow rate of the piston pump.

SVL97-2

6-7

KiSC issued 09, 2021 A

MECHANISM 3. Piston pump

6. HYDRAULIC SYSTEM

3.2.3 Piston pump "Relief cut" function Minimizes the discharging flow rate of the piston pump in case of overloading.

(1) Piston pump (2) Unload LS valve

(3) LS relief valve (4) LS regulator

(5) Spool (6) Piston

• • • • • •

In case of high load on a front attachment, the load pressure (PLS) increases and opens the LS relief valve. The PLS becomes stable at the setting pressure of the LS relief valve. The LS regulator controls the piston pump discharging pressure (PPS) depending on the PLS. As the actuator is overloaded, the PPS continues increasing. PPS becomes higher than the PLS and spring force of the spool in the LS regulator and shifts the spool to the left. The pressurized oil from the piston pump flows to the piston and the piston pushes the swash plate to minimize the swash plate angle. • The discharging flow rate of the piston pump is minimized.

6-8

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 4. Gear pump

6. HYDRAULIC SYSTEM

4. Gear pump 4.1 Gear pump specifications

(1) Section port

(2) Delivery port

(a) Rotation direction Specification

SVL97-2

Manufacturer

Shimadzu Corporation

Model

EGP1A25F2H5-R558

Rotation direction

Clockwise direction as viewed from the shaft side

Rated RPM

2400 rpm

Ideal discharge rate

24.9 cc/rev 1.5 in3/rev

Rated pressure

20.6 MPa 210 kg/cm3 2987 psi

6-9

KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5. Control valve 5.1 Control valve specifications

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

Main relief valve LS relief valve Overload relief valve Main spool Lift arm spool

(6) Bucket spool (7) AUX spool (8) Unload LS valve (9) Backpressure check valve (10) Float switch valve

(11) Solenoid Valve (float) (12) Flow divider ratio adjustment valve (13) Flow divider valve (14) Sequence valve

(15) High pressure selection valve (16) Bleed throttle

Specification

Remarks

Manufacturer

Kawasaki Heavy Industries, Ltd

Model

Main relief valve setting pressure

27.5 MPa 280.5 kgf/cm2 3989 psi

At 20 L/min

LS relief valve setting pressure

23.1 MPa 235.6 kgf/cm2 3350 psi

At 15 L/min

Lift arm down [A1] Lift arm up [B1] Overload relief valve setting pressure

Bucket down [A2] Bucket up [B2]

29.5 MPa 300.9 kgf/cm2 4279 psi

At 20 L/min

AUX-M [A3] AUX-F [B3]

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

Number

Port No. identifier

Connect to

(1)

Lift arm down

(2)

Bucket dump

(3)

AUX operation

(4)

Lift arm up

(5)

Bucket crowd

(6)

AUX operation

(7)

Solenoid Valve (Anti-stall, AUX)

(8)

Pa1

Lift arm down pilot pressure

(9)

Pa2

Bucket dump pilot pressure

(10)

Pa3

AUX operation pilot pressure

(11)

Pb1

Lift arm up pilot pressure

(12)

Pb2

Bucket crowd pilot pressure

(13)

Pb3

AUX operation pilot pressure

(14)

PLS

To regulator

(15)

To piston pump

(16)

To tank

SVL97-2

6-11

KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2 Control valve functions and structures 5.2.1 Control valve "Main relief valve" functions and structures This valve is used to prevent pressure surges inside the hydraulic circuit. Normal (Operating pressure < Pressure setting)

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

Adjustment valve Piston Throttle a Spring chamber A Adjustment part Seat B

(7) Poppet (8) Adjustment spring (9) Tank passage (10) Drain passage (11) Seat

• The hydraulic oil is shut off by seat B. • The poppet does not move, so the circuit will not be relieved. Operated (Operating pressure > Pressure setting)

• This difference in pressure causes the adjustment valve to move to the right. • Hydraulic oil is returned to the tank from the seat of the adjustment valve.

5.2.2 Control valve "LS relief valve" functions and structures This valve sets the maximum load pressure of the LS line. Normal (Operating pressure < Pressure setting)

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

Piston Plunger Seat Poppet

(5) Spring (a) LS line (b) Spring chamber

• The hydraulic oil is at or below the set pressure, so the poppet will not move. • The LS line and spring chamber have the same pressure, so it does not relief. Operated (Hydraulic oil > Pressure setting)

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

Adjustment valve Piston Throttle a Spring chamber A Adjustment part Seat B

(7) Poppet (8) Adjustment spring (9) Tank passage (10) Drain passage (11) Seat

• The poppet opens, and the hydraulic oil returns to the tank via the drain passage. • The pressure in spring chamber A drops, resulting in a difference in pressure before and after throttle a.

6-12

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

Piston Plunger Seat Poppet Spring

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

LS line Spring chamber Inside the chamber Tank passage

• The pressure of the hydraulic oil is greater than the spring force, and the poppet opens. • The piston operates, and the hydraulic oil flows into the chamber.

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

• A difference in pressure occurs between the LS line and spring chamber causing the plunger to open the seat. • The hydraulic oil flows to the tank passage.

5.2.3 Control valve "Overload relief valve" functions and structures During overload, the control valve is relieved of hydraulic oil, and when there is negative pressure, hydraulic oil is supplied to the control valve. Normal (Operating pressure < Pressure setting)

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

Spring Poppet Seat Plunger

(5) Piston (a) Cylinder port (b) Spring chamber

• The hydraulic oil is at or below the set pressure, so the poppet will not move. • The cylinder port and spring chamber are at the same pressure. • The plunger does not move, so the valve is not relieved.

• The poppet will open if the pressure is greater than the spring force. • The piston operates, and the hydraulic oil flows into the chamber. • The plunger will move when there is a difference in pressure between the cylinder port and spring chamber. • The plunger opens the seat, and the hydraulic oil flows to the tank passage. Make-up When the actuator has negative pressure, the hydraulic oil will be replenished from the tank.

(3) Seat (a) Cylinder port

(b) Spring chamber (d) Tank passage

• Negative pressure occurs in the spring chamber, and the seat moves. • The hydraulic oil in the tank passage flows to the cylinder port.

Operated (Hydraulic oil > Pressure setting)

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

Spring Poppet Seat Plunger Piston

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

Cylinder port Spring chamber Inside the chamber Tank passage

• When an overload occurs, the pressure of the cylinder port rises. SVL97-2

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KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2.4 Control valve "Non-operation" hydraulic description

(1) P chamber oil passage (2) Backpressure check valve

(3) Lift arm cylinder (4) Bucket cylinder

(5) Unload LS valve

• The pressure oil from the piston pump passes through the P chamber oil passage and opens the unload LS valve. • The oil from the piston pump returns to the tank.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2.5 Control valve "Lift arm down" hydraulic description

(1) Compensator spool (2) Load check valve

(3) Check valve (4) Lift arm cylinder

(5) Lift arm spool (6) High pressure selection valve

• • • •

When a lift arm down operation is performed, the oil from the gear pump flows to the Pa1 port. The pressure oil of the Pa1 port switches the spool. The oil from the piston pump flows from port P to the lift arm section inside the control valve. The oil from the piston pump flows to the lift arm cylinder (A1 port) via the compensator spool, load check valve, and check valve. • After passing through the compensator spool, oil also flows to the LS port. • The oil returned from the lift arm cylinder (B1 port) is returned to the tank.

SVL97-2

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MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2.6 Control valve "Lift arm up" hydraulic description

(1) Compensator spool (2) Load check valve (3) Check valve

(4) Lift arm cylinder (5) Lift arm spool (6) High pressure selection valve

(7) Flow divider valve ratio adjust- (9) Bucket cylinder ment valve (10) Sequence spool (8) Flow divider valve spool

• • • •

When an arm lift operation is performed, the oil from the gear pump flows to the Pb1 port. The pressure oil of the Pb1 port switches the spool. The oil from the piston pump flows from port P to the lift arm section inside the control valve. The oil from the piston pump flows to the lift arm cylinder (B1 port) via the compensator spool, load check valve, and check valve. • After passing through the compensator spool, oil also flows to the LS port. • The oil returned from the lift arm cylinder (A1 port) is returned to the tank via the lift arm spool. • Some of the returned oil flows to the bucket cylinder from the flow divider valve. 6-16

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2.7 Control valve "Bucket leveling mechanism" hydraulic description Leveling the bucket when lifting up the arm.

(4) Lift arm cylinder (9) Bucket cylinder (7) Flow divider valve ratio adjust- (A) At the end of a dump ment valve

• • • • •

The oil returned from the lift arm cylinder flows to the flow divider valve. The flow divider valve ratio adjustment valve is used to adjust the flow rate of oil into the bucket cylinder. The oil that passes through the flow divider valve and flows to the sequence spool. The oil that passes through the sequence spool and flows to the bucket cylinder dump side. When the bucket cylinder reaches the dump end, the sequence spool switches to return hydraulic oil to the tank.

SVL97-2

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MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2.8 Control valve "Bucket operation" hydraulic description Dump

(4) Lift arm cylinder

(9) Bucket cylinder

• When a bucket dump operation is performed, the oil from the gear pump flows to the Pb2 port. • The oil from the gear pump switches the spool of the bucket section. • The oil from the piston pump flows to the bottom of the bucket cylinder, and the bucket performs a dump. Crowd

(4) Lift arm cylinder

(9) Bucket cylinder

• When a bucket crowd operation is performed, the oil from the gear pump flows to the Pa2 port. • The oil from the gear pump switches the spool of the bucket section. • The oil from the piston pump flows to the rod side of the bucket cylinder, and the bucket performs a crowd.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2.9 Control valve "AUX operation" hydraulic description

(1) AUX section

(2) Compensator spool

(3) Load check valve

(4) High pressure selection valve

• • • •

AUX solenoid valve switches to release the AUX lock with pressing AUX switch. The oil from the gear pump flows to the AUX section of the control valve. The oil from the piston pump flows to each port via the compensator spool and load check valve poppet. At this time, the high pressure selection valve guides the pressure to the LS port after the oil passes through the compensator spool. A1 valve open • The oil from the gear pump flows to the Pa3 port and switches the spool of the AUX section. • The oil from the piston pump flows to the quick coupler (female) of the AUX outlet. • Oil is returned from the quick coupler (male) to the tank via the control valve. A2 valve open • The oil from the gear pump flows to the Pb3 port and switches the spool of the AUX section. • The oil from the piston pump flows to the quick coupler (male) of the AUX outlet. • Oil is returned from the quick coupler (female) to the tank via the control valve.

SVL97-2

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MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2.10 Control valve "Load Sensing (flow control)" hydraulic description Controls the flow rate of the piston pump according to the operating load. Non-operation • The flow rate of the piston pump is reduced, and the pressure oil of the P line is returned to the tank.

(1) Piston pump (2) Unload LS valve

(3) Regulator

Red P line :

Blue T line :

• The unload relief valve opens, and the pressure oil of the P line returns to the tank. • The spool of each section is in neutral, so oil will not flow to the LS line. • The regulator keeps the pump flow rate to a minimum. (Standby flow) Single operation (Lift arm) • The flow rate is increased for the piston pump, and all of the pressure oil of the P line flows to the actuator (cylinder).

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

(5) Orifice (6) Swash-plate (7) High pressure selection valve

Red P line : Blue T line :

Yel- Pressure oil from gear pump low: Gre LS line en:

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

Piston pump Unload LS valve Regulator Lift arm cylinder

• • • • • •

The pressure oil flows to the LS line, and the unload relief valve closes. The pressure oil from the P line flows to the actuator (cylinder). The pressure oil of the LS line flows to the regulator, and switches the spool. The swash plate angle changes, and increases the flow rate of the piston pump. When the operating load increases, the LS line pressure increases, and the regulator spool switches. The swash-plate of the piston pump drops, and increases the flow rate of the piston pump.

Combined operations (Lift arm + Bucket) • The flow rate of the piston pump is increased to match the pressure of the actuator (cylinder) under high load.

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MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

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

Piston pump Unload LS valve Regulator Lift arm cylinder Orifice

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

Swash-plate High pressure selection valve Compensator spool Bucket cylinder

Red P line : Blue T line :

Yel- Pressure oil from gear pump low: Gre LS line en:

• The pressure with the higher operating load goes through the LS line. • The high pressure select valve prevents pressure oil from flowing to sections with a low loads.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2.11 Control valve "Anti-Saturation" hydraulic description During combined operations, the flow rate for the higher load actuator is increased.

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

Piston pump Unload relief valve Regulator Lift arm cylinder Orifice

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

Swash-plate High pressure selection valve Compensator spool Bucket cylinder

Red P line : Blue T line :

Yel- Pressure oil from gear pump low: Gre LS line en:

• When the arm is under high load 1. The load pressure of the arm section will equalize with the maximum load pressure (Pmax), and the area of the compensator spool opening space becomes larger. 2. The maximum load pressure (Pmax) will be greater than the load pressure of the bucket (AUX) section, and the area of the compensator spool opening space becomes smaller. • The area of the compensator spool opening space changes the supplying flow rate to the actuator.

SVL97-2

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MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2.12 Control valve "Lift arm float operation" hydraulic description Moves an attachment along the ground.

(1) Lift arm cylinder (2) Float switch valve spool

(3) Solenoid Valve (float) (4) Check valve

(5) Bucket cylinder

When in neutral (Float switch OFF) • The float switch valve spool shuts off the hydraulic oil in the lift arm cylinder. During operation (Float switch ON) • When the float switch is ON, the Solenoid Valve (Float) switches. • The pressure oil of the PP port pushes the float switch valve spool. • The hydraulic oil of the lift arm cylinder connects with the tank passage.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 5. Control valve

6. HYDRAULIC SYSTEM

5.2.13 Control valve "Hydraulic quick hitch" hydraulic description Uses a switch to hitch the front attachment.

(1) Hydraulic unlock switch (2) Hydraulic pressure quick hitch switch ON

(3) Hydraulic pressure quick hitch switch OFF

(4) Solenoid Valve (Hydraulic pressure quick hitch lock)

(5) Solenoid Valve (Hydraulic pressure quick hitch unlock) (6) Hydraulic quick hitch cylinder

• When you press the hydraulic pressure release switch and set the hydraulic pressure quick hitch switch to ON, the Solenoid Valve (hydraulic pressure quick hitch lock) switches. • Oil from the gear pump will flow to bottom of the quick hitch cylinder.

SVL97-2

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MECHANISM 6. Pilot valve (Travel)

6. HYDRAULIC SYSTEM

6. Pilot valve (Travel)

Hydraulic circuit diagram

6.1 Pilot valve (Travel) specifications

(1) Turning to the left (2) Forward

(3) Turning to the right (4) Backward

Performance diagram (port 1, 3)

(1) Horn switch (2) AUX electrical control switch 1 (3) Travel speed shift switch (4) AUX electrical control switch 3 (5) Blank

(6) Port P (7) Port T (8) Port 1 (forward, RH)) (9) Port 2 (forward, LH) (10) Port 3 (backward, RH)) (11) Port 4 (backward, LH) (a) Front side

Performance diagram (port 2, 4)

Specifications Manufacturer

KPM (Kawasaki Precision Machinery)

Single operation angle (port 1, 3)

19°

Single operation angle (port 2, 4)

23°

Maximum primary pressure

6.9 MPa 70 kgf/cm2 1000 psi

Rated flow rate

15 L/min 4.0 U.S.gals

6-26

(1) Secondary pressure (2) Operation torque (3) Single operation torque (Port 2) (4) Single operation torque (Port 4) (a) Secondary pressure (psi) (b) Secondary pressure (kgf/ cm2)

Secondary pressure (MPa) Operation torque (N⋅m) Operation torque (kgf⋅cm) Operation torque (lbf⋅ft) Push-rod stroke (mm) Operation angle (deg)

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 6. Pilot valve (Travel)

6. HYDRAULIC SYSTEM

Wiring color layout

Electrical circuit diagram

Wiring color

Function

Wiring color

Function

R (Red)

Acc

O (Orange)

AUX electrical control switch 3 (LH)

W (White)

Travel speed shift switch

G (Green)

AUX electrical control switch 3 (RH)

L (Blue)

AUX electrical control switch 1 (LH)

Gy (Glay)

Y (Yellow)

AUX electrical control switch 1 (RH)

Lg (Light green)

Blank

V (Violet)

Horn switch

B (Black)

Ground

(1) (2) (3) (4) (5) (6) (7) (8) (9)

SVL97-2

Acc +B Blank AUX electrical control switch 1 (LH) output AUX electrical control switch 1 (RH) output AUX electrical control switch 3 (LH) output AUX electrical control switch 3 (RH) output Horn switch output Travel speed shift switch output

(10) Ground (a) Blank (b) AUX electrical control switch 1 (LH) (c) AUX electrical control switch 1 (RH) (d) AUX electrical control switch 3 (LH) (e) AUX electrical control switch 3 (RH) (f) Horn switch (g) Travel speed shift switch

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KiSC issued 09, 2021 A

MECHANISM 6. Pilot valve (Travel)

6. HYDRAULIC SYSTEM

6.2 Pilot valve (Travel) functions and structures

Forward operation

6.2.1 Pilot valve (Travel) working principles The pressure of the pilot primary pressure oil is reduced, and the oil flows to the HST pump as secondary pressure. Control lever: Neutral

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

(1) Spool (2) Return spring (3) Spring for setting secondary pressure

(a) Output port (b) Port T

• Oil from port P is shut off by the spool. • The output port and port T are connected.

6-28

Spool Pushrod Spring seat Spring for setting secondary pressure

(a) Output port (b) Port T

• The spool is pushed by the pushrod according to how much pressure is applied by the lever. • The pressure of the oil (primary pressure) from the gear pump is reduced according to the extent of movement by the spool. • The secondary pressure flows to the servo cylinder of the HST pump.

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 6. Pilot valve (Travel)

6. HYDRAULIC SYSTEM

6.2.2 Pilot valve (Shuttle valve) functions

7. Pilot valve (Front operation)

The Shuttle valve is a directional control valve that makes the system possible to drive two motors with one lever. Forward operation

7.1 Pilot valve (Front operation) specifications

(1) Left swivel operation (2) Forward operation (3) Right swivel operation

(4) Reverse operation (5) Shuttle valve

• The Shuttle valve is used to divide the oil into two parts, and the oil flows to the HST pump from 1 and 2.

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

AUX hold switch (RH) AUX knob switch Float switch AUX hold switch (LH) AUX electrical control switch 2 (6) AUX electrical mode change switch

(7) Port 4 (lifting the lift arm) (8) Port 1 (crowding the bucket) (9) Port T (10) Port 2 (lowering the lift arm) (11) Port 3 (dumping the bucket) (12) Port P (a) Front side

Specifications

SVL97-2

Manufacturer

KPM (Kawasaki Precision Machinery)

Single operation angle (port 1, 3)

19°

Single operation angle (port 2, 4)

23°

Maximum primary pressure

6.9 MPa 70 kgf/cm2 1000 psi

Rated flow rate

15 L/min 4.0 U.S.gals

Input voltage

4.5 to 5.5 V

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KiSC issued 09, 2021 A

MECHANISM 7. Pilot valve (Front operation)

6. HYDRAULIC SYSTEM Hydraulic circuit diagram

(1) Crowding the bucket (2) Dumping the bucket

AUX knob switch output

(3) Lowering the lift arm (4) Lifting the lift arm

Performance diagram (port 1, 3)

(1) AUX port variable switch (2) AUX port variable switch output 1 (3) AUX port variable switch output 2

(a) (b) A: B:

Output ratio (%) Output (V) Tilting to the right Tilting to the left

Wiring color layout

Performance diagram (port 2, 4)

(1) Secondary pressure (2) Single operation torque (3) Single operation torque (Port 2) (4) Single operation torque (Port 4) (a) Secondary pressure (psi) (b) Secondary pressure (kgf/ cm2)

6-30

Secondary pressure (MPa) Operation torque (N⋅m) Operation torque (kgf⋅cm) Operation torque (lbf⋅ft) Push-rod stroke (mm) Operating angle (deg)

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 7. Pilot valve (Front operation)

6. HYDRAULIC SYSTEM

Wiring color

Function

Wiring color

Function

R (Red)

Acc

Y (Yellow)

AUX electrical control switch 2 (RH)

W (White)

Float switch

O (Orange)

AUX hold switch (LH)

Gy (Grey)

Ground

P (Pink)

Vcc

L (Blue)

AUX electrical control switch 2 (LH)

Lg (Light green)

AUX electrical mode change switch

V (Violet)

AUX variable switch output 2

G (Green)

AUX hold switch (RH)

Br (Brown)

AUX variable switch output 1

B (Black)

Ground

Electrical circuit diagram

(1) (2) (3) (4) (5) (6) (7) (8) (9)

SVL97-2

+5 V Acc Ground AUX port variable switch output 1 AUX port variable switch output 2 AUX electrical mode change switch output AUX electrical control switch output (LH) AUX electrical control switch output (RH) AUX hold switch output (LH)

(10) AUX hold switch output (RH) (11) Float switch output (12) Ground (a) AUX port variable switch (b) AUX electrical mode change switch (c) AUX electrical control switch 2 (LH) (d) AUX electrical control switch 2 (RH) (e) AUX hold switch (LH) (f) AUX hold switch (RH) (g) Float switch

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KiSC issued 09, 2021 A

MECHANISM 7. Pilot valve (Front operation)

6. HYDRAULIC SYSTEM

7.2 Pilot valve (working equipment operation) functions and structures

Control lever: Operated

7.2.1 Pilot valve (working equipment operation) working principles The pressure of the pilot primary pressure oil is reduced, and the oil flows to the control valve as secondary pressure. Control lever: Neutral

(1) Spool (4) Spring for setting secondary pressure (5) Pushrod

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

Spool Return spring Return spring Spring for setting secondary pressure

(a) Output port (b) Port T

(6) Spring seat (a) Output port (b) Port P

• Oil from port P is shut off by the spool. • The output port and port T are connected.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8. Travel motor 8.1 Travel motor specifications

(a) Lubrication port

(b) Oil level check port

Manufacturer

SAUER DANFOSS DAIKIN

Model

BMVT51 Low-speed

51 cm3 3.10 in3

High speed

34.8 cm3 2.12 in3

Intake amount per rotation

Reduction ratio

24.362

Parking brake release pressure

1.5 MPa 220 psi

Turning direction (as seen from the reduction gear side)

Right turn

A-port: Discharge, Port B: Suction

Left turn

A-port: Suction, Port B: Discharge

Number

Port No. identifier

(1)

High-pressure port

(2)

High-pressure port

(3)

Travel speed shift port

(4)

Parking brake port

(5)

Drain port

SVL97-2

Name

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KiSC issued 09, 2021 A

MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8.2 Travel motor functions and structures

8.2.2 Travel motor "Reduction gear" working principles

8.2.1 Travel motor working principles

The reduction gear is used to lower the speed of the rotary motion and increase the torque.

The travel motor uses Fluid energy (pressure oil flow) as input, and outputs mechanical energy (rotation torque, speed).

(1) Shaft (2) Cylinder lock (3) Swash-plate

(4) Piston (a) Suction / Discharge (b) Output

• The high pressure oil enters the piston from the suction port, and the cylinder block rotates. • The oil inside the piston is discharged from the discharge port in accordance with the tilt angle of the swash-plate. • The cylinder block and shaft are connected, so the rotation of the shaft is transmitted to the reduction gear.

6-34

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

2nd stage planetary gear 1st stage planetary gear 1st stage sun gear 2nd stage sun gear

(5) (a) (b) (c)

Ring gear Input Output Force flow

• The planetary gear mechanism of each stage slows down the rotation of the shaft, and increases the drive force. • The input rotation is opposite to the output rotation.

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8.2.3 Travel motor (Flushing) hydraulic description Forcibly returns hydraulic oil to the tank to lower the travel circuit temperature.

(1) Flushing valve (2) Spool

(3) Relief valve (4) Poppet

(A) When in Neutral (B) When operating

(a) To motor case

When high pressure oil enters from A-port • The hydraulic oil from A-port pushes the spool to the left via passage C. • The hydraulic oil from B port opens the relief valve and returns to the tank. • When the oil is low in the closed circuit, some oil is replenished from the Pilot Pump to the HST pump.

SVL97-2

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MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8.2.4 Travel motor "Parking brake" working principles

8.2.5 Travel motor "Travel speed shift" working principles

Using negative brake that switches ON/OFF with the pressure of the oil from the gear pump.

(1) Hydraulic unlock switch (2) Parking Brake Switch

(3) Brake piston (4) Friction plate

• When the hydraulic pressure release switch is set to ON, the Solenoid Valve (Parking brake) is excited. • The oil from the gear pump pushes the brake piston, and releases the parking brake. • When the hydraulic pressure release switch is set to OFF or the parking brake switch is set to ON, the parking brake Solenoid Valve closes. • Parking brake activates due to no oil supply from the gear pump.

6-36

(1) Travel speed shift switch (2) Travel speed shift switch valve (3) Spool (4) High pressure selection valve (5) Ball

(6) (7) (a) (b) (c) (d)

High speed switch piston Swash-plate From gear pump Low speed High speed To high speed switch piston

• When you press the travel speed shift switch, the travel speed shift switch Solenoid Valve is excited and the oil from the gear pump pushes the spool of the travel speed shift switch valve. • The oil from A-port passes through the high pressure selection valve and travel speed shift switch valve, and pushes the travel speed shift piston. • The swash-plate rises, allowing travel speed shift. • When the travel speed shift switch is OFF, the Solenoid Valve (travel speed shift) is not excited, so only low speed travel is available.

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8.3 Travel system 8.3.1 Travel system "Forward" hydraulic description

(1) Forward (2) Reverse (3) Left swivel

(4) Right swivel (5) Pilot Valve (Travel) (6) HST pump

(7) Travel motor L (8) Travel Motor R (9) Servo cylinder

(a) Machine front (b) Machine rear (c) From Pilot Pump

• When a forward travel operation is performed, the oil from the gear pump flows to the Shuttle valve in the pilot valve (travel). • The shuttle valve divides the oil from the gear pump into two. • One part of the oil flows into the M14 port and pushes the servo cylinder to the left. • The oil flows from port D of the HST pump to port B on the right travel motor, and the right travel motor then rotates in the forward direction. • The other part of the oil flows into the M5 port and pushes the servo cylinder to the left. • The oil flows from B port of the HST pump to A-port on the left travel motor, and the left travel motor then rotates in the forward direction. • Both travel motors will rotate in the forward direction, causing the machine to move forward.

SVL97-2

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MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8.3.2 Travel system "Reverse" hydraulic description

(1) Forward (2) Reverse (3) Left swivel

(4) Right swivel (5) Pilot Valve (Travel) (6) HST pump

(7) Travel motor L (8) Travel Motor R (9) Servo cylinder

(a) Machine front (b) Machine rear (c) From the gear pump

• When a reverse travel operation is performed, the oil from the gear pump flows to the Shuttle valve in the pilot valve (travel). • The shuttle valve divides the oil from the gear pump into two. • One part of the oil flows into the M15 port and pushes the servo cylinder to the right. • The oil flows from port C of the HST pump to A-port on the right travel motor, and the right travel motor then rotates in the reverse direction. • The other part of the oil flows into the M4 port and pushes the servo cylinder to the right. • The oil flows from A-port of the HST pump to B port on the left travel motor, and the left travel motor then rotates in the reverse direction. • Both travel motors will rotate in the reverse direction, causing the machine to move in reverse.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8.3.3 Travel system "Left swivel" hydraulic description

(1) Forward (2) Reverse (3) Left swivel

(4) Right swivel (5) Pilot Valve (Travel) (6) HST pump

(7) Travel motor L (8) Travel Motor R (9) Servo cylinder

(a) Machine front (b) Machine rear (c) From gear pump

• • • •

When a left swivel operation is performed, the oil from the gear pump flows to the Shuttle valve. The shuttle valve divides the oil from the gear pump into two. One part of the oil flows into the M4 port and pushes the servo cylinder to the right (right direction). The oil flows from A-port of the HST pump to B port on the left travel motor, and the left travel motor then rotates in the reverse direction. • The other part of the oil flows into the M14 port and pushes the servo cylinder to the left. • The oil flows from port D of the HST pump to port B on the right travel motor, and the right travel motor then rotates in the forward direction. • The left travel motor will rotate in the reverse direction, while the right travel motor will rotate in the forward direction, causing the machine to swivel to the left.

SVL97-2

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MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8.3.4 Travel system "right swivel" hydraulic description

(1) Forward (2) Reverse (3) Left swivel

(4) Right swivel (5) Pilot Valve (Travel) (6) HST pump

(7) Travel motor L (8) Travel Motor R (9) Servo cylinder

(a) Machine front (b) Machine rear (c) From gear pump

• • • •

When a right swivel operation is performed, the oil from the gear pump flows to the Shuttle valve. The shuttle valve divides the oil from the gear pump into two. One part of the oil flows into the M5 port and pushes the servo cylinder to the left. The oil flows from B port of the HST pump to A-port on the left travel motor, and the travel motor then rotates in the forward direction. • The other part of the oil flows to the M15 port and pushes the servo cylinder to the right. • The oil flows from port C of the HST pump to A-port on the right travel motor, and the right travel motor then rotates in the reverse direction. • The left travel motor will rotate in the forward direction, while the right travel motor will rotate in the reverse direction, causing the machine to swivel to the right.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8.3.5 Travel system "Pivot turn (forward left)" hydraulic description

(1) Forward (2) Reverse (3) Left swivel

• • • • • • •

(4) Right swivel (5) Pilot Valve (Travel) (6) HST pump

(7) Travel motor L (8) Travel Motor R (9) Servo cylinder

(a) Machine front (b) Machine rear (c) From gear pump

When a pivot turn operation is performed, the oil from the gear pump flows to the Shuttle valve. The oil that is divided up by the Shuttle valve flows to the HST pump from ports 1, 2, and 4. The oil from port 2 flows to the M5 port and pushes the servo cylinder to the left. The oil from port 4 flows to the M4 port and pushes the servo cylinder to the right. The servo cylinder is in neutral, so oil will not be discharged from the left HST pump. The oil from port 1 flows to the M14 port and pushes the servo cylinder to the left. The oil flows from port D of the HST pump to port B on the right travel motor, and the right travel motor then rotates in the forward direction.

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KiSC issued 09, 2021 A

MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8.3.6 Travel system "Charge circuit" hydraulic description Replenishes oil to circuit when the oil level of closed circuit is low.

(1) HST pump (2) Travel motor

(3) Gear pump

• The hydraulic oil from the HST pump is returned to the HST pump via the travel motor. • Drainage from the HST pump and travel motor returns to the tank, resulting in insufficient hydraulic oil in the closed circuit. • Oil is supplied from the gear pump to replenish the hydraulic oil when low.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 8. Travel motor

6. HYDRAULIC SYSTEM

8.3.7 Anti-stall function of the travel system This function prevents the engine from stalling under high loads.

(1) Solenoid Valve (Anti-stall) (2) Gear pump

(3) No-load

(4) Engine Stall Prevention System (a) Engine speed (rpm)

(b) HST control pressure (kgf/ cm2)

• The main ECU compares the actual engine speed with target engine speed. • The moving distance of the spool of the Solenoid Valve (anti-stall) changes according to the difference between the target engine speed and actual engine speed. • The moving distance of the spool of the Solenoid Valve (anti-stall) controls the primary pressure of the traveling pilot. Operation during high loads • The opening space of the spool of the Solenoid Valve (anti-stall) gets smaller, and lowers the pressure of the traveling primary pilot. • When the traveling primary pilot pressure drops, the swash plate angle of the HST pump turns smaller, and reduces the HST pump flow rate. • This will reduce the engine load, and prevents a stall of the engine.

SVL97-2

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KiSC issued 09, 2021 A

MECHANISM 9. Hydraulic cylinder

6. HYDRAULIC SYSTEM

9. Hydraulic cylinder 9.1 Hydraulic cylinder specifications

Item

Lift arm cylinder

Bucket cylinder

Hydraulic quick hitch cylinder

Manufacturer

Yanagisawa Seiki

Kubota Seiki

(1) Tube outer diameter

91 mm 3.58 in.

75 mm 2.95 in.

(2) Tube inner diameter

75 mm 2.95 in.

65 mm 2.56 in.

(3) Rod diameter

45 mm 1.77 in.

40 mm 1.57 in.

25 mm 0.98 in.

Stroke

775.5 mm 30.53 in.

387 mm 15.24 in.

237 mm 9.33 in.

Max compressed length

1078 mm 42.44 in.

684 mm 26.9 in.

621.5 mm 24.47 in.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 10. Unload valve (Travel speed shift, parking brake, working equipment)

6. HYDRAULIC SYSTEM

10. Unload valve (Travel speed shift, parking brake, working equipment) 10.1 Unload valve (Travel speed shift, parking brake, work equipment) specifications

(1) Port A1 (2) Port A2 (3) Port A3

(4) Port P (5) Port T2 (6) Port T1

(7) Port PAC (8) Relief valve (9) Check valve Specification

Notes

Rated pressure

4.9 MPa 50 kgf/cm2 710 psi

Relief set pressure

3.5 MPa 36 kgf/cm2 510 psi

At 3.4 L/min At 0.9 U.S.gals/min

Rated voltage

DC 12 V

SVL97-2

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KiSC issued 09, 2021 A

MECHANISM 10. Unload valve (Travel speed shift, parking brake, working equipment)

6. HYDRAULIC SYSTEM

10.2 Unload valve (Travel speed shift, parking brake, work equipment) functions and structures 10.2.1 Unload valve (Travel speed shift, parking brake, work equipment) working principles This valve is used to load/unload the travel speed shift switch, parking brake, and work equipment lock. Solenoid OFF (Unload)

(1) Spool (2) Plunger A: A-port

C: P: T:

Port C Port P Port T

• The A-port/B port and Port T are connected. • Port C and Port P are connected, and when the pressure between C and P exceeds the setting value, oil is returned to the tank via the relief valve. • The pressure oil does not flow to the pilot valve. Solenoid ON (Load)

(1) Solenoid (2) Spool A: A-port

C: P: T:

Port C Port P Port T

• Port C is connected to the A-port/B port, and the pressure oil flows to the pilot valve.

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SVL97-2 KiSC issued 09, 2021 A

MECHANISM 11. Solenoid valve (Anti-stall, AUX)

6. HYDRAULIC SYSTEM

11. Solenoid valve (Anti-stall, AUX) 11.1 Solenoid valve (Anti-stall, AUX) specifications

(1) Port P (G1/4) (2) Port T (G1/4) (3) Port A1 (G1/4)

(4) Port A2 (G1/4) (5) Port A3 (G1/4) A: Solenoid valve (AUX)

B: Solenoid valve (Anti-stall) (A) Hydraulic circuit diagram (B) Control line diagram

(a) Input current (hourly average) (b) Secondary pressure

Specification

Notes

Manufacturer

KPM

Max. pressure

7 MPa 71 kgf/cm2 1000 psi

Maximum flow rate

10 L/min 2.6 gal/min

Drain flow rate

600 cc/min or less 0.16 gal/min or less

Rated current

1600 mA

Coil resistance

3.2 ± 0.5 Ω

At 20 C

Secondary pressure control range

0 to 2.7 MPa

SVL97-2

20 cSt (Viscosity) At 4.9 MPa, 50 kgf/cm2, 710 psi (P port)

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KiSC issued 09, 2021 A

MECHANISM 12. Solenoid valve (Hydraulic pressure quick hitch)

6. HYDRAULIC SYSTEM

12. Solenoid valve (Hydraulic pressure quick hitch) 12.1 Solenoid valve (Hydraulic pressure quick hitch) specifications

(1) Port P (G1/4)

(2) Port T (G1/4)

(3) A-port (G1/4)

(4) B port (G1/4)

Specification

Notes

Manufacturer

NISHINA INDUSTRIAL CO., LTD

Rated pressure

4.9 MPa 50 kgf/cm2 710 psi

Leak rate (P -> T)

220 ml/min or less 0.06 gal/min or less

6-48

At 4.9 MPa, 50 kgf/cm2, 710 psi

SVL97-2 KiSC issued 09, 2021 A

SERVICING 1. Troubleshooting hydraulic

6. HYDRAULIC SYSTEM

SERVICING 1. Troubleshooting hydraulic 1.1 Troubleshooting hydraulic for working equipment The working equipment does not run or is slow Probable cause(s)

Inspection point

Remedy

Engine trouble

Measure the engine speed

Adjust each engine part

Insufficient hydraulic oil volume in the tank, or oil degradation

Check oil level and oil quality in the hydraulic oil tank

Replenish or change the hydraulic oil

Clogged suction line Clogged suction filter

Check the suction line and suction filter

Clean the suction line Replace the suction filter

Electrical system trouble

Check applicable items in tester mode Check the OPC switch Check the armrest switch Check the hydraulic release switch Check the wiring

Replace the switch and/or wiring

Clogged pilot filter

Check for a clogged pilot filter

Replace pilot filter

Defective operation of the unload relief valve Defective performance of pilot pump

Measure the pilot primary pressure

Clean or replace the unload relief valve Replace pilot pump

Faulty pump coupling

Check the pump coupling

Replace pump coupling

Pump drive shaft damaged

Check pump drive shaft

Replace shaft

Pump internal parts galling or damage

Check the pump

Repair or replace pump

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KiSC issued 09, 2021 A

SERVICING 1. Troubleshooting hydraulic

6. HYDRAULIC SYSTEM The working equipment does not move or is slow Probable cause(s)

Inspection point

Remedy

Clogged line filter

Check for a clogged line filter

Clean or replace line filter

Faulty pilot valve

Measure the pilot secondary pressure of applicable cylinder

Disassemble, clean, or replace the pilot valve

Defective operation of the unload relief valve Defective performance of pilot pump

Measure the pilot primary pressure

Clean or replace the unload relief valve Replace pilot pump

Faulty piston pump

Check piston pump

Replace piston pump Replace the internal parts

Faulty gear pump

Check gear pump

Repair or replace gear pump

Faulty spool inside the LS regulator

Check the spool

Check or replace the spool

Poor force of spring in the LS regulator

Check spring in the LS regulator

Replace spring in the LS regulator

Faulty main relief valve

Check main relief valve

Clean or replace the main relief valve

Faulty LS relief valve

Measure the LS relief valve pressure

Clean or replace the LS relief valve

Faulty unload LS valve

Measure unload LS valve pressure

Clean or replace the unload LS valve

Sticking of control valve spool

Check the control valve spool of applicable cylinder

Disassemble and clean the control valve spool

Sticking of compensator spool of control valve

Check the applicable compensator spool

Clean or replace the applicable compensator spool

Electrical system trouble

Check the set-up in tester mode Check the hydraulic release switch and wiring

Hydraulic release switch Replace the wiring

Faulty drain valve of the lift arm

Check the drain valve

Clean or replace the drain valve

Faulty Solenoid Valve (AUX)

Check the Solenoid Valve (AUX)

Clean or replace the Solenoid Valve (AUX)

Incorrect set-up of AUX knob or start-up point

Check the set-up in tester mode Check operation of attachment

Reset using the meter panel

The power of front work equipment is weak Probable cause(s)

Inspection point

Remedy

Defective operation of the unload relief valve Defective performance of pilot pump

Measure the pilot primary pressure

Clean or replace the unload relief valve Replace pilot pump

Faulty operation of main relief valve operation or seating

Measure the main relief valve pressure

Adjust, clean or replace main relief valve

Faulty specified pressure of overload relief valve

Check the overload relief valve of applicable cylinder

Clean or replace the overload relief valve

Faulty unload LS valve

Measure unload LS valve pressure

Clean or replace the unload LS valve

Faulty LS relief valve

Measure the LS relief valve pressure

Clean or replace the LS relief valve

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 1. Troubleshooting hydraulic

6. HYDRAULIC SYSTEM

A great deal of leakage (downward) Probable cause(s)

Inspection point

Remedy

Applicable pilot valve faulty

Measure the pilot secondary pressure of applicable cylinder

Disassemble, clean, or replace the pilot valve

Faulty specified pressure of overload relief valve

Check the overload relief valve of applicable cylinder

Clean or replace overload relief valve seat surface

Sticking of control valve spool

Check the control valve spool of applicable cylinder

Disassemble and clean the control valve spool

Faulty seal inside the cylinder

Check the applicable cylinder

Disassemble cylinder and replace seal

Faulty float valve or Solenoid Valve (float)

Check float valve or Solenoid Valve (float)

Clean or replace float valve, Solenoid Valve (float)

1.2 Troubleshooting hydraulic for traveling Does not run, is slow, or crawling Probable cause(s)

Inspection point

Remedy

Crawler tension trouble or earth blockage around crawler

Check the crawler tension and look for any blockage

Adjust the crawler tension and/or remove any earth that is causing blockage around the crawler

Worn crawler lug

Check the crawler lug

Replace the crawler

Electrical system trouble

Check applicable items in tester mode Faulty parking brake switch Check the connector and wiring

Replace the switch Replace the connector and wiring

Defective operation of travel pilot valve

Measure the travel pilot valve secondary pressure

Disassemble and clean, or replace the travel pilot valve

Defective operation of the unload relief valve Defective performance of pilot pump

Measure the pilot primary pressure

Clean or replace the unload relief valve Replace pilot pump

Faulty charge relief valve

Check the charge relief valve

Clean or replace the charge relief valve

Faulty cylinder block or servo cylinder of the HST pump

Check the HST pump

Repair or replace the HST pump

Faulty travel relief valve of the HST pump

Measure the pressure of the travel relief valve

Replace the travel relief valve

Maladjustment of the HST pump swash-plate

Check the HST pump swash-plate

Adjust the HST pump swash-plate

Faulty cylinder block of the travel motor

Check the travel motor

Repair or replace the travel motor

Faulty travel speed shift valve or piston of the travel motor

Check the travel speed shift valve and piston of the travel motor

Travel speed shift valve of the travel motor Clean or replace the piston

Faulty Solenoid Valve (Anti-stall)

Check the Solenoid Valve (Anti-stall)

Clean or replace the Solenoid Valve (Antistall)

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 1. Troubleshooting hydraulic

6. HYDRAULIC SYSTEM Travel speed does not shift, or too slow Probable cause(s)

Inspection point

Remedy

Faulty charge relief valve

Check the charge relief valve Measure the charge relief valve pressure

Clean or replace the charge relief valve

Maladjustment of the HST pump swash-plate

Check the HST pump swash-plate

Adjust the HST pump swash-plate

Faulty travel relief valve of the HST pump

Measure the pressure of the travel relief valve

Replace the travel relief valve

Faulty travel speed shift valve or piston of the travel motor

Check the travel speed shift valve and piston of the travel motor

Travel speed shift valve of the travel motor Clean or replace the piston

Electrical system trouble

Check the set-up in tester mode Check the travel speed shift switch Check the connector and wiring

Replace the travel speed shift switch Replace the connector and wiring

Faulty Solenoid Valve (travel speed shift)

Check the Solenoid Valve (travel speed shift)

Clean and/or replace the Solenoid Valve (travel speed shift)

The vehicle creeps while in neutral Probable cause(s) Maladjustment of neutral of the HST pump

Inspection point Check the servo piston of the HST pump

Remedy Adjust neutral for the servo piston of the HST pump

The vehicle rolls downhill when parked on a slope Probable cause(s)

Inspection point

Remedy

Abrasion of friction plate

Check the thickness of the friction plate

Replace friction plate

Faulty parking brake spring

Check the parking brake of the travel motor

Replace the parking brake of the travel motor

The engine stalls on key start, and is easy to stall during digging Probable cause(s)

Inspection point

Remedy

Blockage of the PPS port of the piston pump

Check the PPS port of the piston pump

Clean the PPS port of the piston pump

Faulty spring inside the piston pump LS regulator

Check the spool

Check or replace the spool

Faulty or incorrectly set Solenoid Valve (Antistall)

Check the Solenoid Valve (Anti-stall)

Clean or replace the Solenoid Valve (Antistall) Reset on the meter panel

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Measuring this machine

6. HYDRAULIC SYSTEM

2. Measuring this machine 2.1 Hydraulic performance list Specification Arm Hydraulic cylinder operation time Bucket

3.6 to 4.8 sec

Down

2.9 to 3.9 sec

Crowd

1.9 to 2.7 sec

Dump

1.6 to 2.4 sec

Std. when new

≦15.5 mm ≦0.61 in.

Usage limit

≦77.5 mm ≦3.05 in.

Std. when new

≦10.5 mm ≦0.41 in.

Usage limit

≦52.5 mm ≦2.07 in.

Arm Hydraulic cylinder drift Bucket

Travel block performance

0 mm 0 in.

Ability to travel straight

≦600 mm ≦23.6 in.

Travel speed

Rubber crawler

Low speed

8.18 to 10.00 sec / 20 m

Rapid speed

5.58 to 6.86 sec / 20 m

Notes

Engine Max. speed Oil temperature: 50 +/5℃

During bucket loading Measurement time 10 min

Travel speed shift Measurement distance 20 m Forward, reverse Travel speed shift Forward, reverse

2.2 Hydraulic operating time 2.2.1 Measuring the operating time for lift arm cylinder Measurement preparation 1. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉) and the cylinder is sufficiently warm. Measurement 1. Set the bucket to the crowd end, lower the lift arm to the down end, and set the engine to max. speed. 2. Use the control lever to raise the lift arm, and measure the time to reach to lift arm upper end. 3. Measure 3 times, and take the average value. 4. Similarly, measure the full stroke time for lift arm down, and take the average value.

2.2.2 Measuring the operating time for bucket cylinder Measurement preparation 1. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉) and the cylinder is sufficiently warm. Measurement 1. Set the lift arm to the upper end, set the bucket to the crowd end, and set the engine to max. speed. 2. Use the control lever to perform a bucket dump, and measure the time taken to reach the bucket dump end. 3. Measure 3 times, and take the average value.

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 2. Measuring this machine

6. HYDRAULIC SYSTEM 4. Similarly, measure the full stroke time for bucket crowd, and take the average value.

Measurement 1. Set the bucket pin height to 300 mm (11.8 in.) above the ground, and set the bucket to crowd end and engine to the maximum speed. 2. After proceeding 5 m, measure the time taken to travel straight for 20 m. 3. Measure 3 times, and take the average value.

2.2.3 Measuring the drift for working equipment Measurement preparation 1. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉) and the cylinder is sufficiently warm. 2. Insert a 1451 kg (3200 lbs) weight into the bucket. Measurement 1. Park the machine on a level ground. 2. Set the bucket level to the ground, and raise the lift arm to the upper end. 3. Stop the engine. 4. Mark the lift arm cylinder rod and bucket cylinder rod. 5. 10 minutes later, measure the contraction distance of the lift arm cylinder and expansion distance of the bucket cylinder. 6. Measure 3 times, and take the average value.

(1) 5 m (16 ft, 7.9 in.)

(2) 20 m (66 ft, 7.9 in.)

2.2.5 Measuring the block performance for travel motor Measurement preparation 1. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉) and the travel motor is sufficiently warm. 2. Adjust the tension of the crawler. Measurement 1. Park the machine on firm soil or concrete with 20° slope. 2. Set the bucket pin height to 300 mm (11.8 in.) above the ground, and set the bucket to the crowd end. 3. Stop the engine.

2.2.4 Measuring the operating time for travel motor Measurement preparation 1. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉) and the travel motor is sufficiently warm. 2. Adjust the tension of the crawler.

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(a) 15°

4. Mark the crawler and ground, and measure the distance of shift at one minute intervals.

SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Measuring this machine

6. HYDRAULIC SYSTEM

5. Measure 3 times, and take the average value.

2.2.6 Measuring the travel straightness for the travel motor Measurement preparation 1. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉) and the travel motor is sufficiently warm.

3.1.1 Measuring the flow rate for HST pump Measurement preparation 1. Place the vehicle on a jack stand on firm and flat ground. 2. Tilt-up the cabin. 3. Disconnect the high-pressure hose from port D of the HST pump, and then connect a test hose from port D to the flowmeter IN port. 4. Disconnect the high-pressure hose from port C of the HST pump, and then connect a test hose from port C to the flowmeter OUT port. 5. Tilt-down the cabin 6. Fully open the loading valve of the flowmeter and start the engine. 7. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉).

Measurement 1. Set the bucket pin height to 300 mm (11.8 in.) above the ground, and set the bucket crowd end and engine to the maximum speed. 2. After proceeding 5 m, travel for 20 m. 3. At the 10 m mark, measure distance A. 4. Measure 3 times, and take the average value.

(1) Port C (4) Flowmeter (2) Port D (A) Flowmeter IN (B) Flowmeter OUT (3) 2 test hoses (1.3/16-12UN-2B, pressure resistance: 40 MPa, 5800 psi or higher)

(1) 20 m (66 ft, 7.9 in.) (2) 10 m (33 ft, 3.9 n.)

(3) 5 m (16 ft, 7.9 in.) or longer

3. HST pump

1. Set the engine to maximum speed. 2. Fully stroke the travel pilot lever forward. 3. Gradually close the flowmeter's loading valve, then measure the flow rate and engine RPM at each load pressure. 4. Measure 3 times, and take the average value.

3.1 Measuring the HST pump IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-05 HST start-up point setting

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 3. HST pump

6. HYDRAULIC SYSTEM 5. Similarly, measure the flow rate of the other HST ports.

(5) HST pump (C) Forward

(D) Reverse

Forward • Right side Connect the flowmeter IN port to the HST pump D port, and connect the flowmeter OUT port to the HST pump C port. • Left side Connect the flowmeter IN port to the HST pump B port, and connect the flowmeter OUT port to the HST pump A port. Back • Right side Connect the flowmeter IN port to the HST pump C port, and connect the flowmeter OUT port to the HST pump D port. • Left side Connect the flowmeter IN port to the HST pump A port, and connect the flowmeter OUT port to the HST pump B port.

3.1.2 Measuring travel relief pressure for HST pump Measurement preparation 1. Place the vehicle on a jack stand on firm and flat ground, and lower the lift arm to the down end. 2. Tilt-up the cabin. 3. Remove the plug from detection port B of the pump discharge-side adapter, and connect a pressure gauge. 4. Tilt-down the cabin 5. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉). 6. Wedge a rod in the left and right travel sprocket, and check if it is engaged securely.

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Measurement 1. Set the engine to maximum speed. 2. Operate the control lever forward to relieve the pressure, and then measure the pressure. 3. Similarly, measure the travel relief valve pressure for the other HST pump. Operation

Port number

Right forward

Right backward

Left forward

Left backward

3.1.3 Adjusting the travel straightness for the HST pump Measurement preparation 1. Set on a jack stand on firm and flat ground. 2. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉) and the travel motor is sufficiently warm. Measurement 1. Set the engine to maximum speed. 2. Measure the left and right sprocket RPM (Revolutions Per Minute). 3. Stop the engine and tilt-up the cabin. 4. If the right-side sprocket is faster, tighten the right forward adjustment bolt, and if the right-side sprocket is slower, tighten the right backward adjustment bolt. 5. Measure the left and right sprocket RPM again. 6. Adjust so that the difference in RPM between the left and right sprockets is no more than 4.5 rpm for low speed, and 10.0 rpm for rapid speed.

SVL97-2 KiSC issued 09, 2021 A

SERVICING 3. HST pump

6. HYDRAULIC SYSTEM

7. Similarly, if the left-side sprocket is faster, tighten the left forward adjustment bolt, and if the left-side sprocket is slower, tighten the left backward adjustment bolt.

NOTE • Do not turn the left or right neutral adjustment bolt more than 45 deg at one time.

(a) Back of machine (1) Left neutral adjustment bolt (2) Right neutral adjustment bolt (3) Lock nut

(1) Left backing adjustment bolt (2) Right forward adjustment bolt (3) Left forward adjustment bolt (4) Right backing adjustment bolt

(5) Lock nut (6) Max swash-plate angle adjustment bolt

5. Check the movement of the right crawler again, and adjust until it no longer moves. 6. Similarly, if the left-side crawler moves forward, loosen the left neutral adjustment bolt, and if the left-side crawler moves backward, tighten the left neutral adjustment bolt. Lock Nut (3)

3.1.4 Adjusting swash plate neutral for HST pump Measurement preparation 1. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉) and the cylinder is sufficiently warm. 2. Set on a jack stand on firm and flat ground. Measurement 1. Set the engine to maximum speed. 2. Release the hydraulic lock and parking brake. 3. Check the movement of the crawler when the travel control lever is in neutral. 4. If the right-side crawler moves forward, loosen the right neutral adjustment bolt, and if the right-side crawler moves backward, tighten the right neutral adjustment bolt.

SVL97-2

Tightening torque

30 to 50 N⋅m 3.1 to 5.1 kgf⋅m 23 to 36 lbf⋅ft

3.2 Removing/Installing the HST pump CAUTION • The machinery may suddenly move. Stop the engine and lower the working equipment to the ground when removing/disconnecting the hydraulic equipments/hoses. • There is a risk of burns. Cool down the hydraulic equipments and oil when working and checking • There is a risk of injury. Release residual pressure when taking hydraulic equipments off. IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-05 HST start-up point setting

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KiSC issued 09, 2021 A

SERVICING 3. HST pump

6. HYDRAULIC SYSTEM • After the hydraulic pressure repairing (changing, adjusting, and evacuating, hoses, oil) always bleed air from the piston pump.

3.2.1 Draining the hydraulic oil 1. Lower the lift arm to the down end. 2. Set the quick hitch to the dump end.

(6) Drain hose (7) Clamp

(8) Plug

3.2.2 Removing the cabin 1. Dismount the cabin.

(1) Lift arm

(2) Quick hitch

3. Remove two bolts. 4. Remove the front bottom cover.

3.2.3 Removing the step 1. Remove the mat.

(3) Cover

(4) Bolt (M8 × 20) × 2

5. Loosen the hydraulic oil tank cap.

(1) Mat

(5) Plug

Plug (5)

Tightening torque

20.0 to 25.0 N⋅m 2.0 to 2.6 kgf⋅m 14.5 to 18.8 lbf⋅ft

6. Remove the drain hose clamp and plug, and drain the hydraulic oil.

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 3. HST pump

6. HYDRAULIC SYSTEM

2. Remove three bolts.

(7) Bolt (M10 × 20) × 7 (8) Bolt (M10 × 20) × 3

(2) Bolt (M10 × 20) × 3

3. Remove the accelerator potentiometer connector and the accelerator pedal assembly.

6. Remove two bolts and the plate.

(10) Bolt (M10 × 25) × 2 (3) Accelerator potentiometer connector

(4) Accelerator pedal assembly

(9) Step

(11) Plate

7. Remove three bolts and the step.

4. Remove three bolts and the step.

(12) Bolt (M10 × 20) × 3

(5) Bolt (M10 × 20) × 3

(13) Step

(6) Step

5. Remove ten bolts and the plate.

SVL97-2

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SERVICING 3. HST pump

6. HYDRAULIC SYSTEM 8. Remove two bolts and the bracket.

(1) HST pump (14) Bolt (M10 × 20) × 2

(15) Bracket

(2) Nylon sling

3. Remove four mounting bolts for the HST pump and pump coupling.

3.2.4 Removing the LS pump 1. Remove the LS Pump.

(3) Bolt (M16 × 40) × 4

Tightening torque (1) LS pump

3.2.5 Removing the HST pump 1. Disconnect all of the hoses from the HST pump, and plug the adapters and hoses.

(1) HST pump

196.1 to 225.6 N⋅m 20.0 to 23.0 kgf⋅m 144.6 to 166.4 lbf⋅ft

Bolt (3)

4. Pull the HST pump shaft out from the pump coupling.

HST pump weight

SVL95-2s SVL97-2

72.0 kg 158.8 lbs

2. Attach a nylon sling to the HST pump and support with a crane. 6-60

SVL97-2 KiSC issued 09, 2021 A

SERVICING 3. HST pump

6. HYDRAULIC SYSTEM

3.3 Disassembling the HST pump CAUTION • Choose a clean place to prevent contaminants when assembling/disassembling. • Use clean tools and new cleaning oil. • Replace seals and O-rings with new ones, and install it with grease or hydraulic oil. • Clean outside of the motor with plugging each ports after assembling. (3) O-ring

IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-05 HST start-up point setting • After repairing the hydraulic pressure (changing, adjusting, and evacuating, hoses, oil) always bleed air from the piston pump.

4. Remove the shaft assembly.

3.3.1 Disassembling the shaft assembly 1. Remove ring 1. • Tool: Flat tip screwdriver

(4) Shaft assembly

5. Remove the snap ring. • Tool: Snap ring pliers

(1) Ring 1

2. Remove the Oil Seal. • Tool: Flat tip screwdriver

(5) Snap ring

6. Remove the roller bearing from shaft with using a press machine.

(2) Shaft seal

3. Remove the O-ring. (6) Roller bearing

SVL97-2

(7) Shaft

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6. HYDRAULIC SYSTEM 7. Remove the axis seal from oil seal with using a press machine.

(13) Ring

(8) Shaft seal

(9) Oil seal

11. Remove the shaft. • Tools: Hammer and strike rod

8. Remove two bolts. • Tool: 19 mm socket wrench

(14) Shaft

12. Remove the roller bearing from shaft with using a press machine.

(10) Bolt (M12 × 40) × 2

9. Remove the adapter and O-ring.

(15) Shaft (11) O-ring

(16) Ball bearing

(12) Adapter

10. Remove the ring. • Tool: Flat tip screwdriver

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3.3.2 Disassembling the cylinder block 1. After removing six flange bolts, remove the cover assembly. NOTE • Remove by inserting a flat tip screwdriver into the groove. • Tools: 13 mm socket wrench, flat tip screwdriver (6) Valve plate

(7) Swash-plate

5. Remove the needle bearing. • Tool: Slide hammer

(1) Flange bolt (M8) ×6 (2) Cover assembly

(a) Groove

2. Remove the gasket and pin.

(8) Needle bearing

6. Remove the coupling.

(3) Gasket

(4) Pin

3. Remove the cylinder block kit.

(9) Coupling

(5) Cylinder block kit

4. Remove the pin, valve plate and swash-plate.

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3.3.3 Disassembling the relief valve 1. Measure the sinkage dimension of the charge relief valve. NOTE • Required during reassembly. • Tool: Depth gauge

(7) Relief valve plug assembly (8) Relief valve assembly

(9) Spring

3.3.4 Disassembling the servo piston 1. After removing five bolts, remove the servo cover and gasket. • Tool: 5 mm hex wrench (1) Charge relief valve (a) Sinkage dimensions

(b) Depth gauge

2. Remove the lock nut. • Tool: 1-1/16 in. socket wrench

(1) Servo cover

(2) Gasket

2. Measure the mounting surface of the servo cover and the sinkage dimensions of the piston assembly. (2) Lock nut

3. Remove the charge relief valve, O-ring, spring, and poppet, in that order. • Tool: 1/2 in. socket wrench

(3) Charge relief valve (4) O-ring (5) Spring

(6) Poppet

IMPORTANT • Adjust neutral when reassembling. • Tool: Depth gauge

(3) Piston assembly (a) Sinkage dimensions

(b) Depth gauge

4. Remove the relief valve plug assembly, relief valve assembly, and spring. • Tool: 8 mm hex wrench

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3. Write down the adjustment bolt, nut and casing positions. NOTE • Required during reassembly.

(4) Adjustment bolt (5) Nut

(7) Seal lock-nut

6. After removing five bolts, remove the servo cover and gasket. • Tool: 5 mm hex wrench (4) Adjustment bolt (5) Nut

(6) Casing

4. Measure the projection dimension of the adjustment bolt. NOTE • Required during reassembly. • Tool: Depth gauge

(8) Servo cover

(9) Gasket

7. Remove the piston assembly.

(4) Adjustment bolt (c) Projection dimension

(d) Depth gauge

5. Remove seal lock-nut. IMPORTANT • Do not remove the nut and set screw as this will cause deviation of swash-plate neutral.

(10) Piston assembly

8. Remove the bearing assembly.

• Tool: 17 mm socket wrench

(11) Bearing assembly

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6. HYDRAULIC SYSTEM 9. Remove two Piston Rings and two O-rings. NOTE • Cut the Piston Ring to remove.

NOTE • Apply hydraulic oil to the Piston Ring.

• Tools: Flat tip screwdriver and hammer

(2) Piston ring

(12) Piston ring

3. Use the Piston Ring correction jig to correct the Piston Ring. • Tool: Piston Ring correction jig

3.4 Assembling the HST pump CAUTION • Choose a clean place to prevent contaminants when assembling/disassembling. • Use clean tools and new cleaning oil. • Replace seals and O-rings with new ones, and install it with grease or hydraulic oil. • Clean outside of the motor with plugging each ports after assembling. IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-05 HST start-up point setting

3.4.1 Assembling the servo cylinder 1. Install two O-rings. NOTE • Apply hydraulic oil to the O-ring.

(1) O-ring (2) Piston ring

(a) Piston Ring correction jig

(1) O-ring

2. Install the Piston Ring on the upper part only.

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4. Install the bearing assembly. NOTE • Set the mark facing upwards.

NOTE • Apply hydraulic oil to the Piston Ring.

(5) Piston ring (3) Bearing assembly

8. Install the gasket and servo cover.

5. Install the Piston Ring and piston assembly facing the rear direction.

NOTE • Grease the gasket.

NOTE • Apply hydraulic oil to the Piston Ring and piston assembly. • Do not use a hammer, as this may damage the Piston Ring.

(6) Servo cover

(7) Gasket

9. Install the servo cover.

(4) Piston assembly

(b) Top

6. Adjust the projection dimension of the piston assembly on the opposite side. • Tool: Depth gauge

(6) Servo cover

13 mm (0.51 in.) or less

7. Install the Piston Ring on the piston assembly.

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6. HYDRAULIC SYSTEM 10. Adjust the sinkage distance of piston assembly to the distance that was measured before, with holding the nut with wrench. • Tool: Depth gauge and 7 mm spanner

(1) Spring

(2) Relief valve

2. Assemble two O-rings and backup ring on the plug. NOTE • Grease the O-ring and backup ring.

(4) Piston assembly (e) Sinkage dimensions

(f)

Depth gauge

11. Tighten five bolts evenly on the left and right. NOTE • Tighten the bolts evenly on the left and right.

3. Tighten the relief valve plug assembly. • Tool: 8 mm hex wrench

(6) Relief valve plug assembly

(7) Bolt (M6 × 60) × 5

Bolt (7)

(5) O-ring

(3) O-ring (4) Backup ring

Tightening torque

15 to 18 N⋅m 1.53 to 1.84 kgf⋅m 11.1 to 13.3 lbf⋅ft

Relief valve plug assembly (6)

Tightening torque

68 to 95 N⋅m 6.93 to 9.69 kgf⋅m 50.2 to 70.1 lbf⋅ft

3.4.2 Assembling the relief valve 1. Assemble by fixing the spring on the relief valve.

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4. Install the O-ring on the adjuster. NOTE • Grease the O-ring.

(11) Lock nut

Lock Nut (11) (7) Poppet (8) Spring (9) Adjuster

Tightening torque

54 to 136 N⋅m 5.51 to 13.87 kgf⋅m 39.8 to 100.3 lbf⋅ft

(10) O-ring (11) Lock nut

5. Install the poppet, spring and adjuster, in that order. • Tool: 1/2 in. socket wrench

3.4.3 Assembling the cylinder block (Engine side) 1. Install the coupling.

(7) Poppet (8) Spring (9) Adjuster

(10) O-ring (1) Coupling

6. Assemble the lock nut, and adjust the sinkage distance of charge relief valve to the distance that was measured when disassembling. • Tools: 1-1/16 in. socket wrench, depth gauge

(11) Lock nut (a) Sinkage dimensions

(b) Depth gauge

7. Tighten the lock nut, and after measuring again, adjust the value. • Tools: 1-1/16 in. socket wrench, depth gauge

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6. HYDRAULIC SYSTEM 2. Install the needle bearing according projection dimension. • Tools : Hammer and depth gauge • Jig : Needle bearing insertion jig

the

(5) Cylinder block

(6) Pin

5. Install the retainer holder.

(7) Retainer holder (2) Needle bearing A: Body

(a) 2.60 ± 0.25 mm (0.10 ± 0.0098 in.)

3. Install the valve plate and pin. NOTE • Use a crane to position the body vertically. • Check that the needle bearing is sunk below the valve plate. • Grease the back of the valve plate. • Make sure that the valve plate faces the right way.

6. Install the piston assembly and retainer plate in the cylinder block. NOTE • Make sure that the retainer plate faces the right direction. • Apply hydraulic oil to the piston assembly.

(5) Cylinder block (8) Retainer plate

(3) Valve plate

(9) Piston assembly

(4) Pin

4. Install three pins in the cylinder block. NOTE • Grease the pins.

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7. Install the swash-plate and cylinder block kit.

(5) Snap ring (10) Swash-plate

(11) Cylinder block kit

4. Install the shaft assembly.

3.4.4 Assembling the shaft (Engine side) 1. Press-fit the ball bearing into the shaft with using press machine.

(6) Shaft assembly

5. Install the O-ring. NOTE • Grease the O-ring. (1) Ball bearing

(2) Shaft (Engine side)

2. Press-fit the oil seal into the axis seal with using press machine. NOTE • Grease the Oil Seal. • Make sure that the Oil Seal faces the right direction.

(7) O-ring

(3) Oil seal

(4) Shaft seal

3. Use snap ring pliers to install the Snap Ring. • Tool: Snap ring pliers

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6. HYDRAULIC SYSTEM 6. After installing the Oil Seal, install the axis seal. NOTE • Make sure that the shaft seal faces the right direction. • Grease the inner surface of the Oil Seal. • Tool: Hammer • Jig: Oil Seal press-fit jig

(11) Cover assembly

11. Tighten the flange bolts.

(4) Shaft seal

(B) Axis seal press-fit jig

7. Install the ring.

• Tool: 13 mm socket wrench

(8) Ring

(12) Flange bolt (M8 × 20) × 6

8. Lay down the HST pump with crane. 9. Install the gasket and pin, in that order.

(9) Gasket

NOTE • Apply SCOTCH-GRIP2353 to the flange bolts and mount the bolts. • Tighten the flange bolts, starting from near the pin. • Tighten the flange bolts, diagonally and evenly.

Flange bolt (12)

Tightening torque

35 to 43 N⋅m 3.57 to 4.38 kgf⋅m 25.8 to 31.7 lbf⋅ft

(10) Pin

10. Install the cover assembly by tapping with a hammer. • Tool: Hammer

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3.4.5 Assembling the cylinder block (Pump side)

NOTE • Apply hydraulic oil to the piston assembly.

1. Install the valve plate and pin. NOTE • Use a crane to position the body vertically. • Make sure that the valve plate faces the right way. • Grease the valve plate.

(3) Cylinder block (6) Retainer plate

(7) Piston assembly

5. Install the swash-plate and cylinder block kit, in that order.

(1) Pin

(2) Valve plate

2. Install three pins in the cylinder block. NOTE • Grease the pins.

(8) Swash-plate

(9) Cylinder block kit

3.4.6 Assembling the the shaft (Pump side) 1. Press-fit the ball bearing into the shaft (pump side) with the press machine.

(3) Cylinder block

(4) Pin

3. Install the retainer holder.

(1) Ball bearing

(2) Shaft (Pump side)

(5) Retainer holder

4. Install the piston assembly and retainer plate in the cylinder block.

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6. HYDRAULIC SYSTEM 2. Install the shaft (Pump side)

(6) Cover assembly

6. Tighten the flange bolts.

(2) Shaft (Pump side)

3. Install the ring.

NOTE • Apply SCOTCH-GRIP2353 to the flange bolts and mount the bolts. • Tighten the flange bolts, starting from near the pin. • Tighten the flange bolts, diagonally and evenly. • Tool: 13 mm socket wrench

(3) Ring

4. Install the gasket and pin. NOTE • Use a crane to position the body vertically.

(7) Flange bolt (M8 × 20) × 6

Flange bolt (7)

(4) Gasket

Tightening torque

35 to 43 N⋅m 3.57 to 4.38 kgf⋅m 25.8 to 31.7 lbf⋅ft

(5) Pin

5. Install the cover assembly. • Tool: Hammer

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7. Adjust the sinkage distance of piston assembly to the distance that was measured when disassembly. • Tool: Depth gauge and 7 mm spanner

(1) O-ring

(2) Adapter

2. Tighten two bolts. • Tool: 19 mm socket wrench

(8) Piston assembly (a) Sinkage dimensions

(b) Depth gauge

(3) Bolt (M12 × 40) × 2

8. Tighten the bolts evenly on the left and right. Bolt (3)

Tightening torque

91 to 111 N⋅m 9.28 to 11.32 kgf⋅m 67.1 to 81.9 lbf⋅ft

(9) Bolt (M6 × 60) × 5

Bolt (9)

Tightening torque

15 to 18 N⋅m 1.53 to 1.84 kgf⋅m 11.1 to 13.3 lbf⋅ft

3.4.7 Assembling the adapter 1. Install the O-ring and adapter. NOTE • Grease the O-ring.

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3.5 HST pump components

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

Ring Shaft seal O-ring Oil seal Ring Roller bearing Shaft

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(8) Shaft assembly (9) Spring ×4 (10) Relief valve assembly ×4 (11) O-ring ×4 (12) Backup ring ×4 (13) O-ring ×4 (14) Relief valve plug ×4

(15) Relief valve plug ×4 (16) O-ring ×3 (17) Plug ×2 (18) O-ring ×4 (19) Plug ×4 (20) Bolt ×2 (21) Shaft

(22) Ball bearing (23) Ring (24) O-ring (25) Adapter

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(26) Needle bearing ×2 (27) Coupling (28) Housing (29) O-ring ×2 (30) Plug ×2

SVL97-2

6. HYDRAULIC SYSTEM

(31) Needle bearing ×4 (32) Pin ×2 (33) Pin ×2 (34) Bearing ×2 (35) Needle bearing ×2

(36) Bearing assembly ×2 (37) Swash-plate ×2 (38) Gasket ×2 (39) Side cover ×2 (40) Cover assembly ×2

(41) Flange bolt ×12 (42) Valve plate ×2 (43) Cylinder block kit ×2

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(44) Seal lock-nut ×2 (45) Nut ×4 (46) Set screw ×4 (47) Bolt ×10

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(48) O-ring ×8 (49) Plug ×8 (50) Servo cover ×2 (51) Piston Ring ×4

(52) O-ring ×2 (53) Piston assembly ×2 (54) Gasket ×4 (55) Servo cover ×2

(56) Bolt ×10

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(57) Bolt ×8 (58) Cover ×2 (59) Gasket ×2

SVL97-2

6. HYDRAULIC SYSTEM

(60) Plug assembly ×2 (61) Poppet (62) Spring

(63) Charge relief valve (64) Lock nut (65) O-ring

(66) O-ring ×8 (67) Plug ×8

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3.6 Installing adapter layout for HST pump

Adapter

Port

Size

Adapter angles

(1)

L, 125, 115, R1

55°

(2)

(3)

S, 7/8U, G3

(4)

S, 125U, 115U

(5)

S, 125U, 115U

(6)

(7)

M15

S9/16-G3, 14

(8)

S9/16-G3, 14

(9)

(10)

M14

Pipe joint (S, G6, 115U) (2) Pipe joint (S, 125U, 115U) (4), (5)

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Tightening torque

L, 1-5 / 16U, G6 S, G6, 115U

55°

L, 9/16U, HST S, G1/4-9.6

L, 1-5 / 16U, G4 L, G4-G4, 45

55°

L, 9/16U, HST S, G3-G2 165.0 to 175.0 N⋅m 16.8 to 17.8 kgf⋅m 121.7 to 129.1 lbf⋅ft

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3.7 Pump coupling parts drawing

(1) Coupling hub (2) Coupling disk (3) Cap bolt (M10 × 35) ×8

(4) Snap ring (5) Cap bolt (6) Pump housing

(7) Flange bolt (M10 × 50) ×10 (8) Stud (9) Flange nut

Cap bolt (3)

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

Cap bolt (5)

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

Flange bolt (7)

Tightening torque

(10) Parallel pin (a) 35 mm (1.4 in.)

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

Stud (8)

24.1 to 28.0 N⋅m 2.5 to 2.9 kgf⋅m 17.8 to 20.7 lbf⋅ft

Flange nut (9)

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

• Apply thread lock to the cap bolts.

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4. Piston pump 4.1 Measuring the piston pump IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-03 AUX start-up point setting – Service mode / No-12 AUX flow rate setting

4.2 Bleeding air from the piston pump IMPORTANT the hydraulic pressure • After repairing (changing, adjusting, and evacuating, hoses, oil) always bleed air from the piston pump. 1. Tilt-up the cabin, and lock it.

4.1.1 Measuring the flow rate for piston pump Measurement preparation 1. Connect the test hose to port 2 and the IN-side of the flowmeter. 2. Connect the test hose to port 1 and the OUT-side of the flowmeter. 2. Remove the drain plug. 3. Replenish hydraulic oil to piston pump from drain port. 4. Close the drain plug.

(1) Port 1 (Quick connector, female) (2) Port 2 (Quick connector, male) (3) Test hose (G3/4-G3/4, pressure resistance: 27.5 MPa, 4000 psi or higher)

(4) Quick connector (male) (5) Flowmeter (6) Quick connector (female)

3. The AUX flow rate limit is set to 9. NOTE • High-flow model only 4. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉). 5. Press the AUX switch to set to AUX mode. Measurement 1. Set the engine to maximum speed. 2. Press the AUX knob switch to the right end. 3. Gradually close the flowmeter's loading valve, then measure the flow rate and engine RPM at each pressure. 4. Measure 3 times, and take the average value.

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(1) Drain plung

Drain plug (1)

Tightening torque

90 N⋅m 9.2 kgf⋅m 66.4 lbf⋅ft

5. Lower the cabin, and set the engine to low idle.

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6. Dump and crowd the bucket several times. IMPORTANT • Do not move the piston to the stroke end during air bleeding as this can cause a malfunction.

4.3.2 Removing the step 1. Remove the mat.

4.3 Removing/Installing the piston pump CAUTION • The machinery may suddenly move. Stop the engine and lower the working equipment to the ground when removing/disconnecting the hydraulic equipments/hoses. • There is a risk of burns. Cool down the hydraulic equipments and oil when working and checking. • There is a risk of injury. Release residual pressure when taking hydraulic equipments off. IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-03 AUX start-up point setting – Service mode / No-12 AUX flow rate setting • After repairing the hydraulic pressure (changing, adjusting, and evacuating devices, hoses, oil) always bleed air from the piston pump.

(1) Mat

2. Remove three bolts.

(2) Bolt (M10 × 20) × 3

4.3.1 Removing the cabin 1. Dismount the cabin.

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6. HYDRAULIC SYSTEM 3. Remove the accelerator potentiometer connector and the accelerator pedal assembly.

(10) Bolt (M10 × 25) × 2

(11) Plate

7. Remove three bolts and the step. (3) Accelerator potentiometer connector

(4) Accelerator pedal assembly

4. Remove three bolts and the step.

(12) Bolt (M10 × 20) × 3

(13) Step

8. Remove two bolts and the bracket. (5) Bolt (M10 × 20) × 3

(6) Step

5. Remove ten bolts and the plate.

(14) Bolt (M10 × 20) × 2

(7) Bolt (M10 × 20) × 7 (8) Bolt (M10 × 20) × 3

(15) Bracket

(9) Step

6. Remove two bolts and the plate.

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4.3.3 Installing the vacuum pump 1. Plug the breather hose, and attach the vacuum pump.

4.3.4 Removing the piston pump 1. Disconnect all of the hydraulic hoses from the piston pump and gear pump, and plug the adapters and hydraulic hoses.

3. Remove two mounting bolts from the piston pump. 4. Remove the piston pump from the HST pump.

(9) Piston pump

(11) Bolt (M12 × 30) ×2

Tightening torque 77.5 to 90.2 N⋅m 7.9 to 9.2 kgf⋅m 57.2 to 66.5 lbf⋅ft

Bolt (11)

Piston pump weight

SVL95-2s SVL97-2

39.4 kg 86.9 lbs

4.4 Disassembling the piston pump

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

PI hose PA hose GP relief hose PLS hose Drain hose

(6) LS suction hose (7) PPS hose (8) Gear pump suction hose

IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-03 AUX start-up point setting – Service mode / No-12 AUX flow rate setting • After repairing the hydraulic pressure (changing, adjusting, and evacuating devices, hoses, oil) always bleed air from the piston pump.

2. Sling the piston pump with nylon sling, and support it temporarily with a crane.

(9) Piston pump

SVL97-2

(10) Nylon sling

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4.4.1 Removing the gear pump

• Tool: 5 mm hexagon wrench

1. After removing four flange bolts, remove the suction flange. • Tool: 18 mm socket wrench

(1) Hex socket bolt (M6 × 50) ×4 (2) Regulator

2. Remove four hex socket bolts, and the valve cover from the pump casing. (1) Flange bolt (M12× 25) × 4

(2) Suction flange

2. Remove two bolts and the gear pump. • Tool: 16 mm socket

(3) Bolt (M10 × 25) × 2

NOTE • Place the pump horizontally. • Tools: 10 mm screwdriver

hexagon

wrench,

flat

tip

(4) Gear pump

3. Remove the coupling.

(3) Hex socket bolt (M12 × 45) (4) Valve cover

(5) Pump casing

3. Remove the valve plate and O-ring from the valve cover.

(5) Coupling

4.4.2 Removing the valve cover

(6) Valve plate

(7) O-ring

1. Remove four hex socket bolts, and the regulator. 6-86

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4.4.3 Removing internal parts for piston pump 1. Remove the needle bearing and spacer. • Tool: Puller

(4) (5) (6) (7) (8) (1) Needle bearing

(2) Spacer

Piston Plate Bushing Rod Cylinder block

(9) Spacer (10) Spring (11) Spacer (12) Internal circlip

4. Remove the plug, and the tilt piston. • Tool: 17 mm hexagon wrench

2. Remove the cylinder block assembly.

(13) Plug (3) Cylinder block assembly

3. Disassemble the cylinder block assembly into the piston, plate, bushing, rod, cylinder block, spacer, spring and internal circlip. NOTE • Tool: Snap ring pliers

5. Remove shaft with press machine. NOTE • Apply protective material such as vinyl tape to the spline of the HST pump. • Tool: Press machine

(15) Shaft

SVL97-2

(14) Tilting piston

(a) Protective material

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6. HYDRAULIC SYSTEM 6. Remove the stopper. • Tool: 17 mm socket wrench

(20) Internal circlip

(16) Stopper (M12)

7. Remove the swash-plate and return spring.

(21) Oil seal

4.4.4 Disassembling the regulator for piston pump 1. After removing the hex nut, remove the plug. • Tool: 30 mm socket wrench

(17) Swash-plate

(18) Return spring

8. Remove the needle bearing. (1) Hex nut (M20)

(2) Plug

2. Remove the spring, spring seat, sleeve, differential pressure spool, and spring.

(19) Needle bearing

9. Remove the internal circlip, and the Oil Seal. • Tool: 17 mm socket wrench (3) Spring (4) Spring seat (5) Sleeve

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(6) Differential pressure spool (7) Spring

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4.5 Assembling the piston pump IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-03 AUX start-up point setting – Service mode / No-12 AUX flow rate setting

4.5.1 Assembling the regulator for piston pump

4.5.2 Assembling internal parts for piston pump IMPORTANT • Do not re-use the spacer in case of replacing either of the pump casing, valve cover, shaft or tapered roller bearing. • Select proper thickness of the new spacer by measuring the dimension of the piston pump in case of replacing the above parts.

1. Install the spring, spring seat, sleeve, differential pressure spool, and spring, in that order.

(1) Pump casing (2) Tapered roller bearing (3) Shaft

(1) Spring (2) Spring seat (3) Sleeve

(4) Differential pressure spool (5) Spring

2. After installing the plug, fix the plug with a wrench, and tighten the hex nut. NOTE • To avoid damaging the plug, be careful not turn the plug together with the nut when tightening the nut.

Selecting proper thickness of the spacer 1. Install the internal circlip and oil seal to the pump casing. NOTE • Apply hydraulic oil to the surrounding surface of the oil seal. • Do not damage the lip as the damage can cause oil leakage.

(7) Internal circlip (6) Plug

Hex nut

SVL97-2

(7) Nut

Tightening torque

180 N⋅m 18.4 kgf⋅m 132.8 lbf⋅ft

(4) Spacer (5) Tapered roller bearing (6) Valve cover

(8) Oil seal

2. Install the tapered roller bearing to the pump casing. NOTE • Apply hydraulic oil to the inner surface of the tapered roller bearing. 6-89

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SERVICING 4. Piston pump

6. HYDRAULIC SYSTEM

(2) Tapered roller bearing

(9) Jig A

(a) Load

3. Install the shaft to the tapered roller bearing.

6. Measure the dimension C and E to select proper thickness of the spacer. NOTE • Spacer thickness = Dimension E Dimension D + (0 to 30 μm) Dimension D = Dimension A - Dimension B Dimension C

(3) Shaft

4. Install the tapered roller bearing to the shaft. NOTE • Apply hydraulic oil to the inner surface of the tapered roller bearing.

(5) Tapered roller bearing

5. Rotate the shaft 20 times while applying load to the shaft from the top of the jig. NOTE • The load is approximately 50 N (5.1 kgf, 11.2 lbf).

6-90

(1) Pump casing (5) Tapered roller bearing (6) Valve cover (9) Jig A (10) Jig B

(11) Depth gauge (12) Jig C (13) Jig D

Assembling internal parts for piston pump 1. Install the internal circlip and oil seal to the pump casing. SVL97-2 KiSC issued 09, 2021 A

SERVICING 4. Piston pump

6. HYDRAULIC SYSTEM

NOTE • Apply hydraulic oil to the surrounding surfaces. • Do not damage the lip as the damage can cause oil leakage.

(14) Return spring

(15) Swash-plate

4. Install the tilting piston and plug. NOTE • Install the tilt piston so that the slit faces outside. (7) Internal circlip

(8) Oil seal

2. Install the tapered roller bearing.

(16) Tilting piston

(2) Tapered roller bearing

3. Install the swash-plate and return spring to the pump casing. NOTE • Grease the sliding surface of the swashplate and pump casing. • Insert the return spring on the seat of the swash-plate.

SVL97-2

Plug (17)

(17) Plug

Tightening torque

390 N⋅m 39.8 kgf⋅m 288 lbf⋅ft

5. Install the shaft with a hammer. NOTE • Apply hydraulic oil to the inner surface of the tapered roller bearing. • Grease the lip of the oil seal. • Put protective tape on the spline of the shaft to avoid damage on the oil seal. • Do not contact the shaft with the swashplate.

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6. HYDRAULIC SYSTEM

IMPORTANT • Do not re-use the spacer in case of replacing either of the pump casing, valve cover, shaft or tapered roller bearings.

(3) Shaft

(18) Protective tape

6. Install nine pistons, plate, spherical bushing, pushrod, two shims, spring, and internal circlip on the cylinder block. NOTE • Apply hydraulic oil to the pistons, shoe, spherical bushing, and cylinder block.

(4) Spacer

(5) Tapered roller bearing

4.5.3 Assembling valve cover for piston pump 1. Install the valve plate and O-ring on the valve cover. NOTE • Make sure that the valve plate faces the right way. • Grease the valve plate.

(19) Piston (20) Plate (21) Spherical bushing (22) Pushrod (23) Shim

(24) Spring (25) Shim (26) Internal circlip (27) Cylinder block

7. Install the cylinder block assembly to the shaft.

(1) Valve plate (2) O-ring

(3) Valve cover

(28) Cylinder block assembly

8. Install the spacer and tapered roller bearing.

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6. HYDRAULIC SYSTEM

2. Tighten four hex socket bolts, and install the valve cover on the pump casing. NOTE • Apply hydraulic oil to the circumference of the needle bearing.

outer

• Tool: 10 mm hexagon wrench

(1) Coupling

(2) O-ring

2. Assemble the gear pump to the piston pump with tightening it with two plain washers and flange bolts. • Tool: 16 mm socket

(4) Valve cover (5) Pump casing

Hex socket bolt (6)

(6) Hex socket bolt (M12 × 45)

Tightening torque

98 N⋅m 10 kgf⋅m 72 lbf⋅ft

3. Tighten four bolts, and install the LS regulator. • Tool: Socket

(3) Bolt (M10 × 25) × 2

Flange bolt

(4) Gear pump

Tightening torque

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

3. Tighten four flange bolts and install the suction flange. • Tool: 18 mm socket wrench

(7) Regulator

Bolt (8)

(8) Bolt (M6 × 50) × 4

Tightening torque

12 N⋅m 1.2 kgf⋅m 8.9 lbf⋅ft

4.5.4 Assembling the gear pump 1. Install the coupling and O-ring. NOTE • Grease the O-ring.

SVL97-2

(5) Flange bolt (M12× 25) × 4

(6) Suction flange

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6. HYDRAULIC SYSTEM

4.6 Piston pump components

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Plug O-ring Plug Tilting piston O-ring Plug Square ring Oil seal Needle bearing

6-94

(10) Shaft (11) Return spring (12) Spring pin (13) Swash-plate assembly (14) Piston assembly (15) Plate (16) Internal circlip (locking ring) (17) Pump casing (18) O-ring

(19) Minimum tilt stopper (20) Bushing (21) Pushrod (22) Cylinder assembly (23) Spacer (24) Spring (25) Internal circlip (locking ring) (26) O-ring (27) Bearing spacer

(28) Needle bearing (29) Plug (30) O-ring (31) Spring pin (32) Valve cover (33) Spline joint (34) Bolt

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SERVICING 4. Piston pump

(35) Hex nut (36) Hex nut (37) Plug (38) Backup ring (39) O-ring

SVL97-2

6. HYDRAULIC SYSTEM

(40) Stopper (41) O-ring (42) Spring (43) Spring seat (44) Sleeve

(45) Differential pressure spool (46) Plug (47) Casing (48) Hex socket bolt (49) Plug

(50) O-ring (51) Square ring (52) O-ring (53) Throttle (54) Plug

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6. HYDRAULIC SYSTEM

4.7 Installing adapter layout for piston pump

Adapter

Port

(1)

(2)

6-96

Size

Angle

L, PF3/4-B, PF3/4-B

G6, R1

L, G1/2, G1/2

45°

L, G4-G4, 45

G1/2-3

S, U3/4, G4 -

(3)

L45, G4, U3/4

(4)

L, G8-21

45°

(5)

L45, G4, U3/4

10°

(6)

L, G4-G4

(7)

L, G2, U7/16

SVL97-2 KiSC issued 09, 2021 A

SERVICING 4. Piston pump

6. HYDRAULIC SYSTEM

4.8 Servicing standards of piston pump 4.8.1 Measuring the piston clearance 1. Measure diameter of the piston with vernier caliper. 2. Measure diameter of the cylinder block with vernier caliper. 3. Calculate the clearance with subtracting the diameter of piston from the diameter of cylinder block. NOTE • Replace any rod that exceeds its usage limit.

(1) Shoe (2) Piston

(a) Play for the shoe crimping section Clearance

Standard

0.06 to 0.10 mm (0.0024 to 0.0039 in.) or less

Allowable limits

No less than 0.22 mm (0.087 in.)

4.8.3 Measuring shoe thickness 1. Measure the thickness of the shoe with micrometer. (1) Piston (2) Cylinder block (a) Piston diameter

(b) Cylinder block diameter

NOTE • Replace any rod that exceeds its usage limit.

Clearance Standard

0.042 mm (0.0017 in.) or less

Allowable limits

No less than 0.074 mm (0.0029 in.)

4.8.2 Measuring the play for shoe crimping section 1. Measure the play between the piston and shoe crimping section with depth gauge. NOTE • Replace any rod that exceeds its usage limit.

SVL97-2

(1) Shoe

(a) Shoe thickness Clearance

Standard

3.3 mm (0.130 in.)

Allowable limits

3.15 mm (0.123 in.) or less

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6. HYDRAULIC SYSTEM

4.8.4 Measuring the length for cylinder spring 1. Measure the length of the cylinder spring with vernier caliper. NOTE • Replace any rod that exceeds its usage limit.

(1) (2) (3) (a)

Holding plate Spherical bushing Fixing stand Height of fixing stand

(b) Height up to spherical bushing

Clearance

(1) Cylinder spring

(a) Natural length of cylinder spring Clearance

Standard

66 mm (2.60 in.)

Allowable limits

64.7 mm (2.55 in.) or less

4.8.5 Measuring the sinkage for spherical bushing 1. Measure the height of fixing stand. 2. Measure the height from the stand to spherical bushing. 3. Calculate the sinkage with subtracting the height of fixing stand from the height up to the spherical bushing. NOTE • Replace any rod that exceeds its usage limit.

6-98

Standard

11.95 mm (0.47 in.)

Allowable limits

11.0 mm (0.433 in.) or less

5. Control valve 5.1 Measuring the control valve IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-03 AUX start-up point setting – Service mode / No-12 AUX flow rate setting • After repairing the hydraulic pressure (changing, adjusting, and evacuating devices, hoses, oil) always bleed air from the piston pump.

5.1.1 Measuring the unload LS valve Measurement preparation 1. Park the machine on firm and flat ground, and lower the lift arm to the down end, with the bucket touching the ground, and stop the engine. 2. Install the vacuum pump to the hydraulic oil tank. 3. Tilt-up the cabin, and lock it. 4. Connect a pressure gauge to the pressure outlet of the piston pump.

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM Adjustment 1. Loosen the LS relief valve lock nut.

(1) Piston pump

(2) Plug

5. Tilt-down the cabin 6. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉). Measurement 1. Set the engine to the maximum speed, pull down the control lever to relieve the pressure, and check the set pressure.

(6) Lock nut

(4) Control valve (5) LS relief valve

2. Adjust the pressure with adjuster screw, and tighten the lock nut.

5.1.2 Measuring the LS relief valve Measurement preparation 1. Park the machine on firm and flat ground, and lower the lift arm to the down end, with the bucket touching the ground, and stop the engine. 2. Install the vacuum pump to the hydraulic oil tank. 3. Tilt-up the cabin, and lock it. 4. Connect the T joint and pressure gauge to the LS port hydraulic hose of the LS regulator.

(6) Lock nut (7) Adjustment screw (a) Pressure increase direction

(b) Pressure reduction direction

3. Adjust until the set pressure. LS relief valve pressure (reference value) Adjuster screw

1/4

1/2

Pressure change

5.0 MPa 51.0 kgf/cm2 725.2 psi

10.0 MPa 102.0 kgf/cm2 1450.4 psi

5.1.3 Measuring the overload relief valve

(1) LS regulator (2) T-joint

(3) Hose

SVL97-2

Measurement preparation 1. Park the machine on firm and flat ground, and lower the lift arm to the down end, with the bucket touching the ground, and stop the engine. 2. Install the vacuum pump to the hydraulic oil tank. 3. Tilt-up the cabin, and lock it. 4. Disconnect the high-pressure hose from the port to be measured, and plug the hose. 5. Attach a hand pump and pressure gauge to the port. NOTE • If there are 2 ports, plug one of the ports. 6-99

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM

Adjustment 1. Tilt-up the cabin, and lock it. 2. Loosen the lock nut for the flow dividing valve.

(1) Hand pump (2) T-joint (3) Test hose

(4) Pressure gauge

6. Remove the vacuum pump. Measurement 1. Increase pressure until the overload relief valve relives. 2. Measure 3 times, and take the average value.

(1) Control valve

(2) Flow divider valve

3. If the bucket angle is on the crowd side, turn the adjustment screw counterclockwise to adjust, and if on the dump side, turn the screw clockwise to adjust. 4. Tighten the lock nut, and tilt-down the cabin. 5. Measure the angle again and adjust until the angle of the bucket is level.

5.2 Removing/Installing the control valve CAUTION

(5) A1 port (Lift arm cylinder rod) (6) B1 port (Lift arm cylinder bottom) (7) A2 port (Bucket cylinder bottom)

(8) B2 port (Bucket cylinder rod) (9) A3 port (AUX male) (10) B3 port (AUX female) (11) Overload relief valve

5.1.4 Adjusting the flow dividing valve Measurement preparation 1. Park the machine on firm and flat ground, and lower the lift arm to the down end, with the bucket touching the ground. Measurement 1. Set the bucket to the crowd end, and raise the lift arm from the down end to the up end. 2. Lower the lift arm again until the bucket touches the ground, and check the angle of the bucket.

• The machinery may suddenly move. Stop the engine and lower the working equipment to the ground when removing/disconnecting the hydraulic equipments/hoses. • There is a risk of burns. Cool down the hydraulic equipments and oil when working and checking. • There is a risk of injury. Release residual pressure when taking hydraulic equipments off. IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-03 AUX start-up point setting – Service mode / No-12 AUX flow rate setting • After repairing the hydraulic pressure (changing, adjusting, and evacuating devices, hoses, oil) always bleed air from the piston pump.

NOTE • The angle will change, so do not operate the bucket. 6-100

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM

5.2.1 Removing the cabin 1. Dismount the cabin.

(3) Connector

5.2.2 Installing the vacuum pump

3. Disconnect all of the hoses connected to the control valve, and plug the adapters and hydraulic hoses.

1. Plug the breather hose, and attach the vacuum pump.

5.2.3 Removing/Installing the control valve

4. Suspend the control valve temporarily with a crane. 5. Remove three mounting bolts for the control valve.

1. Remove the bolt and the breather filter.

(4) Bolt (M12 × 75) (1) Bolt

(2) Breather filter

2. Remove the float solenoid valve connector.

SVL97-2

Tightening torque Bolt (4)

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

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6. HYDRAULIC SYSTEM 6. Lift the control valve and remove it.

(1) Hex socket bolt (M6 × 50) ×4 (2) Cover

2. Remove the spool assembly from the casing.

(5) Control valve Control valve weight

SVL95-2s SVL97-2

62.9 kg 138.7 lbs

5.3 Disassembling the control valve CAUTION • Choose a clean place to prevent contaminants when assembling/disassembling. • Use clean tools and new cleaning oil. • Before separating the sections, plug in to each port and clean the exterior as an assembly. • Work at flat and level platform to avoid bias/ excess torque and residual strain when assembling/disassembling. • Replace seals and O-rings with new ones, and install it with grease or hydraulic oil. • Clean outside of the motor with plugging each ports after assembling.

(3) Spool assembly

(4) Casing

3. Remove the plug. NOTE • Tool: 12 mm hex wrench

5.3.1 Removing the section for control valve

(5) Plug

1. Remove two hex socket bolts, and the spool cover. NOTE • Tool: 6 mm hex wrench

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6. HYDRAULIC SYSTEM

4. Remove the spring.

(10) Spring

8. Remove the plug.

(6) Spring

5. Tighten an M4 bolt on the compensator spool and then remove the compensator spool with the M4 bolt.

(7) Compensator spool

(11) Poppet

(8) M4 bolt

6. Remove the plug. NOTE • Tool: 10 mm hex wrench

NOTE • Tool: 6 mm hex wrench

(12) Plug

9. Tighten an M4 bolt on the compensator spool and then remove the compensator spool with the M4 bolt.

(13) Stopper

(14) M3 bolt

(9) Plug

7. Remove the spring and poppet.

SVL97-2

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6. HYDRAULIC SYSTEM

5.3.2 Removing the flow divider section for the control valve 1. Remove the plug • Tool: 10 mm hex wrench

(4) Flow divider ratio adjustment valve

4. Remove two plugs. • Tool: 8 mm hex wrench (1) Plug

2. Remove the flow dividing valve spool and spring.

(5) Plug

5. Remove the spring and poppet. (2) Flow divider valve spool

(3) Spring

3. Remove the flow divider ratio adjustment valve. NOTE • The setting will change, so you need to apply a wrench to the 22 mm width portion of the flow divider ratio adjustment valve.

(6) Spring

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(7) Poppet

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM

6. Remove the plug • Tool: 10 mm hex wrench

(1) Main relief valve

2. Remove the LS relief valve. (8) Plug

7. Remove the spring, sequence spool and piston.

NOTE • The set pressure will change, so you need to apply a spanner to the 24 mm width portion of the LS relief valve. • Tool: 24 mm spanner

(9) Spring (10) Sequence spool

(11) Piston

5.3.3 Removing the relief valve for the control valve 1. Remove the main relief valve.

(2) LS relief valve

3. Remove the plug. • Tool: 6 mm hex wrench

NOTE • The set pressure will change, so you need to apply a spanner to the 30 mm width portion of the main relief valve. • Tool: 30 mm spanner

(3) Plug

SVL97-2

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM 4. Tighten an M4 bolt on the LS bleed throttle, and then remove the LS bleed throttle with the M4 bolt.

7. Remove the spring and LS unload spool.

(8) Spring (4) M4 bolt

(5) LS bleed throttle

5. Remove the overload relief valve.

(9) Unload LS spool

8. Loosen the 2 hex socket bolts alternately to remove, and then remove the cover.

NOTE • The set pressure will change, so you need to apply a spanner to the 24 mm width portion of the overload relief valve.

NOTE • There is a risk of the built-in spring flying out, so loosen the hex socket bolts alternately.

• Tool: 24 mm spanner

• Tool: 6 mm hex wrench

(6) Overload relief valve

(10) Hex socket bolt

6. Remove the plug. • Tool: 8 mm hex wrench

9. Remove the spring and poppet.

(12) Spring

(11) Cover

(13) Poppet

(7) Plug

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM

5.3.4 Removing the float solenoid valve for the control valve 1. Remove two hex socket bolts, and the float Solenoid Valve. • Tool: 4 mm hex wrench

(4) Spring

4. Clamp the flat section of the sleeve with needlenose plier, and remove the spool with the sleeve.

(1) Hex socket bolt

(2) Float Solenoid Valve

2. Remove the plug.

NOTE • The oil leak characteristics will change, so do not remove the spool from the sleeve. • Tool: Needle-nose plier

NOTE • Use a crane to place the control valve facing downward. • Tool: 10 mm hex wrench

(5) Sleeve (6) Spool

(a) Flat surface of sleeve

5. Remove the cap seal from the casing.

(3) Plug

3. Remove the spring. • Tool: 10 mm hex wrench

(7) Cap seal

SVL97-2

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM 6. Remove the plug. NOTE • Use a crane to position to control valve faceup. • Tool: 8 mm hex wrench

– Service mode / No-03 AUX start-up point setting – Service mode / No-12 AUX flow rate setting • After repairing the hydraulic pressure (changing, adjusting, and evacuating devices, hoses, oil) always bleed air from the piston pump.

5.4.1 Assembling the section for control valve 1. Insert the spool assembly to the casing.

(8) Plug

7. Remove two springs and poppets.

(1) Spool assembly

(2) O-ring

2. Install the spool cover, and tighten two hex socket bolts. NOTE • Tool: 6 mm hex wrench

(9) Spring

(10) Poppet

5.4 Assembling the control valve CAUTION • Choose a clean place to prevent contaminants when assembling/disassembling. • Use clean tools and new cleaning oil. • Before separating the sections, plug in to each port and clean the exterior as an assembly. • Work at flat and level platform to avoid bias/ excess torque and residual strain when assembling/disassembling. • Replace seals and O-rings with new ones, and install it with grease or hydraulic oil. • Clean outside of the motor with plugging each ports after assembling.

(3) Hex socket bolt (M6 × 50) ×4 (4) Spool cover

Hex socket bolt (3)

Tightening torque

24 to 34 N⋅m 2.4 to 3.5 kgf⋅m 17.7 to 25.1 lbf⋅ft

IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. 6-108

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM

3. Tighten an M4 bolt on the compensator spool and then insert the compensator spool with the M4 bolt. NOTE • To avoid damaging the O-ring, do not rotate the LS bleed throttle when inserting.

Plug (8)

Tightening torque

6. Insert the spring and poppet.

(9) Spring (5) Compensator spool

(6) M4 bolt

4. Insert the spring.

167 to 196 N⋅m 17.0 to 20.0 kgf⋅m 123.2 to 144.6 lbf⋅ft

(10) Poppet

7. Tighten the plug. NOTE • Tool: 10 mm hex wrench

(7) Spring

5. Tighten the plug. NOTE • Tool: 12 mm hex wrench

(11) Plug

Plug (11)

Tightening torque

127 to 147 N⋅m 13.0 to 15.0 kgf⋅m 93.7 to 108.4 lbf⋅ft

(8) Plug

SVL97-2

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM 8. Tighten the M3 bolt for the stopper, and insert the stopper with the M3 bolt. NOTE • To avoid damaging the O-ring, do not rotate the stopper when inserting.

(1) Plug

Plug (1)

Tightening torque

127 to 147 N⋅m 13.0 to 15.0 kgf⋅m 93.7 to 108.4 lbf⋅ft

2. Insert the flow dividing valve spool and spring. (12) Compensator spool

(13) M3 bolt

9. Tighten the plug. NOTE • Tool: 6 mm hex wrench

(2) Flow divider valve spool

(14) Plug

Plug (14)

NOTE • Use a crane to flip the casing over. • Make sure the flow divider valve spool faces the right way.

Tightening torque

(3) Spring

24.5 to 29.5 N⋅m 2.5 to 3.0 kgf⋅m 18.1 to 21.8 lbf⋅ft

5.4.2 Assembling the flow divider section for control valve 1. Tighten the plug. • Tool: 10 mm hex wrench

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM

3. Tighten the plug. • Tool: 10 mm hex wrench

(6) Spring

6. Tighten the plug. • Tool: 8 mm hex wrench

(4) Plug

Plug (4)

(7) Poppet

Tightening torque

127 to 147 N⋅m 13.0 to 15.0 kgf⋅m 93.7 to 108.4 lbf⋅ft

4. Tighten the flow divider ratio adjustment valve. NOTE • Use a crane to set the casing face-up. • The set pressure will change, so you need to apply a wrench to the 22 mm width portion of the flow divider ratio adjustment valve. • Tool: 22 mm spanner (8) Plug

Plug (8)

Tightening torque

39 to 49 N⋅m 4.0 to 5.0 kgf⋅m 28.8 to 36.1 lbf⋅ft

7. Insert the spring.

(5) Flow divider ratio adjustment valve Flow divider ratio adjustment valve (5)

Tightening torque

34 to 39 N⋅m 3.5 to 4.0 kgf⋅m 25.1 to 28.8 lbf⋅ft

5. Insert the spring and poppet. (9) Spring

SVL97-2

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM 8. Tighten the plug. • Tool: 10 mm hex wrench

Plug (13)

Tightening torque

127 to 147 N⋅m 13.0 to 15.0 kgf⋅m 93.7 to 108.4 lbf⋅ft

5.4.3 Assembling the relief valve for the control valve 1. Insert the main relief valve. NOTE • The set pressure will change, so you need to apply a spanner to the 30 mm width portion of the main relief valve. • Tool: 30 mm spanner (10) Plug

Plug (10)

Tightening torque

127 to 147 N⋅m 13.0 to 15.0 kgf⋅m 93.7 to 108.4 lbf⋅ft

9. Insert the sequence spool and piston. • Use a crane to flip the casing over. • Make sure the sequence spool is facing the right way.

(1) Main relief valve

Main relief valve (1)

(11) Sequence spool

Tightening torque

69 to 78 N⋅m 7.0 to 8.0 kgf⋅m 50.9 to 57.5 lbf⋅ft

(12) Piston

10. Tighten the plug. • Tool: 10 mm hex wrench

(13) Plug

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6. HYDRAULIC SYSTEM

2. Install the LS relief valve. NOTE • The set pressure will change, so you need to apply a spanner to the 24 mm width portion of the LS relief valve. • Tool: 24 mm spanner

(5) Plug

Plug (5)

Tightening torque

24.5 to 29.5 N⋅m 2.5 to 3.0 kgf⋅m 18.1 to 21.8 lbf⋅ft

5. Install the overload relief valve. (2) LS relief valve

LS relief valve (2)

Tightening torque

39 to 49 N⋅m 4.0 to 5.0 kgf⋅m 28.8 to 36.1 lbf⋅ft

NOTE • The set pressure will change, so you need to apply a spanner to the 24 mm width portion of the overload relief valve. • Tool: 24 mm spanner

3. Tighten an M4 bolt on the LS bleed throttle, and then insert the LS bleed throttle with the M4 bolt. NOTE • To avoid damaging the O-ring, do not rotate the LS bleed throttle when inserting.

(6) Overload relief valve

Overload relief valve (6)

(3) M4 bolt

Tightening torque

39 to 49 N⋅m 4.0 to 5.0 kgf⋅m 28.8 to 36.1 lbf⋅ft

(4) LS bleed throttle

4. Tighten the plug. • Tool: 6 mm hex wrench

SVL97-2

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM 6. Insert the spring and unload spool.

NOTE • There is a risk of spring deformation, so tighten the hex socket bolts alternately. • Tool: 6 mm hex wrench

(7) Spring

(8) Unload spool

7. Tighten the plug. • Tool: 8 mm hex wrench (12) O-ring (13) Cover

Hex socket bolt (14)

(14) Hex socket bolt

Tightening torque

24 to 34 N⋅m 2.5 to 3.5 kgf⋅m 17.7 to 25.1 lbf⋅ft

5.4.4 Assembling the float solenoid valve for the control valve 1. Install the float Solenoid Valve, and tighten two hex socket bolts. • Tool: 4 mm hex wrench

(9) Plug

Plug (9)

Tightening torque

39 to 49 N⋅m 4.0 to 5.0 kgf⋅m 28.8 to 36.1 lbf⋅ft

8. Insert the spring and poppet.

(1) Hex socket bolt

Hex socket bolt (1)

(10) Spring

(2) Float Solenoid Valve

Tightening torque

6 to 8 N⋅m 0.6 to 0.8 kgf⋅m 4.4 to 5.9 lbf⋅ft

(11) Poppet

9. Tighten two hex socket bolts alternately, and install the cover.

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM

2. Insert the spring and poppet.

(3) Spring

(4) Poppet

3. Tighten the plug. • Tool: 8 mm hex wrench

(6) Spool (7) Sleeve (8) Cap seal

(a) Flat surface of sleeve

5. Insert the spring.

(9) Spring (5) Plug

Plug (5)

Tightening torque

39 to 49 N⋅m 4.0 to 5.0 kgf⋅m 28.8 to 36.1 lbf⋅ft

6. Tighten the plug. • Tool: 10 mm hex wrench

4. Press surface (a) of the sleeve to insert the sleeve, spool, and cap seal. NOTE • Use a crane to place the control valve facing downward. • The oil leak characteristics will change, so do not remove the spool from the sleeve.

(10) Plug

Plug (10)

SVL97-2

Tightening torque

98 to 118 N⋅m 10 to 12.0 kgf⋅m 72.3 to 87.0 lbf⋅ft

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM

5.5 Control valve components

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

Plug Main relief valve Plug O-ring Poppet Spring

6-116

(7) Plug (8) O-ring (9) Plug (10) O-ring (11) Solenoid valve (12) Filter holder

(13) Filter (14) Stopper (15) O-ring (16) Backup ring (17) Hex socket bolt (18) Spool

(19) Sleeve (20) Spring (21) Plug (22) O-ring (23) O-ring (24) Cap seal

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Control valve

(25) Poppet (26) Lift arm spool (27) Bucket spool (28) AUX spool (29) Compensator spool (30) Spring

SVL97-2

6. HYDRAULIC SYSTEM

(31) Plug (32) O-ring (33) O-ring (34) Poppet (35) Poppet (36) Plug

(37) O-ring (38) Overload relief valve (39) Hex socket bolt (40) Spring seat (41) Spring cover (42) Spool cover

(43) O-ring (44) Spacer bolt (45) Spring (46) Stopper (47) Plug (48) O-ring

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6. HYDRAULIC SYSTEM

(49) Throttle screw (50) O-ring (51) Hex nut (52) Needle valve (53) Plug (54) Backup ring (55) O-ring (56) O-ring

6-118

(57) Plug (58) Sequence valve (59) Spring (60) Flow divider valve (61) Piston (62) Spring (63) LS relief valve (64) Spring

(65) Plug (66) O-ring (67) Cover (68) Spring (69) Hex socket bolt (70) O-ring (71) Poppet (72) Spool

(73) Throttle set screw (74) Casing (75) O-ring (76) Backup ring (77) Stopper (78) Steel ball (79) Check valve seat

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Control valve

6. HYDRAULIC SYSTEM

5.6 Installing adapter layout for control valve

SVL97-2

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SERVICING 5. Control valve

6. HYDRAULIC SYSTEM Adapter

Port

Size

Angle

S, G6-G4 (1)

(2)

S, G4-G4

G1/2-2 L, G1/2, G1/2

30°

L, G1/2, G1/2

15°

L, G4-G4, 45

30°

L, G2, G2, 45

15°

Cross, 3-G4, G2

S, G6-G4

S, G1/4

(3)

S, G6, G6

(4)

L, G2, G2

(5)

Pb1

L, G2, G2

30°

(6)

Pb2

L, G2, G2

30°

(7)

Pb3

L, G2, G2

(8)

PLS

S, G2, G2

(9)

45L, G6-G6

5°

S, G8-G6

(10)

S, G6-G6

(11)

S, G6-G6

(12)

Pa3

L, G2, G2

(13)

Pa2

L, G2, G2

L, G1/2, G1/2

10°

S, G6-G4

G1/2-2

L, G1/2, G1/2

S, G6-G4

3-G4

L, G2, G2

15°

(14)

(15)

(16)

Pipe joint (S, G8-G6) (9)

6-120

Pa1

Tightening torque

196.5 to 245.5 N⋅m 20.0 to 25.0 kgf⋅m 144.9 to 181.0 lbf⋅ft

SVL97-2 KiSC issued 09, 2021 A

SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

6. Travel motor 6.1 Removing/Installing the travel motor CAUTION • Jerk up the machine on a support to prevent machine from falling. • Keep away from the crawler while it is rotating. • The machinery may suddenly move. Stop the engine and lower the working equipment to the ground when removing/disconnecting the hydraulic equipments/hoses. • There is a risk of burns. Cool down the hydraulic equipments and oil when working and checking. • There is a risk of injury. Release residual pressure when taking hydraulic equipments off.

6.1.3 Removing the travel motor 1. Remove none bolts and the sprocket.

IMPORTANT • After repairing the hydraulic pressure (changing, adjusting, and evacuating, hoses, oil) always bleed air from the piston pump.

6.1.1 Removing/Installing the rubber crawler 1. Remove the rubber crawler.

(1) Bolt (M16 × 50) × 9

(2) Sprocket

Tightening torque 259.9 to 304.0 N⋅m 26.5 to 31 kgf⋅m 192 to 224 lbf⋅ft

Bolt (1)

Apply a threadlock (Loctite® 271). Install the plain washer with the R section facing the machine exterior. Sprocket weight

SVL95-2s SVL97-2

22.2 kg 48.9 lbs

2. Remove four bolts, and the cover. (1) Rubber crawler

6.1.2 Installing the vacuum pump 1. Plug the breather hose, and attach the vacuum pump.

(3) Bolt (M12 × 35) × 4

SVL97-2

(4) Cover

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SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM 3. Remove five hoses, and plug the hoses and adapters.

6.2 Disassembling the travel motor CAUTION • Choose a clean place to prevent contaminants when assembling/disassembling. • Use clean tools and new cleaning oil. • Replace seals and O-rings with new ones, and install it with grease or hydraulic oil. • Clean outside of the motor with plugging each ports after assembling.

(5) Travel motor

4. Support the travel motor with a crane, and remove nine bolts.

IMPORTANT • After repairing the hydraulic pressure (changing, adjusting, and evacuating, hoses, oil) always bleed air from the piston pump.

6.2.1 Disassembling the gear case for travel motor 1. Remove twelve bolts and washers. • Tool: 10 mm socket wrench

(6) Nylon sling

(7) Bolt (M16 × 50) × 9

Tightening torque 259.9 to 304.0 N⋅m 26.5 to 31 kgf⋅m 192 to 224 lbf⋅ft

Bolt (7)

(1) Bolt

Apply a threadlock (Loctite® 271). 5. Remove the travel motor

2. Remove the cover with hammering the side of it. • Tool: Hammer

(8) Travel motor

Travel motor weight

6-122

(2) Washer

(3) Cover SVL95-2s SVL97-2

83 kg 180 lbs

SVL97-2 KiSC issued 09, 2021 A

SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

3. Remove three bolts and the stopper plate. • Tool: 13 mm socket wrench

7. Remove the sun gear (2nd).

(11) Sun gear (2nd) (4) Stopper plate

(5) Bolt

4. Remove the sun gear (1st).

8. Remove four bolts and the stopper plate. • Tool: 5 mm hex socket

(6) Sun gear

(12) Bolt

5. Remove the carrier plate assembly.

9. Remove four each of planetary gears (2nd), needle bearings (2nd), and washers.

(13) Stopper plate

6. Remove three each of planetary gears (1st), inner races, and needle bearings (1st). (14) Planetary gear (2nd) (15) Needle bearing (2nd)

(7) Planetary gear (1st) (8) Inner race (9) Needle bearing (1st)

SVL97-2

(16) Washer

(10) Carrier plate

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6. HYDRAULIC SYSTEM 10. Remove four inner races. • Jig: Inner race extraction jig

(19) Ring gear

(A) Ring nut fastening jig

13. Remove the ring gear. NOTE • If you do not have a puller, use a hammer to tap the left and right of the ring gear alternately to remove. • Jig: Puller

(17) Inner race (H) Inner race extraction jig

(a) 1.2 mm (0.047 in.)

11. Remove two plugs. • Tool: 5 / 16 inch hex wrench

(20) Ring gear

(21) Housing

14. Remove the floating seal on the ring gear side. • Tool: Flat tip screwdriver

(18) Plug

12. Remove the nut. NOTE • Use clamps to secure the ring gear. • Tool: Clamp • Jig: Ring nut fastening jig

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(22) Floating seal

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SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

15. Remove the floating seal on the housing side. • Tool: Flat tip screwdriver

(23) Floating seal

16. Remove the angular bearing with tapping it evenly with strike rod. • Tools: Hammer and strike rod

(26) Internal circlip

(27) Angular bearing

6.2.2 Disassembling the hydraulic motor for the travel motor (24) Angular bearing

1. Remove two each of plugs, springs, guides, and shuttle spool for flushing spool, in that order. • Tool: 19 mm socket wrench

17. Remove the internal circlip. • Tool: Snap ring pliers

(25) Internal circlip

(1) Plug (2) Spring (3) Guide

(4) Shuttle spool

18. Remove the angular bearing. IMPORTANT • Tap evenly on the angular bearing with the strike rod. • Tools: Hammer and strike rod

SVL97-2

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6. HYDRAULIC SYSTEM 2. Remove the plug, spring and spool of the travel speed spool, in that order. • Tools: 22 mm socket wrench, 1/4 in. hex wrench

(13) End cap (14) Bolt (5 / 16 inch ×30 mm) ×5

(5) Spool (6) Plug (with O-ring)

(7) Spring

(15) Bolt (7 / 32 inch ×85 mm) ×2

6. Insert a flat tip driver into the gap, and tap the end cap with a hammer to remove. • Tools: Flat tip screwdriver and hammer

3. Remove the plug, spring and poppet for the relief valve, in that order. Tool: 17 mm socket wrench

(16) End cap

7. Remove three 3 O-rings. • Tool: Flat tip screwdriver (8) Plug (9) Spring

(10) Poppet

4. Remove two plugs, two seat plugs and a ball for the high pressure selection section, in that order. NOTE • Apply ThreeBond 1324 to the seat plugs. • Tools: 3 / 16, 1 / 4 inch hex socket

(17) O-ring (18) O-ring

(11) Seat plug

(19) O-ring

(12) Ball

5. Remove five bolts from the outer circumference of the end cap, and two mounting bolts. • Tool: 5 / 16, 7 / 32 inch hex socket

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SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

8. Remove the valve plate and eight brake springs.

(24) Plate (20) Valve plate

(21) Brake spring

(25) Friction plate

12. Remove the swash-plate.

9. Remove the brake piston with pressing it down and blowing air from the hole of brake release oil passage. NOTE • Blow air from the passage which does not have the orifice inside. • When air is let in, always hold down the brake piston when carrying out the work so that the brake piston does not fly out. (26) Swash-plate

13. Remove the shaft and roller bearing. • Turn the disassembly / assembly work platform 90°.

(22) Brake piston (a) Hole that oil passes through for travel speed shift

(b) Brake release oil passage hole

10. Remove the cylinder block kit. • Turn the disassembly / assembly work platform 90°.

(27) Roller bearing

(28) Shaft

14. Remove the shaft circlip. • Tool: Snap ring pliers

(23) Cylinder block kit

11. Remove four plates and three friction plates. (29) Shaft circlip

SVL97-2

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6. HYDRAULIC SYSTEM 15. Remove the shaft with press machine. • Tool: Striking rod • Jig: Roller bearing press-fit jig

• Replace seals and O-rings with new ones, and install it with grease or hydraulic oil. • Clean outside of the motor with plugging each ports after assembling. IMPORTANT • After repairing the hydraulic pressure (changing, adjusting, and evacuating, hoses, oil) always bleed air from the piston pump.

6.3.1 Assembling the gear case for travel motor (30) Shaft

16. Remove the control piston and two balls.

(31) Control piston (32) Oil seal

(33) Ball

1. Press-fit the angular bearing into the ring gear with press machine. • Jig: Angular bearing press-fit jig

(1) Angular bearing

(B) Angular bearing press-fit jig

17. Remove the Oil Seal. NOTE • Flip over the disassembly / assembly work platform. • Tools: Flat tip screwdriver and hammer

(34) Housing

(35) Oil seal

6.3 Assembling the travel motor CAUTION • Choose a clean place to prevent contaminants when assembling/disassembling. • Use clean tools and new cleaning oil.

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SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

2. Install an internal circlip and press-fit the angular bearing again. NOTE • Make sure that the angular bearing is assembled in the right direction. • Tool: Snap ring pliers

5. Set the floating seal insertion jig (guide) in the housing, and install the O-ring and floating seal. NOTE • Grease the O-ring. • Jig: Floating seal installation jig (guide)

(2) Internal circlip

(3) Angular bearing

3. Tap 4 bolt holes in the housing.

(4) Floating seal kit (d) O-ring

(E) Floating seal insertion jig (guide)

6. Install the floating seal kit in the gear case with the floating seal insertion jig (pusher). • Jig: Floating seal insertion jig (pusher)

(a) Bolt hole

(b) Tap M8 × 1.25

4. Remove swarfs inside the housing with vacuum pump.

SVL97-2

(F) Floating seal insertion jig (pusher)

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6. HYDRAULIC SYSTEM 7. Install the O-ring in the floating seal kit, and set it on the ring gear. NOTE • Grease the O-ring. • Jig: Floating seal installation jig (guide)

(6) Ring gear

(7) Housing

11. Use clamps to secure the ring gear. • Tool: Clamp

(5) Floating seal kit

(E) Floating seal insertion jig (guide)

8. Install the floating seal kit with the floating seal insertion jig (pusher). • Jig: Floating seal insertion jig (pusher)

(8) Ring gear

(F) Floating seal insertion jig (pusher)

9. Apply gear oil to the sliding surface of the floating seal kit on the ring gear. NOTE • Apply gear oil to 4 locations at 90 deg intervals.

10. Install the ring gear in the housing.

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SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

12. Tighten the nut. IMPORTANT • After tightening, check that the top surface of the nut is lower than the surface with boss on the housing. • Jig: Ring nut fastening jig

(f)

Push-pull gauge

Angular bearing

(g) Bolt (M16)

Turning torque

11 to 15 N⋅m 1.2 to 1.5 kgf⋅m 8.1 to 11 lbf⋅ft

15. Install two plugs. • Tool: 5 / 16 inch hex wrench

(9) Nut (e) Surface with boss

Nut (9)

(A) Ring nut fastening jig

Tightening torque (reference value)

220 to 340 N⋅m 22.4 to 34.7 kgf⋅m 162 to 251 lbf⋅ft

13. Screw the M16 bolt in the sprocket mounting hole. 14. Measure the turning torque of the travel motor with pulling the bolt with push-pull gauge. NOTE • If the turning torque is lower than the standard value, tighten the nut within the applicable torque range, and measure the turning torque again. • If the turning torque is greater than the standard value, slacken the nut and then tighten it within the applicable torque range, and measure the turning torque again.

(10) Plug

Plug (10)

Tightening torque

30 N⋅m 3.1 kgf⋅m 22 lbf⋅ft

16. Drive four inner races into the housing with the oil seal insertion jig. NOTE • Apply gear oil to the inner surface of the inner race. • Tool: Hammer • Jig: Oil Seal press-fit jig

• Tool: Push-pull gauge

(11) Inner race

SVL97-2

(D) Oil Seal press-fit jig

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6. HYDRAULIC SYSTEM 17. Install the thrust plate, needle bearing (2nd), and planetary gear (2nd). NOTE • When installing the thrust plate, the R surface should be facing downwards.

(15) Carrier plate assembly

21. Install the sun gear (1st).

(12) Planetary gear (2nd)

18. Install the plate (2nd), and tighten four bolts. • Tool: 5 mm hex socket

(16) Sun gear (1st)

22. Install the stopper plate.

(13) Bolt

Bolt (13)

Tightening torque (reference value)

20 N⋅m 2.0 kgf⋅m 15 lbf⋅ft

Apply a threadlock (ThreeBond 1324) 19. Install the sun gear (2nd).

(17) Stopper plate

(14) Sun gear (2nd)

20. Install the carrier plate assembly. NOTE • Pass a tap through the carrier sub-assembly before installation. (M8 × 1.25 mm) 6-132

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SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

23. Tighten three bolts for the stopper plate. • Tool: 13 mm socket wrench

NOTE • Turn the disassembly / assembly work bench 90°. • Wrap sealing tape around the plug. • Tool: 5 / 16 inch hex wrench

(18) Bolt

Bolt (18)

Tightening torque

25 N⋅m 2.5 kgf⋅m 18 lbf⋅ft

Apply a threadlock (ThreeBond 1324) 24. Install the cover, and tighten twelve bolts and washers. NOTE • Apply ThreeBond 1215 to the flange section of the cover. • Tool: 10 mm socket wrench

(h) Supply port (i) Oil level check port

Gear oil

(j)

Oil drain port

1.60 L 0.423 gal

Amount

6.3.2 Assembly of travel motor 1. Drive the Oil Seal into the Oil Seal press-fit jig. NOTE • Grease the outer circumference of the Oil Seal. • Face the rubber side downward. • Jig: Oil Seal press-fit jig

(19) Cover (20) Washer

Bolt (21)

(21) Bolt

Tightening torque (reference value)

16 N⋅m 1.6 kgf⋅m 12 lbf⋅ft

25. Put gear oil into the travel motor and plug it.

SVL97-2

(A) Metal side (B) Rubber side

(D) Oil Seal press-fit jig

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6. HYDRAULIC SYSTEM 2. Install two balls and control piston. NOTE • Grease two balls. • Check the sliding surface of the control pin.

(7) Swash-plate

6. Install three pins in the cylinder block. NOTE • Grease the pins. (1) Control piston

(2) Ball

3. Press-fit the roller bearing into the shaft. • Jig: Roller bearing press-fit jig

(a) Cylinder block

(b) Pin

7. Install the retainer holder. (3) Roller bearing (4) Shaft

4. Install the shaft. NOTE • Apply hydraulic oil to the circumference of the roller bearing.

outer

(5) Roller bearing

(6) Shaft

5. Install the swash-plate.

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SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

8. Install the piston assembly and retainer plate in the cylinder block. IMPORTANT • Apply hydraulic oil to the pistons.

(f) No less than 1 mm (0.04 in.) (E) Housing end face

(F) Cylinder block kit sliding surface

11. Check the thickness of four plates and three friction plates, and ensure that it is within the specified range. (d) Retainer plate

(e) Piston

9. Install the cylinder block kit. NOTE • Turn the disassembly / assembly work platform sideways.

NOTE • If the total thickness is 13.5 mm (0.531 in.) or less, replace the plates.

(9) Plate

(8) Cylinder block kit

10. Check the clearance between the housing end face and cylinder block. NOTE • Turn the disassembly / assembly work platform upwards. • Tool: Depth gauge

Plate (9) Friction plate (10)

Thickness

2 mm (0.08 in.) per plate 2 mm (0.08 in.) per plate

12. Assemble four plates and three friction plates. NOTE • Assemble the plates and friction plates alternately.

(9) Plate

SVL97-2

(10) Friction plate

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SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM 13. Install the O-ring on the brake piston. NOTE • Grease the O-ring.

(10) Brake piston (g) O-ring

(h) O-ring

NOTE • Grease the O-ring.

(12) O-ring (13) O-ring (14) O-ring

(15) Valve plate

18. Tighten seven bolts and install the end cap. • Tool: 5 / 16, 7 / 32 inch hex socket

14. Install the brake piston. NOTE • Align the mounting bolt hole with the pin hole to the center of the hole which the oil passes through for travel speed shift.

(16) End cap (17) Bolt (5 / 16 inch ×30 mm) ×5

(18) Bolt (7 / 32 inch ×85 mm) ×2

Bolt (17) (G) Pin hole (H) Mounting bolt hole

(I)

Hole which oil passes through for travel speed shift

15. Install eight brake springs.

Tightening torque Bolt (18)

60 N⋅m 6.1 kgf⋅m 44 lbf⋅ft 30 N⋅m 3.1 kgf⋅m 22 lbf⋅ft

(11) Brake spring

16. Install the valve plate on the end cap. NOTE • Make sure that the valve plate faces the right way. 17. Install three O-rings on the housing. 6-136

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SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

19. Assemble the check valve high pressure selection ball, two seat plugs, and plugs, in that order. NOTE • Apply ThreeBond 1324 to the seat plugs. • Tools: 3 / 16, 1 / 4 inch hex wrench

(22) Plug (23) Spring

Plug (22)

(24) Poppet

Tightening torque

30 N⋅m 3.1 kgf⋅m 22 lbf⋅ft

21. Install the spool, spring, and plug of the travel speed spool. NOTE • Make sure that the spools are facing in the right direction. • Apply hydraulic oil to the spool. • Tools: 22 mm socket wrench, 3/8 in. hex wrench

(19) Plug (20) Seat plug

Plug (19)

(21) Ball

Tightening torque

35 N⋅m 3.6 kgf⋅m 26 lbf⋅ft

20. Install the poppet, spring and plug of the relief valve, in that order. • Tool: 17 mm socket wrench

(25) Plug (26) Spool (27) Spring

(28) Plug

Plug (25) Tightening torque Plug (28)

SVL97-2

35 N⋅m 3.6 kgf⋅m 26 lbf⋅ft 50 N⋅m 5.1 kgf⋅m 37 lbf⋅ft

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SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM 22. Assemble the shuttle spool, two each of guides, springs, and plugs for the flushing spool, in that order. NOTE • Apply hydraulic oil to the shaft spool. • Tool: 19 mm socket wrench

(29) Plug (30) Spring (31) Guide

Plug (29)

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(32) Shuttle spool

Tightening torque

35 N⋅m 3.6 kgf⋅m 26 lbf⋅ft

SVL97-2 KiSC issued 09, 2021 A

SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

6.4 Travel motor components

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

Plug Cover Bolt (M6 × 1.0 × 25 L) Washer Stopper plate Bolt

SVL97-2

(7) Planetary gear (1st) (8) Inner race (9) Needle bearing (1st) (10) Carrier plate (11) Sun gear (1st) (12) Sun gear (2nd)

(13) Nut (14) Ring gear (15) Bolt (16) Stopper plate (17) Internal circlip (18) Angular bearing

(19) Floating seal kit (20) Planetary gear (2nd) (21) Inner race (22) Needle bearing (2nd) (23) Washer (24) Plug

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6. HYDRAULIC SYSTEM

(25) Plug (26) Housing (27) Control piston (28) Orifice (29) O-ring (30) O-ring (31) O-ring (32) Oil seal (33) Shaft circlip (34) Roller bearing (35) Shaft (36) Ball (37) Swash-plate (38) Cylinder block kit

6-140

(39) Plate (40) Friction plate (41) O-ring (42) O-ring (43) Brake piston (44) Brake spring (45) Valve plate (46) Pin (47) Pin (48) Needle bearing (49) Pin (50) End cap (51) Plug (52) Plastic pliers

(53) Plug (54) Plug (55) Spring (56) Guide (57) Shuttle spool (58) Plug (59) Plug (60) Seat plug (61) Ball (62) Plug (63) Plug (64) Spool (65) Plug (66) Spring

(67) Poppet (68) Plug (69) Plug (70) Spring (71) Plug (72) Plug (73) Plug (74) Plug (75) Plug (76) Plug (77) Nameplate (78) Screw (79) Bolt (M12 × 35 L) (80) Bolt (M10 × 80 L)

SVL97-2 KiSC issued 09, 2021 A

SERVICING 6. Travel motor

6. HYDRAULIC SYSTEM

7. Pilot valve

6.5 Installing adapter layout for travel motor

7.1 Measuring the piston pump

Travel motor L

IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-03 AUX start-up point setting – Service mode / No-05 HST start-up point setting – Service mode / No-12 AUX flow rate setting

7.1.1 Measuring pressure for pilot valve

(a) Front of machine Adapter

Port

Size

Angle

(1)

S, G6, 115U

(2)

S, G6, 115U

(3)

PS cylinder

(4)

PS cylinder

(5)

L, G2, G2

Travel Motor R

Port

Size

Angle

L, G6, 115U

0 to 5°

L, 1-1/16U, G6

(6)

L, G6, 115U

5 to 10°

(7)

L, 1-1/16U, G6

(8)

PS cylinder

(9)

PS cylinder

(10)

L, 1-1/16U, G4

SVL97-2

Measurement preparation 1. Place the vehicle on a jack stand on firm and flat ground. 2. Tilt-up the cabin. 3. Remove the right front pilot hose from port 4, and connect a test hose, pilot hose and pressure gauge to the pipe joint.

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

(a) Front of machine Adapter

IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-05 HST start-up point setting

Port 1: Left front Port 2: Right back Port 3: Left back Port 4: Right front

(5) Port P (6) Port T

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SERVICING 7. Pilot valve

6. HYDRAULIC SYSTEM

(7) Hydraulic hose (8) Test hose (9) Pipe joint

(10) Pipe joint (11) Pressure gauge

4. Tilt-down the cabin 5. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉).

(1) Port: 1 Bucket crowd (2) Port: 2 Lift arm down (3) Port: 3 Bucket dump

(4) Port: 4 Lift arm up (5) Port P (6) Port T

(7) Hydraulic hose (8) Test hose (9) Pipe joint

(10) Pipe joint (11) Pressure gauge

Measurement 1. Set the engine to maximum speed, and release the hydraulic lock. 2. Travel forward and measure the pressure. 3. Perform measurement 3 times, and take the average value. 4. Similarly, connect a pressure gauge to the pilot hoses of port 1, port 2, port 3 and port P, and measure the pressure.

7.1.2 Measuring pressure for the pilot valve (Lift arm, bucket) IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-03 AUX start-up point setting – Service mode / No-12 AUX flow rate setting Measurement preparation 1. Place the vehicle on a jack stand on firm and flat ground. 2. Tilt-up the cabin. 3. Remove the lift arm up pilot hose from port 4, and connect a test hose, pilot hose and pressure gauge to the pipe joint.

4. Tilt-down the cabin 5. Warm up the engine until the hydraulic oil temperature reaches 50 ± 5 ℃ (122 ± 9 ℉). Measurement 1. Set the engine to maximum speed, and release the hydraulic lock. 2. Raise the lift arm, and measure the pressure. 3. Measure 3 times, and take the average value. 4. Similarly, measure the pressure of lift arm down, bucket crowd, bucket down, and port P.

7.2 Disassembling the pilot valve CAUTION • Handle the parts very carefully due to its precision, do not hit or drop them. • Hitting the parts too hard will result in performance degradation, oil leak, generating burrs, and breaking. • Pay extra atten ｔ ion for rust and dust when leaving the parts disassembled. IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed.

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SERVICING 7. Pilot valve

6. HYDRAULIC SYSTEM

– Service mode / No-03 AUX start-up point setting – Service mode / No-05 HST start-up point setting – Service mode / No-12 AUX flow rate setting

7.2.1 Removing the reducing valve CAUTION • Handle the parts very carefully due to its precision, do not hit or drop them. • Hitting the parts too hard will result in performance degradation, oil leak, generating burrs, and breaking. • Pay extra atten ｔ ion for rust and dust when leaving the parts disassembled. 1. Remove the adjustment nut and disc nut. • Tools to use: 22 mm and 32 mm spanners (2) U-joint (a) U-joint tightening jig

(b) Jigs (2)

4. Remove the plate.

(1) Adjusting nut

2. Mark the positions of the casing and reducing valve assembly. NOTE • The position of each piston has to be always the same.

(3) Plate

3. Loosen the U-joint with the U-joint tightening jig slowly. NOTE • Loosen the valve assembly slowly, the plug and reducing valve assembly may fly out.

SVL97-2

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SERVICING 7. Pilot valve

6. HYDRAULIC SYSTEM 5. Remove the plug with slipping a flat tip screwdriver in the groove of the plug to.

NOTE • Do not shorten the spring 6 mm or more.

CAUTION • Make sure the plug will not fly out. • Take care not to damage it by offset load. • If a burr is formed, remove it with whetstone. • Tool: Flat tip screwdriver

2. Press the spring seat to remove the spool. • Make sure not to damage the spool.

(4) Plug

6. Attach an identification tag to the reducing valve assembly and spring, and then remove the assembly and spring. NOTE • The position has to be always the same. (1) Spring seat (2) Spring (3) Spring

(4) Washer (5) Spool

3. Remove the plug from the pushrod.

(6) Plug (7) Pushrod

(5) Spring

(8) O-ring

7.2.2 Disassembling the reducing valve 1. Press the spring seat and shorten the spring.

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SERVICING 7. Pilot valve 4. Remove the O-ring and seal from the plug. • Tool: Flat tip screwdriver

6. HYDRAULIC SYSTEM 1. Assemble the washer, spring and spring seat on the spool. NOTE • Do not contract the spring 6 mm or more.

(9) Seal

7.3 Assembling the pilot valve CAUTION • Prepare your work platform in the same way as for disassembly. • Follow the same general precautions as in the disassembly. • When assembling the parts, remove all bits of metal or foreign matter from all the parts and make sure there aren't any burrs or dings on the parts. • Replace used O-rings with new ones. • Make sure not to damage the O-rings when installing them. IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-03 AUX start-up point setting – Service mode / No-05 HST start-up point setting – Service mode / No-12 AUX flow rate setting

(1) Spool (2) Washer (3) Spring

(4) Spring seat

2. Install the O-ring on the plug.

(5) Plug

(6) O-ring

3. Assemble the seal on the plug. NOTE • Make sure that the seal faces the right direction. • Apply hydraulic oil on the outer circumference and lip of the seal.

7.3.1 Assembling the reducing valve CAUTION • Prepare your work platform in the same way as for disassembly. • Follow the same general precautions as in the disassembly. • When assembling the parts, remove all bits of metal or foreign matter from all the parts and make sure there aren't any burrs or dings on the parts. • Replace used O-rings with new ones. • Make sure not to damage the O-rings when installing them.

SVL97-2

(7) Plug (8) Pushrod (9) Seal

(10) O-ring

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SERVICING 7. Pilot valve

6. HYDRAULIC SYSTEM 4. Install the pushrod into the plug. NOTE • Apply hydraulic oil to the pushrod.

(11) Plug (12) Pushrod

(13) O-ring

NOTE • Install it in the same position as before disassembly.

4. Install the plate on the casing.

7.3.2 Assembling the pilot valve 1. Install on return spring. NOTE • Install it in the same position as before disassembly.

(2) Plate

5. Install the U-joint with the U-joint tightening jig.

(1) Spring

2. Install the reducing valve assembly. NOTE • Install it in the same position as before disassembly.

(a) U-joint tightening jig

U-joint

Tightening torque

44 to 50 N⋅m 4.5 to 5.1 kgf⋅m

3. Install the plug assembly.

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SERVICING 7. Pilot valve

6. HYDRAULIC SYSTEM

6. Adjust the disc nut so that it is contacting the four pushrods evenly.

CAUTION • If the disc is screwed in too far, it may push on the pushrod, causing the machine to malfunction.

(3) Disc nut

7. Install the adjusting nut. • Tools: 22 mm spanner (socket), 32 mm spanner

Adjusting nut

Tightening torque

63.7 to 73.5 N⋅m 6.5 to 7.5 kgf⋅m

8. Grease the U-joint and pushrod.

SVL97-2

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SERVICING 7. Pilot valve

6. HYDRAULIC SYSTEM

7.4 Pilot valve components

(1) Casing (2) Plate (3) Washer (4) O-ring (5) Bolt (6) Spring pin (7) Bushing (8) Spool (9) Spool (10) Spool

6-148

(11) Plug (12) Push rod (13) Seal (14) O-ring (15) Spring seat (16) Spring seat (17) Washer (18) Spring (19) Spring (20) Spring

(21) Spring (22) Spring (23) Seat (24) Seat (25) Ball (26) Plug (27) O-ring (28) Joint (29) Plate (30) Nut

(31) Lock nut (32) Lever (33) Handle (34) Spring pin (35) Bushing (36) Housing (37) Pin (38) Bellow

SVL97-2 KiSC issued 09, 2021 A

SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM

8. Lift arm cylinder 8.1 Disassembling/Installing the lift arm cylinder CAUTION • The machinery may suddenly move. Stop the engine and lower the working equipment to the ground when removing/disconnecting the hydraulic equipments/hoses. • There is a risk of burns. Cool down the hydraulic equipments and oil when working and checking. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Release residual pressure when taking hydraulic equipments off.

(1) (-) cable

(2) (+) cable

3. Remove two self-locking nuts, battery retainer, battery cover, and battery.

IMPORTANT • After repairing the hydraulic pressure (changing, adjusting, and evacuating devices, hoses, oil) always bleed air from the piston pump.

8.1.1 Removing the lift arm 1. Dismount the lift arm.

(3) Battery retainer (4) Battery cover (5) Battery

Self-locking nut (6)

(6) Self-locking nut

Tightening torque

4.0 to 5.0 N⋅m 0.41 to 0.51 kgf⋅m 3.0 to 3.7 lbf⋅ft

8.1.3 Removing the lift arm cylinder 1. Remove the bolt and hose clamp. 2. Remove the hydraulic hose from the lift arm cylinder, and plug the hydraulic hose and lift arm cylinder.

8.1.2 Removing the battery 1. Open the rear cover and bonnet.

(1) Hose (2) Bolt (M8 × 16)

(3) Hose clamp

2. Firstly remove the (-) cable, and the (+) cable next.

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SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM 3. Support the lift arm cylinder with a crane.

8.2 Disassembling the lift arm cylinder CAUTION • Choose a clean place to prevent contaminants when assembling/disassembling. • Use clean tools and new cleaning oil. IMPORTANT • After repairing the hydraulic pressure (changing, adjusting, and evacuating devices, hoses, oil) always bleed air from the piston pump.

(4) Lift arm cylinder

(5) Nylon sling

4. Remove the self-locking nut and bolt, and remove the pin.

8.2.1 Disassembling the cylinder rod for lift arm cylinder

NOTE • During assembly, maintain a clearance of 1 to 3 mm (0.04 to 0.1 in.) between the selflocking nut and boss.

1. Drain the oil inside the cylinder, and fasten the bottom of the cylinder in a vice.

(1) Tube (a) Cylinder holder (6) Self-locking nut (M10) (7) Bolt

(b) Block

2. Take off the stopper with punch and hammer. • Tools: Punch and hammer

(8) Pin

5. Remove the lift arm.

(2) Cylinder head (9) Lift arm cylinder

Arm cylinder weight

6-150

SVL95-2s SVL97-2

36.3 kg 80 lbs

SVL97-2 KiSC issued 09, 2021 A

SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM

3. Loosen the cylinder head. • Tool: Cylinder head wrench

IMPORTANT • If the set bolt is being squeezed, shave with a hand drill, etc., and then loosen the set bolt. • After removing, use a hand tap (M8 × 1.25) to carry off the piston side. • Tool: 3 mm hex wrench

(3) Cylinder head

4. Remove the cylinder head and piston rod. IMPORTANT • If the piping is plugged, remove the plug. • Place an oil pan on the cylinder head side, and carry out the work.

(7) Set screw

7. Remove the piston. • Tool: 46 mm socket wrench

(4) Piston rod

(5) Cylinder head

5. Secure the piston rod in the vice. IMPORTANT • Place a cushion underneath so that the piston rod does not become scratched.

(8) Piston

8. Remove the ball and piston.

(9) Piston (6) Piston rod (c) Cylinder holder

(10) Ball

(d) Block

6. Remove the set screw.

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SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM 9. Remove stopper ring. IMPORTANT • Make sure not to damage the cushion bearing.

(17) Cylinder head

13. Remove the slide ring by hand, split the seal ring assembly by tapping it with a flat tip screwdriver, and remove the O-ring. (11) Stopper ring

(12) Cushion bearing

10. Remove the stopper with sliding the cushion bearing.

(13) Cushion bearing

NOTE • Set a cushion plate on the vice so that the piston does not become scratched. • Tools: Flat tip screwdriver and hammer

(14) Stopper

11. Remove the cushion bearing and cushion seal.

(18) Seal ring assembly

(e) Cushion plate

8.2.2 Disassembling the cylinder head for lift arm cylinder 1. Remove two O-rings and backup ring. • Tool: Flat tip screwdriver

(15) Cushion bearing

(16) Cushion seal

12. Remove the cylinder head.

(1) Cylinder head (2) O-ring (3) Backup ring

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(4) O-ring

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SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM

2. Lift the U-ring with a flat tip screwdriver, and remove it from the cylinder head. • Tool: Flat tip screwdriver

• Install back up ring and O-ring with grease or hydraulic oil. • Ensure that the seal, O-ring, and packing are not twisted or scratched during assembly. • Make sure inserting the backup ring to right position. • After assembly, plug in to each port and clean the exterior as an assembly. IMPORTANT • After repairing the hydraulic pressure (changing, adjusting, and evacuating, hoses, oil) always bleed air from the piston pump.

(5) U-ring

3. Remove the wiper ring with hammering it with flat tip screwdriver. • Tools: Flat tip screwdriver and hammer

8.3.1 Assembling the cylinder head for lift arm cylinder 1. Install the bushing by press-fitting it with a press machine. NOTE • Apply hydraulic oil inside the cylinder head. • After press fitting, check that there is no scratching of the bushing. • Jig: Bushing press-fit jig

(6) Wiper ring

4. Place the jig against the bushing and use a press to remove. • Jig to use: Bushing punching jig

(1) Cylinder head (2) Bushing (H) Bushing press-fit jig

(I)

Handle

2. Fit the U-ring insertion inner jig on the cylinder head. • Jig: U ring insertion inner jig

(7) Bushing (I) Handle

(G) Bushing punching jig

8.3 Assembling the lift arm cylinder CAUTION • Replace the seal, O-ring and packing with new parts. Not reused. • Clean each part. The seal and O-ring groove must be sufficiently clean.

SVL97-2

(3) Cylinder head

(D) U ring insertion inner jig

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SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM 3. Install the U-ring on the cylinder head, and use the U-ring assembly jig to insert the U-ring into the mounting groove.

IMPORTANT • Apply hydraulic oil to the 2 O-rings and backup ring.

IMPORTANT • Apply hydraulic oil to the outer circumference of the U-ring. • The U-ring should be softened by immersing it in hot water (at about 90 ℃) for 5 to 10 minutes.

(8) Cylinder head (9) O-ring (10) Backup ring

(11) O-ring

8.3.2 Assembling the cylinder rod for lift arm cylinder 1. Tap set bolt screw holes (M8 × 1.25) for the piston. 2. Install the O-ring for the seal ring assembly. IMPORTANT • Apply hydraulic oil to the O-ring.

(4) Cylinder head (5) Bushing (6) U-ring

(D) U ring insertion inner jig (E) U-ring insertion jig

4. Install the wiper ring by press-fitting it with a press machine. IMPORTANT • Apply hydraulic oil to the circumference of the wiper ring.

(7) Wiper ring (F) Wiper ring press-fit jig

(I)

outer

Handle

(1) O-ring

(2) Piston

3. Fit the seal ring insertion jig on the piston.

(3) Piston

(B) Seal ring insertion inner jig

5. Install two O-rings and backup ring on the cylinder head.

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SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM

4. Use the seal ring insertion jig to install the seal ring assembly.

(6) Piston rod (7) Cylinder head (a) Cylinder holder (4) Seal ring assembly (B) Seal ring insertion inner jig

5. Use the Piston Ring correction jig to correct the seal ring assembly.

(b) Block

8. Install the cushion seal with the slitted surface facing the screw side.

(8) Cushion seal (A) Piston Ring correction jig

6. Install the slide ring.

9. Install the cushion bearing, with paying attention to the machined flat part. NOTE • Make sure that the cushion bearing is assembled in the right direction.

(5) Slide ring

7. Secure the piston rod in a vice, and install the cylinder head.

(9) Cushion bearing

IMPORTANT • Apply hydraulic oil to the wiper ring and Uring. • Place a cushion underneath so that the piston rod does not become scratched.

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SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM 10. Install the stopper.

(16) Piston (10) Stopper

11. Slide the cushion bearing to the stopper side, and install the stopper ring. IMPORTANT • The piston rod and cushion bearing must not be in contact with the stepped surface.

Piston (16)

1076 N⋅m 109.7 kgf⋅m 793.6 lbf⋅ft

13. Insert the ball into the screw hole, and tighten the set bolt. • Tool : 3 mm hex wrench

(17) Ball

Set bolt (18)

(11) Stopper ring (12) Cushion bearing (13) Piston rod

Tightening torque

(18) Set bolt

Tightening torque

16.2 N⋅m 1.65 kgf⋅m 11.9 lbf⋅ft

(14) Cushion seal (15) Stopper

12. Tighten the piston. • Tools : Torque wrench, 46 mm socket wrench

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SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM

14. Punch 2 holes in the outer circumference of the set bolt to prevent the bolt from getting loose.

(24) Cylinder head

Cylinder head (24)

(e) Block

Tightening torque

451 N⋅m 46.0 kgf⋅m 333 lbf⋅ft

17. Punch one hole into the cylinder head as a stopper. • Tool : Pin punch and hammer

(19) Ball (20) Set screw (a) Punch

(b) Crimp

15. Secure the cylinder tube in a vice, and install the piston rod. IMPORTANT • Apply hydraulic oil to the cylinder head and piston. • Set cushion plat so that the cylinder tube will not be scratched.

(25) Cylinder head

8.4 Servicing standards for hydraulic cylinder 8.4.1 Measuring the bend for cylinder rod 1. Put the cylinder rod on the V block. 2. Set the dial gauge in the center of the cylinder rod.

(21) Piston rod (22) Cylinder head (23) Tube

16. Install the cylinder head. • Tool : Cylinder head wrench

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SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM 3. Rotate the cylinder rod slowly and read the dial gauge. NOTE • Half of the measurement value is the bend, and replace any rod that exceeds its usage limit.

8.4.3 Measuring the wear for the cylinder tube and piston wear ring 1. Measure the internal diameter of the cylinder tube and the outside diameter of the piston wear ring, and calculate the clearance. NOTE • Replace any rod that exceeds its usage limit.

Bend Factory spec

0.05 mm or less

Allowable limits

0.5 mm Factory spec

8.4.2 Measuring the wear for cylinder rod and cylinder head 1. Measure the outside diameter of cylinder rod and internal diameter of the cylinder head, and calculate the gap.

Allowable limits

Rod size

Gap

ϕ60 mm or less

0.05 to 0.30 mm

ϕ65 to 115 mm

0.05 to 0.35 mm

ϕ120 mm or more

0.05 to 0.40 mm

ϕ60 mm or less

0.60 mm

ϕ65 to 115 mm

0.70 mm

ϕ120 mm or more

0.80 mm

NOTE • Replace any rod that exceeds its usage limit.

Factory spec

Allowable limits

6-158

Rod diameter

Gap

ϕ25 to 40 mm

0.25 mm or less

ϕ45 to 75 mm

0.30 mm or less

ϕ25 to 40 mm

0.4 mm

ϕ45 to 75 mm

0.5 mm

SVL97-2 KiSC issued 09, 2021 A

SERVICING 8. Lift arm cylinder

6. HYDRAULIC SYSTEM

8.5 Lift arm cylinder components

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

Bushing Piston rod Wiper ring Cylinder head Bushing

SVL97-2

(6) O-ring (7) Backup ring (8) O-ring (9) U-ring (10) Slide ring

(11) Seal ring assembly (12) Piston (13) Ball (14) Set screw (15) Stopper ring

(16) Cushion bearing (17) Cushion seal (18) Stopper (19) Bushing (20) Tube

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SERVICING 9. Bucket cylinder

6. HYDRAULIC SYSTEM

9. Bucket cylinder 9.1 Removing/Installing the bucket cylinder CAUTION • The machinery may suddenly move. Stop the engine and lower the working equipment to the ground when removing/disconnecting the hydraulic equipments/hoses. • There is a risk of burns. Cool down the hydraulic equipments and oil when working and checking. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Release residual pressure when taking hydraulic equipments off.

(5) Bucket cylinder (6) Self-locking nut (M10) (7) Bolt (M10 × 90)

(8) Pin

4. Remove the pin with hammering it with a hammer and rod. • Tools: Hammer and rod

IMPORTANT • After repairing the hydraulic pressure (changing, adjusting, and evacuating devices, hoses, oil) always bleed air from the piston pump.

9.1.1 Removing the bucket cylinder 1. Set the quick hitch to the dump end. (a) Hammer

(b) Rod

5. Set the bucket cylinder to its maximum contraction length. 6. Remove the hydraulic hose from the bucket cylinder, and plug the hydraulic hose and bucket cylinder. NOTE • Place an oil pan under the bucket cylinder.

(1) Lift arm

(2) Quick hitch

2. Remove two bolts, and the cover.

(9) Hose

(3) Bolt (M10 × 20) × 2

(4) Cover

3. Remove the self-locking nut from the bucket cylinder, and the bolt.

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SERVICING 9. Bucket cylinder

6. HYDRAULIC SYSTEM

7. Remove the self-locking nut from the bucket cylinder, and the bolt.

(10) Self-locking nut (M10)

(11) Bolt (M10 × 95)

8. Remove the bucket cylinder with the pin.

(12) Bucket cylinder Bucket cylinder weight

SVL97-2

(13) Pin SVL95-2s SVL97-2

24 kg 52.9 lbs

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SERVICING 9. Bucket cylinder

6. HYDRAULIC SYSTEM

9.2 Bucket cylinder components

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

Bushing Piston rod Wiper ring Cylinder head

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

Bushing O-ring Backup ring O-ring

Set screw (14)

6-162

(13) Ball (14) Set screw (15) Bushing (16) Tube

569 N⋅m 58.1 kgf⋅m 420 lbf⋅ft

Cylinder head (4)

Piston (12)

(9) U-ring (10) Slide ring (11) Seal ring assembly (12) Piston

Tightening torque

975 N⋅m 99.4 kgf⋅m 719 lbf⋅ft 16.2 N⋅m 1.7 kgf⋅m 12 lbf⋅ft

SVL97-2 KiSC issued 09, 2021 A

SERVICING 10. Hydraulic quick hitch cylinder

6. HYDRAULIC SYSTEM

10. Hydraulic quick hitch cylinder 10.1 Removing/Installing the hydraulic quick hitch cylinder CAUTION • The machinery may suddenly move. Stop the engine and lower the working equipment to the ground when removing/disconnecting the hydraulic equipments/hoses. • There is a risk of burns. Cool down the hydraulic equipments and oil when working and checking. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Release residual pressure when taking hydraulic equipments off.

(4) Bolt (M12 × 25) × 2

10.2 Hydraulic quick hitch cylinder components

IMPORTANT • After repairing the hydraulic pressure (changing, adjusting, and evacuating devices, hoses, oil) always bleed air from the piston pump.

10.1.1 Removing the quick hitch cylinder 1. Set the quick hitch cylinder to the contraction stroke end. 2. Set the bucket cylinder to the dump position, and put the quick hitch on a block. 3. Disconnect the hydraulic hose for the quick hitch cylinder, and plug the hydraulic hose and cylinder.

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

Tube (Quick hitch) Center lock nut Bushing Piston Piston tool End

Piston (4)

(1) Quick hitch cylinder (2) Quick hitch (3) Hydraulic hoses

(7) O-ring (8) Packing (9) Retaining ring (10) Scraper (11) Rod

Tightening torque

177 to 215 N⋅m 18.0 to 21.9 kgf⋅m 131 to 159 lbf⋅ft

(a) Block

4. Remove two bolts, and the quick hitch cylinder.

SVL97-2

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SERVICING 11. Unload valve

6. HYDRAULIC SYSTEM

11. Unload valve 11.1 Removing/Installing the unload valve 11.1.1 Installing the vacuum pump 1. Plug the breather hose, and attach the vacuum pump.

(8) Hose (Quick connector, tank) (10) Hose (Tank) (9) Hose (High-flow valve, drain)

2. Remove two bolts.

11.1.2 Cabin lock 1. Tilt-up the cabin, and lock it. (11) Clamp

Bolt (12)

(12) Bolt (M8 × 20) ×2

Tightening torque

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

3. Remove the connector.

11.1.3 Removing the unload valve 1. Disconnect the hydraulic hoses of the unload valve, and plug the adapters and hydraulic hoses.

(13) Clamp

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

Hose (travel, L) Hose (travel, L brake) Hose (High-flow valve, PP) Hose (Control valve, PP) Hose (travel, R brake)

6-164

(14) Connector

(6) Hose (travel, R) (7) Hose (engine stall- Solenoid Valve)

SVL97-2 KiSC issued 09, 2021 A

SERVICING 11. Unload valve

6. HYDRAULIC SYSTEM

4. Remove three bolts. Bolt (15) Tightening torque Bolt (19)

(15) Bolt (M10 × 30) ×2

Bolt (15) (16)

48.1 to 55.9 N⋅m 4.9 to 5.7 kgf⋅m 35.5 to 41.2 lbf⋅ft 39.2 to 45.1 N⋅m 4.0 to 4.6 kgf⋅m 28.9 to 33.3 lbf⋅ft

(16) Bolt (M10 × 70)

Tightening torque

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

5. Remove the unload valve, and four connectors.

(17) Connector

(18) Wire harness

6. Remove four bolts and the bracket.

(15) Bolt (M10 × 30) ×2

SVL97-2

(19) Bolt (M10 × 20) ×2

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SERVICING 11. Unload valve

6. HYDRAULIC SYSTEM

11.2 Installing adapter layout for unload valve

Adapter

Port

Size

Angle

T, G1/4 (1)

L, G1/4, G1/4

L, G1/4, G1/4 T, G1/4 (2)

L, G2, G2

L, G2, G2 (3)

L, G2, G2

(4)

G3-G2

5°

T, 3-3-3

L, G3/8, G3/8

45°

L, G3/8, G3/8

25°

(5)

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SERVICING 12. Solenoid valve (Anti-stall, AUX)

6. HYDRAULIC SYSTEM

12. Solenoid valve (Anti-stall, AUX) 12.1 Disassembly/Assembly of solenoid valves (Anti-stall, AUX) IMPORTANT • When performing measurement, adjustment, or repairs, set-up the meter panel as needed. – Service mode / No-05 HST start-up point setting

12.1.1 Installing the vacuum pump 1. Plug the breather hose, and attach the vacuum pump.

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

Hose (HST, filter) Hose (Tank) Hose (Relay P/V, tank) Hose (Proportional, A2)

(5) Hose (Proportional, A1) (6) Hose (Relay L, P) (7) Hose (Switching valve, P)

2. Remove three connectors.

12.1.2 Cabin lock 1. Tilt-up the cabin, and lock it.

(8) Connector

3. Remove bolts and the stay from the body.

12.1.3 Removal of solenoid valve (Antistall, AUX) 1. Disconnect the hydraulic hoses of the proportional valve, and plug the adapters and hydraulic hoses. (9) Bolt (M10 × 20) × 2

SVL97-2

(10) Stay

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KiSC issued 09, 2021 A

SERVICING 12. Solenoid valve (Anti-stall, AUX)

6. HYDRAULIC SYSTEM 4. Remove two bolts proportional valve.

and

the

stay

from

the

13. Solenoid valve (Hydraulic pressure quick hitch) 13.1 Installing adapter layout for solenoid valve (Hydraulic quick hitch)

(13) Proportional valve

(11) Bolt (M8 × 20) × 2 (12) Stay

12.2 Installing adapter layout for solenoid valve (Anti-stall, AUX)

Adapter

Port

Size

Angle

(1)

L, PF 1/4-B, PF 3/8-B

40°

(2)

L, PF 1/4-B, PF 3/8-B

40°

(3)

G2-G3

(4)

S, G2, G2

G2-G3

14. Hydraulic oil tank 14.1 Removing/Installing the hydraulic oil tank

Adapter

Port

Size

Angle

(1)

L, G2, G2

45°

(2)

L, G2, G2

45°

(3)

L, PF 1/4-B, PF 3/8-B

45°

(4)

L, PF 1/4-B, PF 3/8-B

(5)

L, G2-G2, 45

15°

(6)

L, G2, G2

6-168

IMPORTANT the hydraulic pressure • After repairing (changing, adjusting, and evacuating devices, hoses, oil) always bleed air from the piston pump.

14.1.1 Draining the hydraulic oil 1. Lower the lift arm to the down end.

SVL97-2 KiSC issued 09, 2021 A

SERVICING 14. Hydraulic oil tank

6. HYDRAULIC SYSTEM

2. Set the quick hitch to the dump end.

(1) Lift arm

(2) Quick hitch

3. Remove two bolts. 4. Remove the front bottom cover.

(6) Drain hose (7) Clamp

(8) Plug

14.1.2 Cabin lock 1. Tilt-up the cabin, and lock it.

(3) Cover

(4) Bolt (M8 × 20) × 2

5. Loosen the hydraulic oil tank cap.

14.1.3 Removing the step 1. Remove the mat.

(5) Plug

Plug (5)

Tightening torque

20.0 to 25.0 N⋅m 2.0 to 2.6 kgf⋅m 14.5 to 18.8 lbf⋅ft

(1) Mat

6. Remove the drain hose clamp and plug, and drain the hydraulic oil.

SVL97-2

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SERVICING 14. Hydraulic oil tank

6. HYDRAULIC SYSTEM 2. Remove three bolts.

(7) Bolt (M10 × 20) × 7 (8) Bolt (M10 × 20) × 3

(2) Bolt (M10 × 20) × 3

3. Remove the accelerator potentiometer connector and the accelerator pedal assembly.

6. Remove two bolts and the plate.

(10) Bolt (M10 × 25) × 2 (3) Accelerator potentiometer connector

(4) Accelerator pedal assembly

(9) Step

(11) Plate

7. Remove three bolts and the step.

4. Remove three bolts and the step.

(12) Bolt (M10 × 20) × 3

(5) Bolt (M10 × 20) × 3

(13) Step

(6) Step

5. Remove ten bolts and the plate.

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 14. Hydraulic oil tank

6. HYDRAULIC SYSTEM

8. Remove two bolts and the bracket.

(14) Bolt (M10 × 20) × 2

(15) Bracket

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

Suction hose Suction hose Hose (LS regulator) Hose (Drain)

(5) Hose (Breather) (6) Hose

14.1.4 Removing the LS pump 1. Remove the LS Pump.

(1) LS pump

(7) Hose (PV) (8) Hose (PV) (9) Hose (Unload valve) (10) Hose (Piston pump) (11) Hose

(12) Hose (13) Hose (Control valve) (14) Hose (Electromagnetic proportional valve)

14.1.5 Removing the hydraulic oil tank 1. Disconnect all of the hydraulic hoses of the hydraulic oil tank, and plug the adapters and hydraulic hoses.

SVL97-2

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SERVICING 14. Hydraulic oil tank

6. HYDRAULIC SYSTEM 2. Remove four mounting bolts of the connector and hydraulic oil tank, and the hydraulic oil tank.

(15) Connector

(16) Bolt (M10 × 25) × 4

Hydraulic tank weight

6-172

22.8 kg 49.6 lbs

SVL97-2 KiSC issued 09, 2021 A

SERVICING 14. Hydraulic oil tank

6. HYDRAULIC SYSTEM

14.2 Hydraulic oil tank components

(a) (b) (1) (2) (3) (4) (5)

47.5 mm (1.87 in.) 87 mm (3.4 in.) Hydraulic oil tank Bolt Cover O-ring Bolt

(6) Suction filter (7) Return filter (8) Plate (9) Bolt (10) Oil tank gauge (11) Hydraulic oil temperature sensor

(12) Gasket (13) Pipe (14) Bolt (15) Plug (16) O-ring (17) Oil supply hose (18) Hose band

Suction filter (6)

30.0 to 50.0 N⋅m 3.1 to 5.1 kgf⋅m 22.1 to 36.9 lbf⋅ft

Return filter (7)

50.0 to 70.0 N⋅m 5.1 to 7.1 kgf⋅m 36.9 to 51.6 lbf⋅ft

Hydraulic oil temperature sensor (11)

Tightening torque

16.6 to 22.6 N⋅m 1.7 to 2.3 kgf⋅m 12.2 to 16.7 lbf⋅ft

Plug (15)

20.0 to 25.0 N⋅m 2.0 to 2.6 kgf⋅m 14.8 to 18.4 lbf⋅ft

Bolt (20)

8.0 to 10.0 N⋅m 0.8 to 1.0 kgf⋅m 5.9 to 7.4 lbf⋅ft

SVL97-2

(19) Hose band (20) Bolt (21) Hose clamp (22) Hose (23) Hose (24) Hose clamp

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6. HYDRAULIC SYSTEM

(25) Hose clamp (26) Hex socket bolt (27) Spring washer (28) Cover (29) Headed pin (30) Elbow pipe joint (31) Relief valve (32) Pipe joint (33) Drain valve (34) Hose clamp

(35) Breather tube (36) Breather hose (37) Breather (38) Body (Port P) (39) Spool (40) Spring (41) O-ring (42) Body (Port P) (43) Shim (44) O-ring

Flange bolt (49)

6-174

(55) Spring washer (56) Shaft (57) O-ring (58) Spring (59) Lever (60) Stay (61) Body (62) Pipe joint

2.45 to 3.43 N⋅m 0.25 to 0.35 kgf⋅m 1.81 to 2.53 lbf⋅ft

Hex socket bolt (26)

Relief valve (31)

(45) Base (46) Filter (47) Washer (48) Washer with rubber (49) Flange bolt (50) Spring (51) Ball (52) Spring pin (53) O-ring (54) Hex socket bolt

Tightening torque

58.8 to 63.7 N⋅m 6.0 to 6.5 kgf⋅m 43.4 to 47.0 lbf⋅ft 23.5 to 27.5 N⋅m 2.4 to 5.7 kgf⋅m 17.4 to 41.2 lbf⋅ft

SVL97-2 KiSC issued 09, 2021 A

SERVICING 14. Hydraulic oil tank

6. HYDRAULIC SYSTEM

14.3 Installing adapter layout for hydraulic oil tank

Hydraulic quick hitch

Mechanical hitch

Adapter

SVL97-2

Size

Angle

(1)

L, G2 - G2, 45

(2)

L, G3 - G3, 45

(3)

L, G1/2 - G1/2

30°

(4)

S, G1/2 - G1/2

(5)

G3/8

(6)

S, G6, G6

(7)

S, G1, G2

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

15. Hydraulic hoses

(a) Total length

15.1 Total length for hydraulic hoses The notation for total length of each type of hydraulic hose

15.2 Hydraulic hose fittings Types of metal fittings for each hoses

(a) Straight type Parallel pipe female screw (Male 30° seat)

6-176

(b) 45° type (c) 90° type (d) Quick connector Parallel pipe female screw 45° Parallel pipe female screw 90° (Male 30° seat) (Male 30° seat)

SVL97-2 KiSC issued 09, 2021 A

SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

15.3 Hose route 15.3.1 Piston pump

(a) Piston pump (b) Control valve

SVL97-2

(e) Regulator (f) HST filter

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

No.

Point used

(1)

Hose

Fitting

Total length

Size

Tape color

Max. pressure

Left

Right

Piston pump P C/V (P)

540 mm 21.3 in.

3/4

Nothing - Red 1

250 kgf 3555 psi

G3/4, Straight

(2)

Regulator Low HST filter

980 mm 38.6 in.

1/2

Nothing - Pink 1/Brown 2

143 kgf 2033 psi

G1/2, Straight

(3)

Piston pump Dr - Hydraulic oil tank

325 mm 12.8 in.

1/2

Nothing - Blue 1/Pink 1

35 kgf 498 psi

G1/2, Straight

(4)

C/V (PLs) - Piston pump (PL)

910 mm 35.8 in.

1/4

Nothing - Pink 1/Red 1

250 kgf 3555 psi

G1/4, Straight

(5)

Gear pump P Regulator High

510 mm 20.0 in.

1/2

N/A

143 kgf 2033 psi

G1/2, Straight

(58)

Regulator Low GP relief valve

500 mm 19.7 in.

1/2

Nothing - Pink 1/Blue 2

70 kgf 995 psi

G1/2, Straight

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

15.3.2 HST pump, HST filter

(a) HST pump (b) Travel motor L (c) Travel Motor R

SVL97-2

(d) HST filter (e) Relay (Left) (f) Relay (Right)

(g) Control valve A: Mechanical hitch model B: Hydraulic hitch model

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

No.

Point used

(6)

Hose

Fitting

Total length

Size

Tape color

Max. pressure

Left

Right

C/V (Pp) - HST filter

850 mm 34.6 in.

1/4

Red 1/Brown 1 Nothing

70 kgf 995 psi

G1/4, Straight

(7)

HST (Filter) Proportional valve (P)

280 mm 11.0 in.

3/8

Nothing - Red 1/ Yellow 1

70 kgf 995 psi

G3/8, Straight

(20)

HST pump (right rear) to relay (Left PV1)

860 mm 33.6 in.

3/8

Nothing - Green 1

70 kgf 995 psi

G3/8, 90°

G3/8, Straight

(21)

HST pump (left front) to relay (Left PV2)

935 mm 36.8 in.

3/8

Nothing - Yellow 1

70 kgf 995 psi

G3/8, 90°

G3/8, Straight

(22)

HST pump (left rear) to relay (Left PV3)

1200 mm 47.2 in.

3/8

Nothing - Blue 1

70 kgf 995 psi

G3/8, Quick

G3/8, Straight

(23)

HST pump (right front) to relay (Left PV4)

1185 mm 46.7 in.

3/8

Nothing - Pink 1

70 kgf 995 psi

G3/8, Straight

(29)

HST pump (Dr) to pipe (return)

685 mm 27.0 in.

5/8

Aqua 1 - Nothing

35 kgf 498 psi

G1/2, Straight

(57)

HST (charge pressure) - HST filter check

990 mm 39.0 in.

3/8

Nothing - Brown 1

70 kgf 995 psi

G3/8, 90°

G3/8, Straight

(62)

HST pump (A) to travel M left (front)

605 mm 23.8 in.

3/4

Aqua 2 - Nothing

350 kgf 4977 psi

G1"3/16, Straight

(63)

HST pump (B) to travel M left (rear)

595 mm 23.4 in.

3/4

Aqua 1 - Nothing

350 kgf 4977 psi

G1"3/16, Straight

(64)

HST pump (C) to travel M right (front)

580 mm 22.8 in.

3/4

Orange 2 Nothing

350 kgf 4977 psi

G1"3/16, Straight

(65)

HST pump (D) to travel M right (rear)

645 mm 25.4 in.

3/4

Orange 1 Nothing

350 kgf 4977 psi

G1"3/16, Straight

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

15.3.3 Control valve

(a) Control valve (b) Proportional valve

SVL97-2

C/V - Relay (Right)

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

(a) Control valve (d) Lift arm

6-182

(e) Lift arm cylinder (f) Hydraulic oil tank

C: D:

C/V - Lift arm C/V - Tank

SVL97-2 KiSC issued 09, 2021 A

SERVICING 15. Hydraulic hoses

No.

Point used

(12)

6. HYDRAULIC SYSTEM Hose

Fitting

Total length

Size

Tape color

Max. pressure

Left

Right

C/V (Pb2) - Relay (Right PV1)

850 mm 33.5 in.

1/4

Nothing - Pink 1

70 kgf 995 psi

G1/4, Straight

(13)

C/V (Pa1) - Relay (Right PV2)

860 mm 33.9 in.

1/4

Nothing - Green 1

70 kgf 995 psi

G1/4, Straight

(14)

C/V (Pa2) - Relay (Right PV3)

790 mm 31.1 in.

1/4

Nothing - Yellow 1

70 kgf 995 psi

G1/4, 90°

G1/4, Straight

(15)

C/V (Pb1) - Relay (Right PV4)

1155 mm 45.5 in.

1/4

Nothing - Blue 1

70 kgf 995 psi

G1/4, Straight

(17)

C/V (Pb3) - Proportional valve (A1)

480 mm 18.9 in.

1/4

Red 1 - Nothing

70 kgf 995 psi

G1/4, Straight

(18)

C/V (Pa3) - Proportional valve (A2)

310 mm 12.2 in.

1/4

Red 1/Yellow 1 Nothing

70 kgf 995 psi

G1/4, Straight

(47)

C/V (B1) - Arm cyl (L) bottom

1770 mm 69.7 in.

1/2

Red 1/Aqua 2 Nothing

250 kgf 3555 psi

G1/2, Straight

G1/2, 90°

(48)

C/V (B1) - Arm cyl (R) bottom

1210 mm 47.63 in.

1/2

Red 1/Orange 2 - Nothing

250 kgf 3555 psi

G1/2, Straight

G1/2, 90°

(49)

C/V (A1) - Arm cyl (L) bottom

2470 mm 97.2 in.

1/2

Red 1/Aqua 1 Aqua 1

250 kgf 3555 psi

G1/2, Straight

(50)

C/V (A1) - Arm cyl (R) bottom

2040 mm 80.32 in.

1/2

Red 1/Orange 1 - Orange 1

250 kgf 3555 psi

G1/2, Straight

(51)

C/V (A2) - Piping (Bucket cyl bottom)

3305 mm 130.1 in.

1/2

Red 1 - Nothing

250 kgf 3555 psi

G1/2, Straight

(52)

C/V (B2) - Piping (Bucket cyl rod)

3485 mm 137.2 in.

1/2

Red 1/Orange 1 - Orange 1

250 kgf 3555 psi

G1/2, Straight

(53)

Valve, assembly (drain) - C/V (B1)

650 mm 25.6 in.

1/4

Nothing - Red 1

250 kgf 3555 psi

G1/4, 90°

G1/4, Straight

(54)

C/V (T) - Hydraulic oil tank

720 mm 28.3 in.

3/4

N/A

35 kgf 498 psi

G3/4, Straight

(60)

C/V (A3) - SP piping (M)

3190 mm 125.6 in.

3/4

Red 1 - Nothing

280 kgf 3982 psi

G3/4, Straight

(61)

C/V (B3) - SP piping (F)

3280 mm 129.1 in.

3/4

Nothing - Red 1

280 kgf 3982 psi

G3/4, Straight

SVL97-2

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

15.3.4 Bucket cylinder

(a) Bucket cylinder (Left)

No.

Point used

(55)

(56)

6-184

(b) Bucket cylinder (Right) Hose

Fitting

Total length

Size

Tape color

Max. pressure

Left

Right

Bucket piping Bucket cyl rod

575 mm 22.6 in.

3/8

N/A

250 kgf 3555 psi

G3/8, Straight

Bucket piping Bucket cyl bottom

500 mm 19.7 in.

1/2

N/A

250 kgf 3555 psi

G1/2, 90°

G1/2, Straight

SVL97-2 KiSC issued 09, 2021 A

SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

15.3.5 Unload valve

(a) Unload valve (b) Hydraulic oil tank

SVL97-2

(e) Relay (Right) (f) Proportional valve

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

No.

Point used

(9)

Hose

Fitting

Total length

Size

Tape color

Max. pressure

Left

Right

Switching valve (T) - Hydraulic oil tank

1520 mm 59.8 in.

3/8

Green 1 - Nothing

70 kgf 995 psi

G3/8, Straight

(10)

SP return piping - Switching T

3185 mm 125.4 in.

3/8

N/A

70 kgf 995 psi

G3/8, Straight

(11)

Switching valve (A3) - Relay (Right PVP)

990 mm 39.0 in.

1/4

Nothing - Gray 1

70 kgf 995 psi

G1/4, Straight

(25)

Switching valve (A2) - Travel M (L) brake

580 mm 22.8 in.

1/4

Green 1/Aqua 1 - Nothing

70 kgf 995 psi

G1/4, Straight

G1/4, 90°

(26)

Switching valve (A2) - Travel M (R) brake

1460 mm 57.5 in.

1/4

Green 1/Orange 1 - Nothing

70 kgf 995 psi

G1/4, Straight

G1/4, 90°

(27)

Switching valve (A1) - Travel speed shift M (L)

665 mm 26.2 in.

1/4

Green 1/Aqua 2 - Nothing

70 kgf 995 psi

G1/4, Straight

G1/4, 90°

(28)

Switching valve (A1) - Travel speed shift M (R)

1390 mm 54.7 in.

1/4

Green 1/Orange 2 - Nothing

70 kgf 995 psi

G1/4, Straight

G1/4, 90°

(59)

Proportional valve (P2) Switching valve (P)

1280 mm 50.4 in.

1/4

Nothing - Green 2

70 kgf 995 psi

G1/4, Straight

G1/4, 90°

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

15.3.6 AUX solenoid valve

(a) AUX Solenoid Valve (b) Hydraulic oil tank (c) Control valve

SVL97-2

(d) Unload valve (e) Relay (Left) (f) Pipe

(g) Travel motor (Left) (h) Travel motor (Right) (i) Oil cooler (Radiator)

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6. HYDRAULIC SYSTEM

No.

Point used

(8)

Hose

Fitting

Total length

Size

Tape color

Max. pressure

Left

Right

Hydraulic oil tank - Proportional valve (T)

710 mm 28.0 in.

1/4

Blue 1 - Nothing

70 kgf 995 psi

G1/4, Straight

(19)

Proportional valve (A3) - Relay (Left PVP)

780 mm 30.7 in.

3/8

Nothing - Gray 1

70 kgf 995 psi

G3/8, Straight

(42)

Pipe (Return) Travel M (L) drain

1680 mm 66.1 in.

5/8

Aqua 1 - Nothing

35 kgf 498 psi

G1/2, Straight

G1/2, 90°

(43)

Travel M (R) drain - Valve (Return)

450 mm 17.7 in.

5/8

Nothing - Pink 1

35 kgf 498 psi

G1/2, 90°

G1/2, Straight

(44)

Pipe (Return) check - Hydraulic oil tank

675 mm 26.6 in.

5/8

Nothing - Blue 1

35 kgf 498 psi

G1/2, Straight

(45)

O/C (Lower) Hydraulic oil tank

1550 mm 61.0 in.

3/4

N/A

35 kgf 498 psi

G3/4, Straight

(46)

O/C (Upper) Pipe (Return)

1150 mm 45.3 in.

3/4

N/A

35 kgf 498 psi

G3/4, Straight

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

15.3.7 Relay, pilot valve

(a) Relay (right) (b) Relay (left)

(e) Hydraulic oil tank (f) Guide bar

IMPORTANT • Align the left pilot houses position in the guide bar to have enough clearance between the hoses and the socket. • Lay the hose (38) and hose (40) side by side as shown in B-B.

SVL97-2

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6. HYDRAULIC SYSTEM

No.

Point used

Hose

Fitting

Total length

Size

Tape color

Max. pressure

Left

Right

(16)

Hydraulic oil tank - Relay (Right PVT)

1350 mm 53.1 in.

1/4

Nothing - Red 1

70 kgf 995 psi

G1/4, Straight

(24)

Hydraulic oil tank - Relay (Left PVT)

1520 mm 59.8 in.

3/8

Nothing - Red 1

70 kgf 995 psi

G3/8, Straight

(30)

Relay (Right PVP) - Right PVP

1630 mm 64.2 in.

1/4

Gray 1 - Gray 1

70 kgf 995 psi

G1/4, Quick

(31)

Relay (Right PV1) - Right PV1

1620 mm 63.8 in.

1/4

Pink 1 - Pink 1

70 kgf 995 psi

G1/4, Quick

(32)

Relay (Right PV2) - Right PV2

1550 mm 61.0 in.

1/4

Green 1 - Green 1

70 kgf 995 psi

G1/4, Quick

(33)

Relay (Right PV3) - Right PV3

1580 mm 62.2 in.

1/4

Yellow 1 - Yellow 1

70 kgf 995 psi

G1/4, Quick

(34)

Relay (Right PV4) - Right PV4

1430 mm 56.3 in.

1/4

Blue 1 - Blue 1

70 kgf 995 psi

G1/4, Quick

(35)

Relay (Right PVT) - Right PVT

1510 mm 59.4 in.

1/4

Red 1 - Red 1

70 kgf 995 psi

G1/4, Quick

(36)

Relay (Left PVP) - Left PVP

1470 mm 57.9 in.

3/8

Gray 1 - Gray 2

70 kgf 995 psi

G3/8, Quick

(37)

Relay (Left PV1) - Left PV2

1490 mm 58.7 in.

3/8

Green 1 - Green 2

70 kgf 995 psi

G3/8, Quick

(38)

Relay (Left PV2) - Left PV3

1420 mm 55.9 in.

3/8

Yellow 1 - Yellow 2

70 kgf 995 psi

G3/8, Quick

(39)

Relay (Left PV3) - Left PV4

1400 mm 55.1 in.

3/8

Blue 1 - Blue 2

70 kgf 995 psi

G3/8, Quick

(40)

Relay (Left PV4) - Left PV1

1405 mm 55.3 in.

3/8

Pink 1 - Pink 2

70 kgf 995 psi

G3/8, Quick

(41)

Relay (Left PVT) - Left PVT

1425 mm 56.1 in.

3/8

Red 1 - Red 2

70 kgf 995 psi

G3/8, Quick

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SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

15.3.8 Quick hitch model

(a) Hydraulic quick hitch cylinder (b) Hydraulic oil tank

SVL97-2

(d) Solenoid Valve (Hydraulic Pressure Quick Hitch)

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KiSC issued 09, 2021 A

SERVICING 15. Hydraulic hoses

6. HYDRAULIC SYSTEM

No.

Point used

(66)

Hose

Fitting

Total length

Size

Tape color

Max. pressure

Left

Right

HST filter - QC valve (P)

830 mm 32.7 in.

3/8

Brown 1 - Nothing

70 kgf 995 psi

G3/8, Straight

G3/8, 90°

(67)

Hydraulic oil tank - QC valve (T)

1190 mm 46.9 in.

3/8

Blue 1/Gray 1 Nothing

70 kgf 995 psi

G3/8, Straight

G3/8, 90°

(68)

QC valve (A) QC piping bottom side

3110 mm 122.5 in.

3/8

N/A

70 kgf 995 psi

G3/8, Straight

(69)

QC valve (B) QC piping rod side

3125 mm 123.0 in.

3/8

Gray 1 - Gray 1

70 kgf 995 psi

G3/8, Straight

(70)

Relay (QC) QCcyl rod

1210 mm 47.6 in.

1/4

Nothing - Yellow 1

70 kgf 995 psi

G1/4, Straight

(71)

Relay (QC) Qccyl bottom

950 mm 37.4 in.

1/4

N/A

70 kgf 995 psi

G1/4, Straight

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SVL97-2 KiSC issued 09, 2021 A

7. ELECTRICAL SYSTEM

KiSC issued 09, 2021 A

MECHANISM 1. Electrical device

7. ELECTRICAL SYSTEM

MECHANISM 1. Electrical device 1.1 Layout of electrical device

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

Meter panel SCR meter Key switch Hydraulic unlock switch Parking Brake Switch Fuse box Work light switch

SVL97-2

(8) Hydraulic quick hitch switch (9) Wiper switch (10) DPF regeneration inhibitor switch (11) Front control lever (12) Travel control lever (13) Right armrest switch

(14) Left armrest switch (15) DM connector (16) OPC switch (17) Wiper motor (18) Power socket (19) Main ECU (20) Front work light

(21) Room light (22) Room light switch (23) Horn (24) Rear work light (25) Air Conditioner Unit (26) Control panel (27) Washer motor

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KiSC issued 09, 2021 A

MECHANISM 1. Electrical device

7. ELECTRICAL SYSTEM

(28) AUX power socket (29) Fuel sensor (30) Unload valve (Travel speed shift, parking brake, working equipment)

7-2

(31) ACU (32) Back buzzer (33) Accelerator pedal sensor (34) Hydraulic oil temperature sensor

(35) Solenoid Valve (Anti-stall, AUX) (36) Relay box (37) Solenoid Valve (Hydraulic Quick Hitch)

(38) Solenoid Valve (float) (39) Slow-blow fuse (40) Intake air heater relay (41) Engine ECU (42) Battery

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 1. Electrical device

7. ELECTRICAL SYSTEM

(43) Alarm buzzer

(44) Accelerator dial sensor

(45) Arm pressure switch

(46) Backward pressure switch

(47) Horn switch (48) AUX electrical control switch (49) Travel speed shift switch (50) Blank

(51) AUX electrical control switch (high-flow specification only) (52) AUX electrical control switch (53) AUX knob switch

(54) AUX hold switch (left) (55) AUX hold switch (right) (56) Float switch

(57) AUX electrical mode change switch (high-flow specification only)

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KiSC issued 09, 2021 A

MECHANISM 2. Meter panel

7. ELECTRICAL SYSTEM

2. Meter panel

No.

Name

2.1 Meter panel display

(1)

Travel speed shift lamp

Light: High speed

(2)

Parking brake lamp

Light: Parking brake is ON

(3)

Hydraulic lock lamp

Light: Hydraulic lock is ON

(4)

AUX lamp

Light: AUX is in use Blink: AUX mode setting is 10 or higher

(5)

Float lamp

Light: Float is ON

(6)

Coolant temperature warning lamp

Light: Coolant temperature is 123 ℃ (255 ℉) or higher

(7)

Hydraulic oil temperature lamp

Blink: Hydraulic oil temperature is 108 ℃ (226 ℉) or higher

(8)

Glow lamp

(9)

Low fuel warning lamp

Blink: Low fuel

(10)

DPF regeneration lamp

Light: DPF regeneration is in progress

(11)

Engine oil lamp

Light: Engine oil pressure switch ON, low oil

(12)

Charging lamp

Light: Low battery voltage

(13)

Warning lamp

Blink: Warning (Error) occurred

(14)

Engine speed warning lamp

(15)

Fuel meter

(16)

Coolant temperature meter

(17)

LCD

(18)

AUX electrical mode change lamp

Light: AUX electrical mode change is ON

No.

Name

Function

(19)

Air cleaner warning lamp

7-4

Function

Light: Warming the engine

Blink: DPF regeneration is in progress, or when the engine speed is 1800 rpm or less

Light: Air cleaner is clogged

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 2. Meter panel

7. ELECTRICAL SYSTEM

DEF/AdBlue monitor

Switch name

Operation

Symbol

Function

Press

Select a mode / Increase a number

Hold

Set a mode

Press

Decrease a number

Hold

Exit a mode

Press

Activate AUX

Hold

------------

SW1

SW2

SW3

2.2 Lamps No.

Name

Function

(1)

DEF/AdBlue level gauge

Remaining DEF/AdBlue level

(2)

DEF/AdBlue warning lamp

Light: Low DEF/AdBlue level

(3)

SCR system warming lamp

Light: SCR system error occurred

(4)

DEF/AdBlue quality warning lamp

Light: Low DEF/AdBlue quality (concentration)

(5)

DEF/AdBlue thawing lamp

Light: Thawing DEF/AdBlue (1) Off (2) Lit

Switch

(3) Blink

2.3 Buzzer

(1) SW1 (Display switch) (2) SW2 (User setting switch)

SVL97-2

(3) SW3 (AUX switch)

(1) Mute (2) Beep

(3) Pi, Pi, Pi (4) Long beep

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KiSC issued 09, 2021 A

MECHANISM 2. Meter panel

7. ELECTRICAL SYSTEM

2.4 Meter panel functions Mode

Function

Operation

Hour meter Tachometer

Normal mode

AUX setting mode

Press SW1 to change the function.

AUX Error code

Displays when error(s) occurs.

AUX flow rate setting

Press SW2 in the normal mode

Tester mode AUX knob-switch setting AUX start-up point setting AUX current fine setting Service mode

HST start-up point setting Accelerator pedal/dial setting

Hold SW1 and turn the starter switch to [RUN] to enter o service mode.

Read error history Clear error history Read all error history AUX flow rate adjustment

2.5 Normal mode

In case of error

Display normal mode with turning the key switch to "RUN"

2.5.1 Normal mode display Display four functions of hour-meter, tachometer, AUX and error code.

(1) Warning lamp

(2) LCD

• Blinks the warning lamp and displays error code(s) on the LCD. Activate the AUX

• Change function with press SW1. NOTE • Normally, doesn't display error code and AUX.

• Select AUX1～5 with press SW3. 7-6

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 2. Meter panel

7. ELECTRICAL SYSTEM

2.6 User settings mode Individual AUX settings Press SW2 at the normal mode.

2.6.1 AUX flow rate setting in user setting mode Set the flow rate for each AUX (1 to 5).

• Set the left and right flow rates individually for AUX1 to 5. NOTE • Set flow rate volume from 0 to 14. • Setting a flow rate more than 10 is the highflow, and blink AUX lamp.

SVL97-2

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KiSC issued 09, 2021 A

MECHANISM 2. Meter panel

7. ELECTRICAL SYSTEM

2.7 Service mode Maintenance, adjustment and setting for the machine. Turn the key switch to "RUN" with holding-press SW1.

2.7.1 Service mode settings list Mode

Item

Explanation

Tester mode

Displays the machine information, and the status of the sensors and solenoids.

AUX knob-switch setting

Sets the L/R ends and neutral for the AUX knob switch. • When replaced the AUX knob switch

AUX start-up point setting

Sets the origin of the AUX. • When replaced an attachment or cylinder • When repaired hydraulic equipment

AUX current fine setting

Fine setting for the start-up point of the actuator (cylinder) attached to AUX.

HST start-up point setting

Sets the travel forward/reverse start-up point • When the HST pump, anti-stall Solenoid Valve, or travel pilot valve is replaced

Accelerator dial/pedal setting

Adjusts the Accelerator dial/pedal • These settings are required when the ECU, accelerator dial/ pedal, or accelerator sensor is replaced

Read error history

Displays an error code and hour meter that occurred in the past.

Clear error history

Clear error history of No-09

Read all error history

Displays all error codes and hour meters that occurred in the past. • Cannot clear with No-10 (clear error history)

AUX flow rate adjustment

Adjusts the AUX flow rate • When repaired related hydraulic equipments.

IMPORTANT • When replaced the main ECU, necessary to set all items. NOTE • Quit service mode with turn the key switch to [STOP].

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 1. Troubleshooting electrical issues

7. ELECTRICAL SYSTEM

SERVICING 1. Troubleshooting electrical issues 1.1 Troubleshooting electrical Engine does not start Probable cause(s)

Inspection point

Remedy

Blowing slow-blow fuses and fuses

Check slow-blow fuses and fuses

Check the cause of blowing fuses, and replace them.

Ground disconnection

Check the connecting ground wire to the machine.

Tighten GND wire bolt(s)

Faulty battery

Check battery voltage and specific gravity

Recharge or replace the battery

Faulty key switch

Check conduction between key switch terminals

Replace the key switch

Breaking harness or starter relay

Measure voltage on terminal B of the starter

Repair the harness Replace the harness, starter relay and/or fuses

Breaking harness, starter relay and/or fuses

Measure voltage on S terminal of the starter

Repair the harness Replace the harness, starter relay and/or fuses

2. Troubleshooting errors 2.1 Error warning list Display

Lamp

Error

Probable cause(s) •

Does not communicate between the main ECU and the meter

•

The hydraulic oil temperature is higher than 103 ℃ and lower than 108 ℃

Meter CAN non-communication

High hydraulic oil temperature advance warning

High hydraulic oil temperature warning

•

The hydraulic oil temperature is higher than 108 ℃

•

Connector disconnected Breaking in harness

Fuel sensor error •

Remarks

•

Hydraulic blinks

oil

lamp

•

Hydraulic oil lamp blinks at high speed

(Continued)

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM Display

Lamp

Error

Probable cause(s) •

Accelerator sensor error

• • •

Travel speed shift solenoid error

• • •

Parking brake solenoid error

• • •

Float solenoid error

• • •

Hydraulic lock release solenoid error

• • •

Low hydraulic oil temperature error

• •

Hydraulic quick hitch solenoid error

AUX knob-switch error

Connector disconnected Breaking in harness Short circuit of harness Connector disconnected Breaking in harness Short circuit of harness The hydraulic oil temperature is less than 5℃ Connector disconnected Breaking in harness

Connector disconnected Breaking in harness Short circuit of harness

• • AUX left solenoid error • • Anti-stall solenoid error •

Hydraulic oil temperature sensor error

Connector disconnected Breaking in harness Short circuit of harness

•

Battery overvoltage

Connector disconnected Breaking in harness Short circuit of harness

Short circuit of harness

AUX right solenoid error

5 V error

Connector disconnected Breaking in harness Short circuit of harness

•

• •

•

AUX flow rate is limited to 90 L/min

Connector disconnected Breaking in harness Connector disconnected Breaking in harness Connector disconnected Breaking in harness

•

Short circuit in the 5 V line

•

More than 18 V

•

Connector disconnected Breaking in harness Short circuit of harness

• •

Remarks

(Continued)

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors Display

7. ELECTRICAL SYSTEM Lamp

Error

Probable cause(s) •

CRS CAN communication error

ACU CAN communication error

•

• Breaking/short foot accelerator

Engine overheating

Engine oil pressure error

Battery charging error

Water separator error

• •

Remarks

Does not communicate between the main ECU and the engine ECU

•

Low idle

Does not communicate between the main ECU and ACU

•

Low idle

Connector disconnected Breaking in harness Short circuit of harness

•

Low idle

• •

Low idle Light water temperature lamp

•

High coolant temperature

• •

Faulty oil switch Short circuit of harness

•

Light oil lamp

• • •

Faulty fan belt Faulty alternator Faulty alternator terminal

•

Light charging lamp

•

Increase water level in the water separator

•

Blink warning lamp with yellow

2.2 Engine error warning list NOTE • Use the engine diagnostic tool to check the details. Display

Error

Display

Error

E:9000

Level 2 Regeneration request

E:9214

Regeneration too frequent

E:9001

Level 3 Regeneration request

E:9300

P/L valve opening error

E:9002

Level 3 Regenerating

E:9301

Rail pressure error high pressure

E:9003

Level 4 Warning

E:9302

Fuel leak (high-pressure fuel system)

E:9004

Level 5 Warning

E:9303

SCV sticking diagnosis

E:9006

Level 2 Inhibit warning

E:9304

Supply pump error (high-pressure)

E:9007

Level 3 Inhibit warning

E:9305

Insufficient intake error

E:9010

Engine stop to protect DPF (Stopping the engine for DPF)

E:9306

Turbo boost insufficient increase error

E:9100

RPM sensor system error

E:9307

Exhaust temperature increase error T0

E:9101

Fuel/rail pressure system error

E:9308

Exhaust temperature increase error T1

E:9102

SCV system error

E:9309

Exhaust temperature increase error T2

E:9103

Intake temperature sensor system error

E:9310

Starter drive inhibit error (Continued)

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM Display

Error

Display

Error

E:9104

Water temperature sensor system error

E:9400

Other engine ECU, DPF

E:9105

Fuel temperature sensor system error

E:9500

Diesel Exhaust Fluid piping pressure sensor error

E:9106

Injector system error

E:9501

Diesel Exhaust Fluid tank temperature Sensor error

E:9107

Intake pressure sensor system error

E:9502

Diesel Exhaust Fluid tank level Sensor error

E:9108

Battery voltage error

E:9503

Tank level: Empty

E:9109

Sensor voltage system error

E:9504

Tank leakage detected

E:9110

Main relay system error

E:9505

SCR temperature sensor error

E:9112

Atmospheric pressure sensor system error

E:9506

CAN1 bus off communication error

E:9113

EGR valve system error

E:9507

CAN2 bus off communication error

E:9114

EGR starting to close warning

E:9508

NOx sensor CAN communication error

E:9115

Emissions warning (overheat)

E:9509

CAN receive data error

E:9116

Overheating

E:9510

Urea injector error

E:9117

Air heater system error

E:9511

Suction line heater HT1 (S) error

E:9118

Engine oil hydraulic system error

E:9512

Delivery line heater HT3 (D) error

E:9119

Battery charging error

E:9513

Return line heater HT (R) error

E:9120

Separator full of water warning

E:9514

Supply unit heater HT2 (E) error

E:9121

Engine ECU error

E:9515

Heater relay error

E:9122

Communication error

E:9516

Tank heater coolant Valve malfunction

E:9123

PCV error

E:9517

Diesel Exhaust Fluid piping pump error

E:9124

PRV error

E:9518

SCR purification system

E:9125

HP5 system error

E:9519

Diesel Exhaust Fluid tank quality Sensor error

E:9126

CCV pressure error*1

E:9520

Diesel Exhaust Fluid quality error

E:9127

Continuous CCV pressure error*2

E:9521

Pre-NOx sensor

E:9200

Air mass flow sensor system error

E:9522

Post-NOx sensor

E:9203

Intake throttle error

E:9523

Urea injection pressure detection

E:9204

Pressure differential sensor system error

E:9524

5 V analog power supply

E:9205

Exhaust temperature sensor (DOC intake) error

E:9525

System power supply

E:9206

Exhaust temperature sensor (DOC outlet) error

E:9526

ACU flash ROM

E:9207

Exhaust temperature sensor (DPF outlet) error

E:9527

EGR system error

E:9208

Simultaneous disconnection of all exhaust temperature sensors error

E:9550

Other SCR system-related error

E:9211

DOC reaction error

E:9600

Horsepower limit for pump protection (Continued)

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

Display

Error

Display

Error

E:9212

DPF regeneration time up error

E:9601

Engine output limit

E:9213

Insufficient DPF regeneration/water temperature rise

E:9602

Engine idling limit

*1 The CCV pressure switch is installed at factory only for Canadian market. *2 E9127 occurs 45 minutes after E9126 has occurred.

2.3 E:001 CAN communication error Does not communicate with CAN between the ECU and meter.

• Check damage of cover for the wiring, and not touching the body.

2.3.1 Checking on the meter panel for E:001 CAN communication error 1. Check the meter panel.

(b) Meter connector

(1) Warning lamp

(2) Error code E:001

3. Check the main ECU. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

2.3.2 Checking on the meter panel for E:001 CAN communication error 1. Check the fuse (METER (+B)).

(a) METER (+B)

2. Check the meter panel. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode.

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.3.3 Checking with circuit tester for E:001 CAN communication error 1. Check the conductivity of the wire harness. • Turn the key switch to "STOP" and disconnect the main ECU connector and meter panel connector.

(1) Hydraulic oil temperature lamp

(2) Error code E:005

2. Check the hydraulic oil temperature in tester mode.

(a) Main ECU connector

(b) Meter panel connector Main ECU

Meter panel

CAN-H (Red)

CAN-L (Blue)

Normal

Conduction

2.4 E:005 High hydraulic oil temperature The hydraulic oil temperature is 108 ℃ or higher while the engine is running (700 rpm or higher)

2.4.1 Checking on the meter panel for E:005 high hydraulic oil temperature

(a) Engine speed (b) Battery voltage Normal

-30 to 120 ℃

2.4.2 Checking devices for E:005 high hydraulic oil temperature 1. Check the hydraulic oil. • Check the quantity of hydraulic oil

1. Check the meter panel.

(1) Gauge

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2. Cool the hydraulic oil down. • Turn the engine speed to low idle at firm and flat ground.

Normal

No-18

3±2 to 110±5 Ω

2.5.2 Checking devices for E:008 fuel sensor error 1. Check the fuel sensor. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body. (2) Lift arm

(3) Quick hitch

2.5 E:008 Fuel sensor error Fuel sensor resistance is 135 Ω or higher

2.5.1 Checking on the meter panel for E:008 fuel sensor error 1. Check the meter panel. (a) Fuel sensor connector

2. Check the main harness to engine harness. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(1) Warning lamp

(2) Error code E:008

2. Check the fuel level sensor resistance in tester mode.

(b) Relay 1 connector

(a) Engine speed (b) Battery voltage

SVL97-2

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KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.5.3 Checking circuit tester for E:008 fuel sensor error 1. Measure the resistance of the fuel sensor. • Disconnect the fuel sensor connector.

(e) Engine harness relay 1 connector (a) Full (b) Half

Normal

Float position

F (a)

½ (b)

E (c)

Normal

3±2Ω

38 Ω

110 ± 5 Ω

Key OFF

Key ON

12 V

2. Measure voltage of the wire harness. • Disconnect the fuel sensor connector, and measure the voltage • Disconnect the engine harness relay 1 connector, and measure the voltage

(d) Fuel sensor connector

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

3. Check conduction for the wire harness. • Disconnect the fuel sensor connector and main harness relay 1 connector.

Main ECU connector

Engine harness relay 1 connector

+12 V (Red) GND (Blue) Normal

Body GND

○ Conduction

2.6 E:009 Accelerator dial sensor (Break or short) The main voltage of the accelerator dial sensor is 0.25 V or less, or 4.75 V or higher, the sub-output of the accelerator dial sensor 0.25 V or less, or 4.75 V or higher, 4.5 V < Main sensor + sub sensor < 5.5 V (f)

Fuel sensor connector

(g) Main harness relay 1 connector

Fuel sensor connector

Main harness relay 1 connector

+12 V (Red)

GND (Blue)

2.6.1 Checking on the meter panel for E:009 accelerator sensor error 1. Check the meter panel.

• Disconnect the main ECU connector and engine harness relay 1 connector.

(1) Warning lamp

(h) Main ECU connector

SVL97-2

(i)

(2) Error code E:009

Engine harness relay 1 connector

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KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM 2. Check the voltage of the accelerator dial sensor in tester mode.

(a) Accelerator sensor connector Normal (a) Engine speed (b) Battery voltage (c) no-11: Accelerator dial sensor main voltage

Normal

(d) no-12: Accelerator dial sensor sub voltage

No-11

0.26 to 4.74 V

No-12

0.26 to 4.74 V

1 kΩ ± 20%

2. Measure voltage of the wire harness. • Disconnect the accelerator dial connector, and measure the voltage

sensor

2.6.2 Checking devices for E:009 accelerator sensor error 1. Check the accelerator dial sensor • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(b) Accelerator dial sensor

Normal

(a) Meter panel connector

Key OFF

Key ON

(b) Accelerator dial sensor

2.6.3 Checking with circuit tester for E:009 Accelerator sensor error 1. Measure the accelerator dial sensor resistance. • Disconnect the accelerator dial sensor connector.

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

3. Check conduction for the wire harness. • Disconnect the accelerator dial connector and the main ECU connector.

2.7 E:010 Travel speed shift solenoid error During travel speed shift Solenoid Valve output, the detection port is low (short in solenoid or harness) or high (break in solenoid or harness)

2.7.1 Checking on the meter panel for E:010 travel speed shift solenoid error 1. Check the meter panel.

(1) Warning lamp

(2) Error code E:010

2. Check condition of the travel speed shift SOL in tester mode.

(d) Main ECU connector

Accelerator dial connector

Main ECU connector

5V (Red)

GND (Blue)

Main (Green)

Sub (Green)

Normal

(a) Engine speed (b) Battery voltage (c) no-20: Travel speed shift switch

SVL97-2

Travel speed shift switch ON

Travel speed shift switch OFF

Travel speed shift switch

OFF

Travel speed shift SOL

OFF

Conduction Normal

(d) no-21: Travel speed shift SOL

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KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.7.2 Checking devices for E:010 travel speed shift solenoid error 1. Check the travel speed shift SOL. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body. (a) Travel speed shift switching solenoid connector Normal

12 Ω ± 10%

(a) Travel speed shift switching solenoid connector

(b) Relay 1 connector

2.7.3 Checking with circuit tester for E:010 travel speed shift solenoid error 1. Measure the resistance of the travel speed shift SOL. • Disconnect the travel speed shift SOL connector.

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2. Measure voltage of the wire harness. • Disconnect the travel speed shift SOL connector, and measure the voltage • Disconnect the unload valve relay connector, and measure the voltage • Disconnect the engine harness relay 1 connector, and measure the voltage

• Disconnect the main ECU connector and engine harness relay 1 connector.

(g) Main ECU connector

(h) Engine harness relay 1 connector

Main ECU connector

Engine harness relay 1 connector

+12 V (Red)

• Disconnect the main harness relay 1 connector and unload valve relay connector.

(b) Travel speed shift SOL con- (e) Engine harness relay 1 connector nector (c) Unload valve relay connector (f) Main harness relay 1 connector (d) Engine harness relay 5 connector

Normal

Key OFF

Key ON

12 V

(i)

Main harness relay 1 connector

+12 V (Red)

3. Check conduction for the wire harness.

SVL97-2

GND (Blue)

(j)

Unload valve relay connector

Main harness relay 1 connector

Unload relay connector

4 3

Body GND

○

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KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM • Disconnect the unload valve relay connector and travel speed shift SOL connector.

(a) Engine speed (b) Battery voltage (c) no-30: Parking brake switch (k) Unload valve relay connector (l)

Travel speed shift SOL connector

Unload valve relay connector

Travel speed shift SOL connector

+12 V (Red)

GND (Blue)

Normal

Conduction

2.8 E:011 Parking brake solenoid error During parking brake SOL output, the detection port is low or high

2.8.1 Checking on the meter panel for E:011 parking brake solenoid error 1. Check the meter panel.

Normal

(d) no-31: Parking brake SOL

Parking brake switch ON

Parking brake switch OFF

Parking brake switch

OFF

Parking brake SOL

OFF

2.8.2 Checking devices for E:011 parking brake solenoid error 1. Check the parking brake SOL. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(a) Parking brake solenoid connector (1) Warning lamp

(2) Error code E:011

2. Check the condition of the parking brake SOL in tester mode.

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7. ELECTRICAL SYSTEM

(b) Relay 1 connector

2.8.3 Checking with circuit tester for E:011 parking brake solenoid error 1. Measure the resistance of the parking brake SOL. • Disconnect the parking brake SOL connector.

(a) Parking brake solenoid connector Normal

12 Ω ± 10%

2. Measure voltage of the wire harness. • Disconnect the parking brake SOL connector, and measure the voltage • Disconnect the unload valve relay connector, and measure the voltage • Disconnect the main harness relay 1 connector, and measure the voltage

SVL97-2

(b) Parking brake SOL connec- (e) Engine harness relay 1 connector tor (c) Unload valve relay connector (f) Main harness relay 1 connector (d) Engine harness relay 5 connector

Normal

Key OFF

Key ON

12 V

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7. ELECTRICAL SYSTEM 3. Check conduction for the wire harness. • Disconnect the main ECU connector and engine harness relay 1 connector.

Main harness relay 1 connector

Unload relay connector

+12 V (Red) GND (Blue)

Body GND

○

• Disconnect the unload valve relay connector and parking brake SOL connector.

(k) Engine harness relay 5 connector

(g) Main ECU connector

(h) Engine harness relay 1 connector

Main ECU connector

Engine harness relay 1 connector

+12 V (Red)

• Disconnect the main harness relay 1 connector and unload valve relay connector.

(l)

Parking brake SOL connector

Unload valve relay connector

Parking brake SOL connector

+12 V (Red)

GND (Blue)

Normal

Conduction

2.9 E:012 Float solenoid error During float SOL output, the detection port is low or high

2.9.1 Checking on the meter panel for E:012 float solenoid error 1. Check the meter panel.

(i)

Main harness relay 1 connector

(j)

Unload valve relay connector

(1) Warning lamp

7-24

(2) Error code E:012

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2. Check tester mode. • Check the condition of the float SOL in tester mode.

• Check damage of cover for the wiring, and not touching the body.

(b) Relay 1 connector

(a) Engine speed (b) Battery voltage (c) no-32: Float switch

Normal

2.9.3 Checking with circuit tester for E:012 float solenoid error

(d) no-33: Float SOL

Float switch ON

Float switch OFF

Float switch

OFF

Float SOL

OFF

1. Measure the resistance of the float SOL. • Disconnect the float SOL connector.

2.9.2 Checking devices for E:012 float solenoid error 1. Check the float SOL. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(a) Float solenoid connector Normal

12 Ω ± 10%

(a) Float solenoid connector

2. Check the main harness to engine harness. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode.

SVL97-2

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7. ELECTRICAL SYSTEM 2. Check the voltage of the wire harness. • Disconnect the float SOL connector, and measure the voltage • Disconnect the engine harness relay 1 connector, and measure the voltage

(e) Main ECU connector

Normal

(d) Main harness relay 1 connector

Key OFF

Key ON

12 V

Engine harness relay 1 connector

Main ECU connector

Engine harness relay 1 connector

+12 V (Red)

(b) Float SOL connector (c) Engine harness relay 1 connector

(f)

• Disconnect the main harness relay 1 connector and float solenoid valve connector.

3. Check conduction for the wire harness. • Disconnect the main ECU connector and engine harness relay 1 connector.

(g) Float SOL connector

Float SOL connector

Main harness relay 1 connector

+12 V (Red)

GND (Blue)

Normal

7-26

(h) Main harness relay 1 connector

Body GND

○ Conduction

SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.10 E:013 Hydraulic lock release solenoid error During hydraulic lock release SOL output, the detection port is low or high

2.10.1 Checking on the meter panel for E:013 hydraulic lock release solenoid error

• Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

1. Check the meter panel.

(a) Hydraulic lock release solenoid connector

(1) Warning lamp

(2) Error code E:013

2. Check the condition of the hydraulic lock release SOL in tester mode.

(d) no-23: Hydraulic lock release (a) Engine speed SOL (b) Battery voltage (c) no-22: Hydraulic lock release switch

Normal

Hydraulic lock release switch ON

Hydraulic lock release switch OFF

Hydraulic lock release switch

OFF

Hydraulic lock release SOL

OFF

(b) Relay 1 connector

2.10.2 Checking devices for E:013 hydraulic lock release solenoid error 1. Check the hydraulic lock release SOL SVL97-2

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7. ELECTRICAL SYSTEM

2.10.3 Checking with circuit tester for E:013 hydraulic lock release solenoid error 1. Measure the resistance of the hydraulic lock release SOL. • Disconnect the hydraulic lock release SOL connector.

(b) Hydraulic lock release sole- (e) Engine harness relay 1 connoid connector nector (c) Engine harness relay 5 con- (f) Main harness relay 1 connector nector (d) Unload valve relay connector (a) Hydraulic hitch release SOL connector Normal

Normal

Key OFF

Key ON

12 V

12 Ω ± 10%

2. Check the voltage of the wire harness. • Disconnect the hydraulic lock release SOL connector, and measure the voltage • Disconnect the unload valve relay connector, and measure the voltage • Disconnect the engine harness relay 1 connector, and measure the voltage

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7. ELECTRICAL SYSTEM

3. Check conduction for the wire harness. • Disconnect the main ECU connector and engine harness relay 1 connector.

Main harness relay 1 connector

Unload valve relay connector

+12 V (Red) GND (Blue)

Body GND

○

• Disconnect the engine valve relay 5 connector and parking brake SOL connector.

(k) Engine harness relay 5 connector

(g) Main ECU connector

(h) Engine harness relay 1 connector

Main ECU connector

Engine harness relay 1 connector

+12 V (Red)

(l)

Hydraulic hitch release SOL connector

Engine harness relay 5 connector

Hydraulic hitch release SOL connector

+12 V (Red)

GND (Blue)

Normal

Conduction

• Disconnect the main harness relay 1 connector and unload valve relay connector.

(i)

Main harness relay 1 connector

SVL97-2

(j)

Unload valve relay connector

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7. ELECTRICAL SYSTEM

2.11 E:014 Low hydraulic oil temperature error Hydraulic oil temperature is lower than 5 ℃ or broken wiring.

2.12 Checking on the meter panel for E:014 low hydraulic oil temperature 1. Check the meter panel.

(a) Hydraulic oil temperature sensor

2. Check the main harness to engine harness. • Check connection for the connector (loose or poor). • Disconnect and reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body. (1) Warning lamp

(2) Error code E:014

2. Check the hydraulic oil temperature in tester mode.

(b) Relay 1 connector

(a) Engine speed (b) Battery voltage Normal

-30 to 120 ℃

2.13 Checking devices for E:014 low hydraulic oil temperature error 1. Check the hydraulic oil temperature sensor. • Check connection for the connector (loose or poor). • Disconnect and reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.14 Checking with circuit tester for E:014 low hydraulic oil temperature error

• Disconnect the hydraulic oil temperature sensor connector and main harness relay 1 connector.

1. Measure the resistance of the hydraulic temperature sensor. • Disconnect the hydraulic temperature sensor.

Hydraulic oil temperature

-10 ℃

0℃

10 ℃

Resistance

9.16 kΩ

5.74 kΩ

3.70 kΩ

(1) Main harness relay 1 connector

(2) Hydraulic oil temperature sensor connector

Hydraulic oil temperature sensor connector

Main harness relay 1 connector

+5 V (Red)

GND (Blue)

2. Measure voltage of the wire harness.

• Disconnect the main ECU connector and engine harness relay 1 connector.

(1) Main harness relay 1 connector

(2) Hydraulic oil temperature sensor connector

• Disconnect the hydraulic oil temperature sensor connector, and measure the voltage. • Disconnect the engine harness relay 1 connector, and measure the voltage. Normal

Key [OFF]

Key [ON]

3. Check conduction for the wire harness. SVL97-2

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7. ELECTRICAL SYSTEM

(a) Engine speed (b) Battery voltage

Normal

(3) Engine harness relay 1 connector

(4) Main ECU connector

Main harness relay 1 connector

Main ECU connector

+5 V (Red)

GND (Blue)

2.15 E:015 Hydraulic hitch solenoid error During hydraulic hitch SOL output, the detection port is low

Hydraulic hitch switch ON

Hydraulic hitch switch OFF

Hydraulic hitch switch

OFF

Hydraulic hitch SOL

OFF

2.15.2 Checking devices for E:015 hydraulic hitch solenoid error 1. Check the hydraulic hitch SOL. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

2.15.1 Checking on the meter panel for E:015 hydraulic hitch solenoid error 1. Check the meter panel.

(a) Hydraulic hitch release solenoid connector

(1) Warning lamp

(b) Hydraulic hitch lock solenoid connector

(2) Error code E:015

2. Check the the status of hydraulic hitch SOL in tester mode. 7-32

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7. ELECTRICAL SYSTEM

2. Check the hydraulic hitch switch. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(a) Hydraulic hitch solenoid connector Normal

12 Ω ± 10%

2. Measure the conduction of the hydraulic hitch switch. • Disconnect the hydraulic hitch switch connector.

3. Check the main harness to engine harness. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(b) Hydraulic hitch switch Hydraulic hitch switch

(d) Relay 1 connector

2.15.3 Checking with circuit tester for E:015 hydraulic hitch solenoid error

Hydraulic hitch switch lock position

Hydraulic hitch switch release position

Normal

Conduction

1. Measure the resistance of the hydraulic hitch release SOL and hydraulic hitch lock SOL. • Remove the hydraulic pressure hitch unlock SOL and hydraulic pressure hitch lock SOL connector.

SVL97-2

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7. ELECTRICAL SYSTEM 3. Measure voltage of the wire harness. • Disconnect the hydraulic hitch switch connector, and measure the voltage

(f) (c) Hydraulic hitch switch connector

Normal

Key OFF

Key ON

12 V

4. Check conduction for the wire harness. • Disconnect the main ECU connector and hydraulic hitch switch connector.

(d) Main ECU connector

+12 V (Red)

Hydraulic hitch switch connector

(g) Engine harness relay 1 connector

Hydraulic hitch switch connector

Engine harness relay 1 connector

+12 V (Red)

• Disconnect the main harness relay 1 connector, hydraulic hitch release solenoid connector, and hydraulic hitch lock solenoid connector.

(e) Hydraulic hitch switch connector

Main ECU connector

Hydraulic hitch switch connector

• Disconnect the hydraulic hitch switch connector and engine harness relay 1 connector.

(h) Hydraulic hitch release SOL connector (i) Hydraulic hitch lock SOL connector Hydraulic hitch release SOL connector +12 V (Red)

(j)

Hydraulic hitch lock SOL connector

Main harness relay 1 connector

Body GND

17 1

30 (Continued)

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SERVICING 2. Troubleshooting errors Hydraulic hitch release SOL connector

7. ELECTRICAL SYSTEM

Hydraulic hitch lock SOL connector

Main harness relay 1 connector

GND (Blue)

Body GND ○

○

Normal

Conduction

2.16 E:016 AUX knob-switch error

2.16.2 Checking devices for E:016 AUX knob-switch error 1. Check the AUX knob sensor. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

During AUX operation, the AUX knob sensor output is 0.25 V or less, or 4.75 V or more (Break/short)

2.16.1 Checking on the meter panel for E:016 AUX knob-switch error 1. Check the meter panel.

(a) Right control lever connector

2.16.3 Checking with the circuit tester for E:016 AUX knob-switch error 1. Check the voltage of the wire harness. • Remove the right control lever, and measure the voltage (1) Warning lamp

(2) Error code E:016

2. Check the status of the AUX knob sensor in tester mode.

(a) Right control lever connector

Normal (a) Engine speed (b) Battery voltage Normal

SVL97-2

Key OFF

Key ON

0.26 to 4.74 V

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7. ELECTRICAL SYSTEM 2. Check conduction for the wire harness. • Disconnect the main ECU connector and hydraulic pressure hitch switch connector.

(1) Warning lamp

(2) Error code E:018

2. Check the current of the AUX right SOL in tester mode.

(b) Main ECU connector

+12 V (Red)

Main ECU connector

Right control lever connector

GND (Blue)

Signal (Green)

Normal

(a) Engine speed (b) Battery voltage (c) no-43: AUX knob voltage

Normal

(d) no-47: AUX current

No-43

0.26 to 4.74 V

No-47

1.6 A or less

Conduction

2.17 E:018 AUX right solenoid error During AUX right SOL operation, resistance is 13 Ω or higher (Break)

the

solenoid

2.17.1 Checking on the meter panel for E:018 AUX right solenoid error 1. Check the meter panel.

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7. ELECTRICAL SYSTEM

2.17.2 Checking devices for E:018 AUX right solenoid error 1. Check the AUX right SOL. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body. (a) AUX right solenoid connector

Normal

3.2 ± 0.5 Ω Oil temperature: At 20 ℃

(a) AUX right solenoid connector

(b) Relay 2 connector

2.17.3 Checking with circuit tester for E:018 AUX right solenoid error 1. Measure the resistance of the AUX right SOL. • Remove the AUX right SOL.

SVL97-2

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7. ELECTRICAL SYSTEM 2. Check conduction for the wire harness. • Disconnect the AUX right SOL connector and main harness relay 2 connector.

Normal

Conduction

2.18 E:019 AUX left solenoid error During AUX left SOL operation, the solenoid resistance is 13 Ω or higher (Break)

2.18.1 Checking on the meter panel for E:019 AUX left solenoid error 1. Check the meter panel.

(b) AUX right SOL connector

AUX right SOL connector

Main harness relay 2 connector

+12 V (Red)

GND (Blue)

3 (1) Warning lamp

• Disconnect the main ECU connector and engine harness relay 2 connector.

2. Check the current of the AUX left SOL in tester mode.

(a) Engine speed (b) Battery voltage (c) no-43: AUX knob voltage

Normal

(d) Main ECU connector

(d) no-47: AUX current

No-43

0.26 to 4.74 V

No-47

1.6 A or less

(e) Engine harness relay 2 connector

Main ECU connector

Engine harness relay 2 connector

+12 V (Red)

GND (Blue)

7-38

(2) Error code E:019

SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.18.2 Checking devices for E:019 AUX left solenoid error 1. Check the AUX right SOL. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body. (a) AUX left SOL connector

Normal

3.2 ± 0.5 Ω Oil temperature: At 20 ℃

(a) AUX left SOL

(b) Relay 2 connector

2.18.3 Checking with circuit tester for E:019 AUX left solenoid error 1. Measure the resistance of the AUX left SOL. • Remove the AUX left SOL.

SVL97-2

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7. ELECTRICAL SYSTEM 2. Check conduction for the wire harness. • Disconnect the AUX left SOL connector and main harness relay 2 connector.

Normal

Conduction

2.19 E:020 Anti-stall solenoid error The solenoid resistance is 13 Ω or higher (Break) while anti-stall SOL output

2.19.1 Checking on the meter panel for E:020 Anti-stall solenoid error 1. Check the meter panel.

(b) AUX left SOL connector

AUX left SOL connector

Main harness relay 2 connector

+12 V (Red)

GND (Blue)

3 (1) Warning lamp

• Disconnect the main ECU connector and engine harness relay 2 connector.

2. Check the current of the anti-stall SOL in tester mode.

(a) Engine speed (b) Battery voltage Normal

(d) Main ECU connector

No-51

1.6 A or less

(e) Engine harness relay 2 connector

Main ECU connector

Engine harness relay 2 connector

+12 V (Red)

GND (Blue)

7-40

(2) Error code E:020

SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.19.2 Checking devices for E:020 Antistall solenoid error 1. Check the anti-stall SOL. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body. (a) Anti-stall SOL

Normal

3.2±0.5 Ω Oil temperature: At 20 ℃

(a) Anti-stall SOL

(b) Relay 2 connector

2.19.3 Checking with circuit tester for E:020 Anti-stall solenoid error 1. Measure the resistance of the anti-stall SOL. • Remove the anti-stall SOL.

SVL97-2

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7. ELECTRICAL SYSTEM 2. Check conduction for the wire harness. • Disconnect the anti-stall SOL connector and main harness relay 2 connector.

Normal

Conduction

2.20 E:021 5 V error During 5 V output, the detection port is high (Short)

2.20.1 Checking on the meter panel for E:021 5 V error 1. Check the meter panel.

(b) Anti-stall SOL connector

Anti-stall SOL connector

Main harness relay 2 connector

+12 V (Red)

GND (Blue)

• Disconnect the main ECU connector and engine harness relay 2 connector.

(1) Warning lamp

(2) Error code E:021

2.20.2 Checking devices for E:021 5 V error 1. Check the right control lever connector. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(a) Right control lever connector

(d) Main ECU connector

(e) Engine harness relay 2 connector

Main ECU connector

Engine harness relay 2 connector

+12 V (Red)

GND (Blue)

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2. Check the accelerator dial sensor • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(e) Relay 1 connector

(b) Meter panel

3. Check the foot accelerator sensor. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(d) Foot accelerator sensor

4. Check the main harness to engine harness. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

SVL97-2

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7. ELECTRICAL SYSTEM

2.20.3 Checking external 5 V short with a circuit tester 1. Check the voltage of the wire harness. • Disconnect the accelerator dial sensor connector, and measure the voltage. • Disconnect the foot accelerator sensor connector, and measure the voltage. • Disconnect the right control lever, and measure the voltage. • Disconnect the main harness relay 1 connector, and measure the voltage.

(a) Accelerator dial sensor connector (b) Foot accelerator sensor connector

(e) Engine harness relay 1 connector (f) Right control lever connector (multi-function lever)

Standard lever specification Accelerator dial sensor connector

Foot accelerator sensor connector

Right control lever connector

Engine harness relay 1 connector

+5 V (Red)

GND (Blue)

Accelerator dial sensor connector

Foot accelerator sensor connector

Right control lever connector

Engine harness relay 1 connector

+5 V (Red)

GND (Blue)

Multi-function lever specification

Normal

7-44

Key OFF

Key ON

SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2. Check the resistance of the wire harness. • Disconnect the accelerator dial sensor connector, foot accelerator sensor connector, right control lever connector and main harness relay 1 connector.

(a) Accelerator dial sensor connector (b) Foot accelerator sensor connector

(e) Engine harness relay 1 connector (f) Main ECU connector

(g) Right control lever connector (multi-function lever)

Standard lever specification Accelerator dial sensor connector

Foot accelerator sensor connector

Right control lever connector

Engine harness relay 1 connector

Main harness relay 1 connector

Main ECU connector 12

+5 V (Red)

7 1

13 7

14 4

GND (Blue)

14 2

15 14

Multi-function lever specification Accelerator dial sensor connector +5 V (Red)

Foot accelerator sensor connector

Right control lever connector

Engine harness relay 1 connector

Main harness relay 1 connector

Main ECU connector 12 (Continued)

SVL97-2

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7. ELECTRICAL SYSTEM Accelerator dial sensor connector

Foot accelerator sensor connector

Right control lever connector

Engine harness relay 1 connector

3 +5 V (Red)

Main harness relay 1 connector 7

13 7

14 4

GND (Blue)

14 9

15 14

Normal

7-46

Main ECU connector

14 Conduction

SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.21 E:023 Overvoltage Power supply voltage is 18 V or higher

2.21.1 Checking on the meter panel for E:023 overvoltage 1. Check the meter panel.

(a) 12 V

(1) Warning lamp

(2) Error code E:023

2. Check the battery voltage in tester mode.

(b) 24 V

2.21.3 Checking with circuit tester for E:023 overvoltage 1. Measure voltage of the alternator. • Measure the voltage between terminal B of the alternator and body GND

(a) Engine speed

Normal

(b) No2: Battery voltage

No2

Engine stop

Engine running

12 V

Approx. 14 V

Normal

Engine stop

Engine running

12 V

Approx. 14 V

2.21.2 Checking devices for E:023 overvoltage 1. Check the battery. • Check if the machine does not jump start at 24 V • Check if 24 V battery is not used

SVL97-2

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7. ELECTRICAL SYSTEM

2.22 E:024 Hydraulic oil temperature sensor error The hydraulic oil temperature is -50 ℃ or lower, or 150 ℃ or higher

2.22.1 Checking on the meter panel for E:024 hydraulic oil temperature sensor error 1. Check the meter panel. (a) Hydraulic oil temperature sensor

2.22.3 Checking with circuit tester for E:024 hydraulic oil temperature sensor error 1. Measure the resistance of the hydraulic oil temperature sensor. • Disconnect the hydraulic oil temperature sensor connector. (1) Warning lamp

(2) Error code E:024

2. Check the hydraulic oil temperature in tester mode.

(a) Hydraulic oil temperature sensor connector

(a) Engine speed (b) Battery voltage Normal

-49 to 149 ℃

2.22.2 Checking devices for E:024 hydraulic oil temperature sensor error 1. Check the hydraulic oil temperature sensor. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

7-48

Normal

Temperature (℃ / ℉)

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

SVL97-2 KiSC issued 09, 2021 A

SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2. Check the voltage of the wire harness. • Disconnect the hydraulic oil temperature sensor connector, and measure the voltage • Disconnect the engine harness relay 1 connector, and measure the voltage

(e) Hydraulic oil temperature sensor connector

(f)

Main harness relay 1 connector

Hydraulic oil temperature sensor connector

Main harness relay 1 connector

+12 V (Red)

GND (Blue)

• Disconnect the engine harness connector and main ECU connector.

(b) Hydraulic oil temperature sensor connector (c) Engine harness relay 1 connector

Normal

relay

(d) Main harness relay 1 connector

Key OFF

Key ON

3. Check conduction for the wire harness. • Disconnect the hydraulic oil temperature sensor connector and main harness relay 1 connector.

(g) Engine harness relay 1 connector

SVL97-2

(h) Main ECU connector

Engine harness relay 1 connector

Main ECU connector

+12 V (Red)

GND (Blue)

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7. ELECTRICAL SYSTEM Normal

Conduction

2.23 E:026 CRS CAN communication error Communication has been cut off between main ECU and engine ECU

2.23.1 Checking on the meter panel for E:026 CRS CAN communication error 1. Check the meter panel.

(1) Warning lamp

(1) Slow-blow fuse 1 (2) Slow-blow fuse 2 (3) Slow-blow fuse 3

(a) Engine / SBF-30A.

Normal

Conduction

(2) Error code E:026

2.23.2 Checking devices for E:026 CRS CAN communication error 1. Check the engine / SBF-30A.

7-50

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2. Check the engine (CRS / RELAY).

4. Check the engine ECU connector. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(d) Engine ECU connector

(4) Relay box

(b) Engine (CRS / RELAY)

5. Check the joint connector. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

Coil Normal

91 to 112 Ω

Contact point Normal

Non-conduction

3. Check the main ECU connector. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

SVL97-2

(e) CAN / 2H joint connector

(f)

CAN / 2L joint connector

7-51

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7. ELECTRICAL SYSTEM

2.23.3 Checking with circuit tester for E:026 CRS CAN communication error

2.24 E:027 ACU CAN communication error

1. Measure the resistance of the wire harness. • Disconnect the main ECU connector, engine harness relay 2 connector, and engine ECU connector.

Communication has been cut off between main ECU and ACU

2.24.1 Check on the meter panel for E:027 ACU CAN communication error 1. Check the meter panel.

(1) Warning lamp

(a) Main ECU connector (b) Engine ECU connector (c) Engine harness relay 2 connector

Main ECU connector

CAN-2H (Red)

CAN-2L (Blue)

7-52

(d) Main harness relay 2 connector

Engine ECU connector

Engine harness relay 2 connector

Main harness relay 2 connector

1 76

1 2

59 Normal

(2) Error code E:027

2 Conduction

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.24.2 Checking devices for E:027 ACU CAN communication error 1. Check ACU / SBF-40A.

(4) Fuse box Normal

(1) Slow-blow fuse 1 (2) Slow-blow fuse 2 (3) Slow-blow fuse 3 Normal

(b) ACU Conduction

(a) ACU / SBF-40A

Conduction

2. Check the ACU fuse.

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7. ELECTRICAL SYSTEM 3. Check the ACU COMP relay.

(d) Main ECU connector

5. Check the ACU connector. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

(e) ACU connector

(5) Relay box

6. Check the junction. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

Coil Normal

72 to 88 Ω

Contact point Normal

Non-conduction

4. Check the main ECU connector. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body. 7-54

(f)

CAN / 2H joint connector

(g) CAN / 2L joint connector

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.24.3 Check with circuit tester for E:027 ACU CAN communication error

2.25 E:028 Foot accelerator sensor error

1. Measure the resistance of the wire harness. • Disconnect the main ECU connector, engine harness relay 2 connector, and ACU connector.

The main output or sub-output value of the foot accelerator sensor is 0.25 V or less, or 4.75 V or more / 4.5 V < Main sensor + sub sensor <5.5 V

2.25.1 Checking on the meter panel for E:028 foot accelerator sensor error 1. Check the meter panel.

(1) Warning lamp

(2) Error code E:028

2. Check the voltage of the foot accelerator sensor in tester mode.

(a) Main ECU connector (b) ACU connector (c) Engine harness relay 2 connector

Main ECU connector

CAN-H

CAN-L

ACU connector

Engine harness relay 2 connector

Main harness relay 2 connector

1 28

(a) Engine speed (b) Battery voltage (c) no-09: Foot accelerator sensor main voltage

Normal

(d) no-10: Foot accelerator sensor sub voltage

No-09

0.26 to 4.74 V

No-10

0.26 to 4.74 V

2 27

Normal

SVL97-2

(d) Main harness relay 2 connector

2 Conduction

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7. ELECTRICAL SYSTEM

2.25.2 Checking devices for E:028 foot accelerator sensor error 1. Check the foot accelerator sensor. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body. (a) Accelerator sensor connector Normal

1 kΩ ± 20%

2. Check the voltage of the wire harness. • Disconnect the foot accelerator sensor connector, and measure the voltage • Disconnect the engine harness relay 1 connector, and measure the voltage (a) Foot accelerator sensor

(b) Relay 1 connector

2.25.3 Checking with circuit tester for E:028 foot accelerator sensor error 1. Measure the resistance of the foot accelerator sensor. • Disconnect the foot accelerator sensor connector.

(b) Foot accelerator sensor con- (d) Main harness relay 1 connector nector (c) Engine harness relay 1 connector

Normal

7-56

Key OFF

Key ON

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

3. Check conduction for the wire harness. • Disconnect the main ECU connector and engine harness relay 1 connector.

(g) Foot accelerator sensor con- (h) Main harness relay 1 connector nector

(e) Main ECU connector

(f)

Foot accelerator sensor connector

Main harness relay 1 connector

+12 V (Red)

GND (Blue)

Main (Green)

Sub (Green)

Engine harness relay 1 connector

Main ECU connector

+12 V (Red)

GND (Blue)

Main (Green)

Sub (Green)

Normal

Conduction

• Disconnect the foot accelerator sensor connector and main harness relay 1 connector.

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7. ELECTRICAL SYSTEM

2.26 E:9116 Engine overheating Water temperature is 123 ℃ or Higher, engine speed does not raise from idling.

2.26.1 Checking on the meter panel for E:9116 Engine overheating 1. Check the meter panel.

(1) Coolant temperature lamp

(b) Error code E:9116

2. Check the Coolant temperature in tester mode.

(1) Reserve tank (2) Radiator cap

(3) Radiator

2.27 E:9118 Engine oil pressure error Oil switch is ON while the engine is rotating (700 rpm or more)

2.27.1 Checking on the meter panel for E:9118 engine oil pressure error 1. Check the meter panel. (a) Engine speed (b) Battery voltage Normal

No-07

-49 to 149 ℃

2.26.2 Checking devices for E:9116 engine overheating CAUTION • There is a risk of coolant spurting out. Cool down the coolant before working. 1. Cool down the coolant. 2. Check the remaining of coolant. • Check the reserve tank • Check the radiator

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(1) Warning lamp (2) Error code E:9118

(3) Oil lamp

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2. Check the status of the oil switch in tester mode.

(a) Engine speed (b) Battery voltage

(b) Cap (c) Oil checker

(d) Oil level range

• Measure the engine oil pressure

No-03

Engine stop

Engine start

Normal

OFF

NOTE • The oil pressure switch will turn on if the pressure is lower than 49 kPa.

2.27.2 Checking devices for E:9118 engine oil pressure error 1. Check the oil switch. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

Normal

Idling speed

Rated speed

98kPa 1.0 kgf/cm2 14.2 psi or greater

196 to 392 kPa 2.0 to 4.0 kgf/cm2 28.4 to 56.9 psi

(a) Oil switch connector

2. Check the engine oil. • Check the remaining of engine oil.

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7. ELECTRICAL SYSTEM

2.27.3 Checking with circuit tester for E:9118 engine oil pressure error 1. Measure the resistance of the oil switch. • Disconnect the oil switch connector.

(b) Oil switch connector

Normal

Oil switch connector

Main harness relay 1 connector

+12 V (Red)

(1) Oil switch Engine stop

Engine start

Conduction

Non-conduction

2. Check the voltage of the wire harness. • Disconnect the oil switch connector, and measure the voltage

(d) Main ECU connector

(a) Oil switch connector

Normal

+12 V (Red) Key OFF

Key ON

12 V

Normal

(e) Engine harness relay 1 connector

Main ECU connector

Engine harness relay 1 connector

27 Conduction

3. Check conduction for the wire harness. • Turn the key switch to STOP, and disconnect the oil switch connector and main harness relay 1 connector. • Turn the key switch to STOP, and disconnect the engine harness relay 1 connector and main ECU connector.

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7. ELECTRICAL SYSTEM

2.28 E:9119 Battery charging error Charging switch is ON while the engine is rotating (700 rpm)

2. Check the engine oil. • Check for breaking, loosen, or slippage of fan belt

2.28.1 Checking on the meter panel for E:9119 battery charging error 1. Check the meter panel.

(1) V belt

Normal

(1) Warning lamp (2) Error code E:9119

Deflection of the fan belt (b)

4.0 to 5.0 mm 0.16 to 0.19 in.

(3) Charging lamp

2. Check the status of the status of the charging switch in tester mode.

(a) Engine speed (b) Battery voltage

(a) 50 to 60 N (11.0 to 13.5 lbs)

2.28.3 Checking with circuit tester for E:9119 battery charging error 1. Measure voltage of the alternator. • Measure the voltage between terminal B of the alternator and body GND

(a) B terminal

No-04

Engine stop

Engine start

Normal

OFF

Normal

Engine stop

Engine running

12 V

Approx. 14 V

2.28.2 Checking devices for E:9119 battery charging error 1. Check the alternator. • Check connection for the connector. (loose or poor) • Disconnect/reconnect the connector, and recheck in tester mode. • Check damage of cover for the wiring, and not touching the body.

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7. ELECTRICAL SYSTEM 2. Check conduction for the wire harness. • Disconnect the alternator connector and main harness relay 1 connector.

(1) Warning lamp

(2) Error code E:9120

2. Check the status of the water separator switch in tester mode. (b) Alternator connector

Alternator connector

Main harness relay 1 connector

L terminal

• Disconnect the main ECU connector and engine harness relay 1 connector.

(a) Engine speed (b) Battery voltage

(d) Main ECU connector

L terminal

(e) Engine harness relay 1 connector

Main ECU connector

Engine harness relay 1 connector

Normal

No-19

When full of water

When not full of water

Normal

OFF

2.29.2 Checking devices for E:9120 water separator error 1. Drain water from the water separator

Conduction

2.29 E:9120 Water separator error Water separator switch ON

2.29.1 Checking on the meter panel for E:9120 water separator error 1. Check the meter panel. (1) Water separator

7-62

(2) Drain plug

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

2.29.3 Checking with circuit tester for E:9120 water separator error 1. Check the conduction of the water level switch. • Disconnect the water level switch connector, and check the conduction.

• Disconnect / reconnect the connector, and recheck the meter panel. • Check damage of cover for the wiring, and not touching the body.

(a) CCV pressure switch connector

Normal

When full of water

When not full of water

Conducting

Not conducting

2. Check the oil separator. • Check if the oil separator is clogging.

2.30 E:9126 CCV pressure error CCV pressure switch is OFF due to high pressure in the CCV circuit or broken harness.

2.30.1 Checking on the meter panel for E:9126 CCV pressure error 1. Check the meter panel.

(1) Oil separator

3. Check the CCV heater. • Check with your hand that the CCV heater is warm. • Check the CCV heater for crack and gas leakage.

(1) Warning lamp

(2) Error code E:9126

2.30.2 Checking devices for E:9126 CCV pressure error Only for KCL* or with additional CCV heater option 1. Check the CCV pressure switch. • Check connection for the connector (loose or poor).

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7. ELECTRICAL SYSTEM *KCL:Kubota Canada Ltd.

Except for KCL* and with an additional CCV heater option 1. Check the engine harness. • Check connection for the connector (loose or poor). • Disconnect / reconnect the connector, and recheck the meter panel. • Check damage of cover for the wiring, and not touching the body.

2. (d) CCV pressure plugged switch connector (2) CCV heater (A) Touch point (3) CCV heater (only for KCL* or with an additional CCV heater option)

4. Measure the CCV pressure.

*KCL:Kubota Canada Ltd.

2.30.3 Checking with circuit tester for E:9126 CCV pressure error Only for KCL* or with additional CCV heater option 1. Check conduction of the CCV pressure switch. • Remove the CCV pressure switch. • Disconnect the CCV pressure switch connector.

Normal

Less than 5.5 kPa 0.056 kgf/cm2 0.80 psi

IMPORTANT • To prevent serious damage to the engine, stop the engine immediately, after checking the CCV pressure. NOTE • Apply a threadlock (Loctite® 271) to the screw of CCV pressure switch on assembly.

7-64

(1) CCV pressure switch Normal

Conduction

2. Measure voltage of the wire harness. • Disconnect the CCV pressure switch connector, and measure the voltage.

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SERVICING 2. Troubleshooting errors

7. ELECTRICAL SYSTEM

(a) CCV pressure switch connector

Normal

Key OFF

Key ON

12 V

3. Check conduction for the wire harness. • Disconnect the Engine ECU connector and the CCV pressure switch connector.

(d) CCV pressure plugged switch connector (male-side) Normal

Conduction

2. Measure voltage of the wire harness. • Disconnect the CCV pressure plugged switch connector, and measure the voltage.

(b) Engine ECU connector

Engine ECU connector

CCV pressure switch connector

+12 V (Red) Normal

Conduction

*KCL:Kubota Canada Ltd. Except for KCL* and with additional CCV heater option 1. Measure the conduction of the CCV pressure plugged switch. • Disconnect the CCV pressure plugged switch connector.

(a) CCV pressure plugged switch connector (femaleside)

Normal

Key OFF

Key ON

12 V

3. Check conduction for the wire harness. • Disconnect the engine ECU connector and the CCV pressure plugged switch connector. SVL97-2

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2.31 E:9127 Continuous CCV pressure error 2.31.1 Checking on the meter panel for E:9127 continuous CCV pressure error 1. Check the meter panel.

(b) Engine ECU connector

Engine ECU connector

CCV pressure plugged switch connector

+12 V (Red) Normal

Conduction

• Disconnect the CCV pressure plugged switch connector and the ground wiring.

(1) Warning lamp

(2) Error code E:9127

NOTE • This error occurs 45 minutes after E9126 has occurred. • Refer to the troubleshooting procedure for E9126 as the cause of this error is the same as E9126.

3. Meter panel settings 3.1 Meter panel switches operation

(e) CCV pressure plugged (f) switch connector (male-side)

Ground wiring

CCV pressure plugged switch connector

Ground wiring

+12 V (Red) Normal

(1) SW1 (Display switch) (2) SW2 (User settings switch)

(3) SW3 (AUX switch)

Conduction

*KCL:Kubota Canada Ltd.

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SERVICING 3. Meter panel settings Switch name

SW1

SW2

SW3

Operation

7. ELECTRICAL SYSTEM

Symbol

Function

Short press

Select a mode / Increase a number

Long press

Sets a mode

Short press

Decrease a number

Long press

Mode return

Short press

Activate AUX

Long press

------------

3. Display “AUX-1” with long-press SW1. 4. Select from AUX-1 to AUX-05 with press SW1/ SW2. 5. Set a needed AUX No.5 with long-press SW1. NOTE • Set the flow rate volume from 0 to 14. 6. Display flow rate of right side. 7. Perform set-up for “AUX-2” to “AUX-5” in the same manner. NOTE • Setting a flow rate more than 10 is the highflow, and blink AUX lamp.

3.2 AUX flow rate setting Sets adjusting the AUX (1 to 5) flow rate. 1. Display "AUX" (Setting for AUX flow rate) and light AUX lamp with press SW2 in the normal mode. 2. Press SW1/SW2 to switch between AUX 1 to 5.

3.3 Service mode operations 1. 2. 3. 4.

Turn the key switch to [RUN] with holding-press SW1. Select the functions (modes) to "no-02", "no-03" with press SW1/SW2. Set "no-01" with long-press SW1. Set a needed function (mode) with long-press SW1.

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7. ELECTRICAL SYSTEM 5. Set the key switch to [OFF] to end service mode.

(1) Key switch (2) SW1

(A) [STOP] (B) [RUN]

3.4 No-01 Tester mode Displays the machine information, and the status of the sensors and solenoids. 1. Select the “No-01” in the service mode. 2. Set "no-01" with long-press SW1. 3. Select number of the tester from 1～60 with press SW1/SW2. 4. Return to "no-01" (select functions) with long-press SW1.

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7. ELECTRICAL SYSTEM

Display list Number

Item

Display

Explanation

Engine speed

xxxx

xxxx rpm When engine stopped: 0 rpm

Battery voltage

xx.x

V Battery voltage ±0.5 V

Engine oil

ON OFF

Engine start: OFF Engine stop: ON

Charge

ON OFF

Engine start: OFF Engine stop: ON

Starter position

ON OFF

Key switch START: ON Other: OFF

Work lamp

ON OFF

Switch ON: ON OFF: OFF

Coolant temperature

xxx.x

℃

Hydraulic oil temperature

xxx.x

℃

Accelerator pedal main voltage

x.xx

Accelerator pedal sub voltage

x.xx

Accelerator dial main voltage

x.xx

Accelerator dial sub voltage

x.xx

Accelerator pedal main voltage (MIN setting)

x.xx

Accelerator pedal main voltage (MAX setting)

x.xx

Accelerator dial main voltage (MIN setting)

x.xx

Accelerator dial main voltage (MAX setting)

x.xx

Fuel voltage

x.xx

xxx

x.xx Ω Full tank (F): 3 ± 1 Ω Remaining (F): 56.5 ± 1 Ω Empty (E): 110 ± 1 Ω

Fuel resistance

Water separator full of water switch

ON OFF

When full of water: ON Other: OFF

Travel speed shift switch

ON OFF

Press switch: ON Release: OFF

Travel speed shift solenoid

ON OFF

Solenoid started: ON Solenoid stopped: OFF

Hydraulic lock release switch

ON OFF

Press switch: ON Default state: OFF

Hydraulic lock release SOL

ON OFF

Solenoid started: ON Solenoid stopped: OFF

ON OFF

Always: OFF

AUX relay

ON OFF

Press switch: ON Release: OFF

AUX switch

ON OFF

Press switch: ON Release: OFF

ON OFF

Always: OFF

Seat bar right switch

ON OFF

Seat bar down: ON Seat bar up: OFF (Continued)

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7. ELECTRICAL SYSTEM Number

Item

Display

Explanation

Seat bar left switch

ON OFF

Seat bar down: ON Seat bar up: OFF

Parking brake switch

ON OFF

Switch ON: ON Switch OFF: OFF

Parking brake SOL

ON OFF

Solenoid started: ON Solenoid stopped: OFF

Float switch

ON OFF

Switch ON: ON Release: OFF

Float SOL

ON OFF

Solenoid started: ON Solenoid stopped: OFF

Boom up pressure switch

ON OFF

Pressure not detected: ON Pressure detect: OFF

Boom down pressure switch

ON OFF

Pressure detect: ON Pressure not detected: OFF

Settings connector

ON OFF

Always: OFF

Back buzzer switch

ON OFF

When backing: ON Other than backing: OFF

Back buzzer output

ON OFF

Buzzer sound is on: ON Buzzer: OFF

OPC switch

ON OFF

Rides on seat: ON Does not ride on seat: OFF

DPF inhibit switch lamp

ON OFF

DPF inhibit status: ON Other: OFF

DPF inhibit switch

ON OFF

Switch ON position: ON Switch OFF position: OFF

DPF forced manual regeneration switch

ON OFF

Switch ON: ON OFF: OFF

AUX1 knob voltage (current value)

x.xx

AUX1 knob voltage (left setting value)

x.xx

AUX 1 knob voltage (setting value neutral)

x.xx

AUX1 knob voltage (right setting value)

x.xx

AUX current

x.x

x.x A

AUX left current start-up point setting value

x.x

x.x A

AUX right current start-up point setting value

x.x

x.x A

Hydraulic quick hitch SOL

Anti-stall current

x.x

Cab relay output

ON OFF

Air conditioner switch ON: ON Air conditioner switch OFF: OFF

Buzzer

ON OFF

Buzzer ON: ON Buzzer OFF: OFF

Model setting

High flow setting

ON OFF

High-flow spec machine: ON Normal spec machine: OFF

DEF/AdBlue water level

xxx%

x.xx%

ON OFF

Solenoid started: ON Solenoid stopped: OFF x.x A

3: SVL75-2 4: SVL90-2 5: SVL95-2S

(Continued)

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7. ELECTRICAL SYSTEM Item

Display

DEF/AdBlue concentration

xx.x%

x.xx%

DEF/AdBlue temperature

xxx ℃

℃

Time until engine output limit

xxx

xxx min

Time until idling output limit

xxx

xxx min

3.5 No-02 AUX knob setting Sets the left and right ends and neutral position for the AUX knob switch.

(1) AUX knob switch

Explanation

3. Display “3：----”. 4. Start the engine and set the accelerator dial to the maximum position. 5. Press the hydraulic unlock switch and SW3 (AUX switch).

(2) LCD screen

1. Select the “No-02” in the Service mode. 2. Set “No-2” with long-press SW1. 3. Set “nob-R” with turning and holding the AUX knob switch to the right end, and long-press SW1. 4. Set “nob-L” with turning and holding the AUX knob switch to the left end, and long-press SW1. 5. Set “nob-n” with the AUX knob switch on the neutral, and long-press SW1. 6. Return to “No-02”, and complete setting.

(1) Hydraulic unlock switch

(2) AUX switch

6. AUX lamp is lit and the meter panel displays “set. .”.

3.6 No-03 AUX start-up point setting Set the start-up point of the actuator (cylinder) attached to AUX. 1. Select the “No-03” in the Service mode. 2. Set “No-3” with long-press SW1. SVL97-2

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7. ELECTRICAL SYSTEM 7. Move the attachment cylinder to half on the stroke with turning the AUX knob switch.

(4) Attachment cylinder.

(3) AUX knob switch

(4) Attachment cylinder

(5) SW1 (Display switch)

13. Return to “No-03” and turn the key switch to "STOP", and complete setting.

8. Set a half position with long-press SW1. 9. Set “set-L” with long-press SW1. 10. Press the SW1 immediately with moving the cylinder automatically.

(6) Hydraulic unlock switch/AUX switch release

3.7 No-04 AUX current fine setting (4) Attachment cylinder.

(5) SW1 (Display switch)

11. Set “set-R” with long-press SW1. 12. Press the SW1 immediately with moving the cylinder automatically. NOTE • The cylinder direction.

7-72

moves

the

opposite

Fine setting for the start-up point of the actuator (cylinder) attached to AUX. 1. Select the “No-04” in the Service mode. 2. Set “No-04” with long-press SW1. 3. Display “4：----”. 4. Start the engine and set the accelerator to MAX.

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SERVICING 3. Meter panel settings

7. ELECTRICAL SYSTEM

5. Press the hydraulic unlock switch and SW3 (AUX switch).

3.8 No-05 HST start-up point setting Set the travel start-up point 3 times. 1. Select the “No-05” in the Service mode. 2. Set “No-05” with long-press SW1. 3. Display “5：----”. 4. Start the engine, and set the engine speed to approx. 1150 ± 100 rpm. 5. Press the hydraulic unlock switch.

(1) Hydraulic unlock switch

(2) SW3 (AUX switch)

6. Light the AUX lamp, and Display “L：○○”. 7. Select a value of current with press SW1/SW2. Set a value with long-press SW1 Setting value: -40 to 40 8. Display “R：○○”. 9. Select a value of current with press SW1/SW2. Set a value with long-press SW1. Setting value: -40 to 40 10. Return to “No-04” and turn the key switch to "STOP", and complete setting.

6. Display “set. .”, and move the machine to flat ground with releasing the parking brake. 7. Long-press SW-1. Display “set-3”, and operate the pilot lever to the travel-forward. (1st pressureincreasing) NOTE • Does not display “set-3” if remaining locked the parking brake. 8. Press the SW1 immediately with moving the machine to the forward.

9. Display “set-2”, and operate the pilot lever to the travel-forward again. (2nd pressure-increasing) 10. Press the SW1 immediately with moving the machine to the forward. 11. Display “set-1”, and operate the pilot lever to the travel-forward again. ((3rd pressure-increasing) 12. Press the SW1 immediately with moving the machine to the forward.

(3) Hydraulic unlock switch/AUX switch release

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SERVICING 3. Meter panel settings

13. Display “OFF” and turn the key switch to "STOP", and complete setting. NOTE • Display “FAIL” if operate in mistake or locked the parking brake during procedure from 7 to 10. • Start procedure from 1st again with press SW1 if display “FAIL”.

3.10 No-09 Read error history Displays error history (error code, number of times and hour meter) 1. Select the “No-09” in the Service mode. 2. Set “No-09” with long-press SW1. 3. The error code “E：○○○○” is displayed. 4. Display other error code with long press SW1.

(3) Hydraulic unlock switch/AUX (4) Operation mistake or locked switch release the parking brake

3.9 No-07 Accelerator pedal/dial setting

NOTE • If the display does not switch from the “No-09” screen even when you long-press SW1, there is no error history. 5. Display “EC ： ○○○” (issued number of time) with press SW1. 6. Display “○○○” (hour meter recently) with press SW1. 7. Display “○○○” (hour meter firstly) with press SW1.

Set the maximum and minimum accelerator position for the pedal and dial. 1. Select the “No-07” in the service mode. 2. Set “No-07” with long-press SW1. 3. Display “set-H”. 4. Set “set-H” with turning and holding the two accelerators (pedal and dial) to the maximum turned position, and long-press SW1. 5. Display “set-L”. 6. Set “set-L” with turning and holding the two accelerators (pedal and dial) to the minimum turned position, and long-press SW1. 7. Return to “No-07”, and complete the setting.

3.11 No-10 Clear error history Clear error history of no-09. 1. Select the “No-10” in the Service mode. 2. Set “No-10” with long-press SW1. 3. Display “0：y n”. 4. Select blinking Y or N with press SW1/SW2.

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7. ELECTRICAL SYSTEM

5. Return to “No-09” with long-press SW1.

(1) Flowmeter

3.12 No-11 Read all error history Displays error history (error code, number of times and hour meter) 1. Select the “No-11” in the Service mode. 2. Set “No-11” with long-press SW1. 3. The error code “E：○○○○” is displayed. 4. Display other error code with long press SW1.

2. 3. 4. 5. 6.

(2) AUX outlet

Select the “No-12” in the Service mode. Set “No-12” with long-press SW1. Display “12：----”. Start the engine and set the accelerator to MAX. Press the hydraulic unlock switch and SW3 (AUX switch).

NOTE • If the display does not switch from the “No-11” screen even when you long-press SW1, there is no error history. 5. Display “EC ： ○○○” (issued number of time) with press SW1. 6. Display “ooo” (hour meter recently) with press SW1. 7. Display “ooo” (hour meter firstly) with press SW1.

(1) Hydraulic unlock switch

3.13 No-12 AUX flow rate adjustment Adjust the AUX flow rate. 1. Connect flowmeter to the AUX outlet.

SVL97-2

(2) AUX switch

7. Display “SET--”. 8. Set with long-press SW1. Display “SET-1”, and start to flow the hydraulic oil to the flow-meter automatically. 9. Increase the flow rate gradually. Set with press SW1 when come at 90 L on the flow-meter. 10. Display “SET-2”. 7-75

KiSC issued 09, 2021 A

7. ELECTRICAL SYSTEM

SERVICING 3. Meter panel settings

11. Increase the flow rate gradually again. Set with press SW1 when come at 120 L on the flow-meter. 12. Display “SET-3”. 13. Increase the flow rate gradually again. Set with press SW1 when come at 150 L on the flow-meter. 14. Return to “no-12”, and complete setting.

(3) Hydraulic locked switch/AUX (5) Press SW1 at 120 L (6) Press SW1 at 150 L switch release (4) Press SW1 at 90 L

7-76

SVL97-2 KiSC issued 09, 2021 A

8. AIR CONDITIONING AND HEATER SYSTEM

KiSC issued 09, 2021 A

MECHANISM 1. Air conditioning system

8. AIR CONDITIONING AND HEATER SYSTEM

MECHANISM 1. Air conditioning system 1.1 Air conditioning equipments layout

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

SVL97-2

Air Conditioner Unit Compressor Condenser Receiver

(5) Control panel (6) Fresh air inlet (7) Cabin air inlet

8-1

KiSC issued 09, 2021 A

8. AIR CONDITIONING AND HEATER SYSTEM

(8) Air Conditioner Unit (9) Compressor (10) Condenser (11) Receiver (12) Pressure sensor (13) Water valve

8-2

MECHANISM 1. Air conditioning system

(14) Control cable (15) Control panel (a) Refrigerant IN (b) Refrigerant OUT (c) Coolant IN (d) Coolant OUT

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 1. Air conditioning system

8. AIR CONDITIONING AND HEATER SYSTEM

1.2 Air conditioning system general description The air conditioning temperature is controlled by a cooling cycle using the vaporization heat of refrigerant gas, and a heating cycle using the heat of engine coolant.

(1) Capillary tube (heat sensitive capillary tube) (2) Expansion valve (3) Evaporator (4) Blower motor (5) Compressor

(6) Engine cooling fan (7) Condenser (8) Receiver (9) Dryer (10) Pressure switch (11) Heater core

(12) Hot water valve E: A: Cooled air B: Low pressure and temperaF: ture vapor G: C, Air passes through inner/outer D: air filter

High-pressure and high-temperature gas Hot air Liquid

• Cooling: The cabin air (fresh air) is cooled and dehumidified by the evaporator. • Heating: The cabin air (fresh air) is heated up by the heater core. • Cabin air recirculation: Air enters the Air Conditioner Unit via the duct from the cabin air inlet. • Fresh air intake: Air enters the Air Conditioner Unit via the duct from the fresh air inlet. Cooling cycle • The refrigerant is compressed by the compressor, and is then sent to the condenser. • After being cooled and liquefied by the condenser, the refrigerant is sent to the receiver. • The receiver removes moisture and impurities from the refrigerant, and it is then sent to the expansion valve. • The expansion valve is used to spray refrigerant into the evaporator. • When the sprayed refrigerant vaporizes, the ambient temperature drops rapidly. • The refrigerant is returned to the compressor again. Heater cycle • The flow rate of the coolant heated up by the engine is adjusted by the temperature valve, and the coolant then flows to the heater core. • The ambient temperature is adjusted according to the flow rate of the coolant that is passing through the heater core. • The coolant is returned to the engine again.

SVL97-2

8-3

KiSC issued 09, 2021 A

MECHANISM 2. Compressor

8. AIR CONDITIONING AND HEATER SYSTEM

2. Compressor A device that compresses refrigerant gas

2.1 Compressor specifications

(1) Compressor

(2) Pulley with magnetic clutch

(3) Temperature sensor

Compressor

(4) Safety valve Magnetic clutch

Model

SV07E

Model

K20

Discharge volume

70 cm2

Transmission torque

22 N⋅m or higher

Maximum allowable rpm

6000 rpm

Maximum allowable rpm

6000 rpm

ND-OIL8

Power consumption

35 W

110 to 120 cm3

Effective pulley diameter

ϕ108

1.8 kg

Mass

1.1 kg

Lubricant Mass

Temperature sensor

Safety valve

115 to 125 ℃

Release pressure

3.43 to 4.12 MPa

OFF

153 to 163 ℃

Fully closed pressure

2.75 MPa

8-4

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 2. Compressor

8. AIR CONDITIONING AND HEATER SYSTEM

2.2 Compressor functions and structures

2.3 Magnetic clutch functions and structures Connects pulley electromagnet.

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

Cylinder Intake port Rotor Vane

(5) (A) (B) (C)

Discharge port Compression cycle Discharge cycle Intake cycle

Pressure plate Ball bearing Snap ring Pulley

and

compressor

shaft

(5) Rotor w/ pulley (6) Stator (7) Snap ring

• When the air conditioner is OFF, only pulley rotates because the magnetic clutch is also OFF. • When the air conditioner is ON, the compressor drives because the magnetic clutch is ON.

Capacity change of cylinder and behavior of refrigerant. • When the capacity of cylinder increases, refrigerant gas is taken in from the intake port. • When the capacity of cylinder decreases, the refrigerant gas is compressed. • Under high pressure, the discharge valve is pressed and opens, and the refrigerant gas is discharged from the outlet port.

SVL97-2

8-5

KiSC issued 09, 2021 A

MECHANISM 2. Compressor

8. AIR CONDITIONING AND HEATER SYSTEM

2.4 Safety valve functions and structures

2.5 Temperature sensor functions and structures

A valve that discharges refrigerant into the atmosphere when the pressure of the refrigerant increases abnormally.

Detects the refrigerant temperature and turns the switch on/off.

(1) Temperature sensor (2) Compressor (a) To + battery terminal

A: B: C:

Contact point Bimetallic strip Rod

• The temperature sensor is composed of a bimetallic strip and contacts. • When the temperature reaches the set value, the switch turns off. • When the refrigerant temperature rises abnormally, the Magnet Clutch of the compressor turns off. OFF

153 to 163 ℃ 307 to 325 ℉

120 ± 5 ℃ 248 ± 41 ℉

Operating ranges

(1) (A) (B) (C) (D) (a)

Safety valve Refrigerant leakage route Functional characteristics Amount of refrigerant leaked Pressure 113 L/min. (27.2 U.S.gals/ min., 24.86 Imp.gals/min.)

(b) 2.75 MPa (28.1 kgf/cm2, 399.7 psi) (c) 3.43 MPa (35.0 kgf/cm2, 497.8 psi) (d) 4.12 MPa (42.0 kgf/cm2, 598.0 psi)

• When the refrigerant pressure reaches or exceeds the set value of the spring, the safety valve opens and refrigerant is discharged into the atmosphere. • When the refrigerant pressure is below the set value of the spring, the safety valve is closed, preventing the discharge of refrigerant.

Temperature sensor

Tightening torque

2.6 Compressor oil functions and structures The compressor oil is circulated through the refrigeration system as a lubricant. • Always use R134a-specific compressor oil (synthetic PAG oil). • The R134a-specific oil mixes well with the refrigerant gas, and optimally lubricates the whole system. Oil quantity 110 to 120 cc 0.116 to 0.127 U.S.qts 0.098 to 0.106 Imp.qts

8-6

11.8 ± 1.47 N⋅m 1.2 ± 0.15 kgf⋅m 8.7 ± 1.08 lbf⋅ft

Product name ND-OIL8 <PAG* oil>

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 3. Air conditioning unit

8. AIR CONDITIONING AND HEATER SYSTEM

3. Air conditioning unit 3.1 Air conditioning specifications

(1) Water valve (2) Blower resistor

(a) Refrigerant IN (b) Refrigerant OUT

Cooling capacity

2.7 to 3.3 kW

Compressor 2496 rpm Air flow 225 to 275 m3/h

Heating capacity

2.5 to 3.1 kW

Water flow 6 L/min Air flow 135 to 165 m3/h

Mass

7.0 kg

Blower motor rotating speed

3800 to 4600 rpm

Current

10 A or less

SVL97-2

8-7

KiSC issued 09, 2021 A

MECHANISM 3. Air conditioning unit

8. AIR CONDITIONING AND HEATER SYSTEM

3.2 Evaporator functions and structures

3.4 Blower motor functions and structures

A cooling device that uses vaporization heat generated by evaporation of liquid refrigerant.

An electric motor that rotates the blower fan.

(1) Blower (A) Circuit diagram

(a) Fin (b) Tube

(A) Inlet (B) Outlet

• The evaporator vaporizes the liquid refrigerant sprayed from the expansion valve. • The vaporization heat is used to cool the surrounding air.

3.3 Heater core functions and structures A heat exchanger that uses engine coolant.

(1) Heater core (A) IN

(a) Positive Terminal (b) Negative Terminal

• The blower motor rotates when the relay is turned on. • The rotating speed of the blower motor changes in three levels with the blower resistor. Blower motor Specifications (at 20 ℃) Model

DC ferrite

Rated voltage

13.5 V

No load rotating speed

4700 rpm ± 10%

No load current

3 A or less

Direction of rotation (viewed from drive side)

Left

Rated load torque

185m N⋅m

Rotating speed

4360 rpm ± 10%

Current

9.3 A ± 10%

(B) OUT

• High temperature coolant passes through the heater core from the engine, and heats up the surrounding air.

8-8

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 3. Air conditioning unit

8. AIR CONDITIONING AND HEATER SYSTEM

3.5 Blower resistor functions and structures

3.6 Expansion valve functions and structures A valve for spraying the optimum amount of refrigerant to the evaporator.

(1) MI (2) Unused (3) HI

(4) LO (A) Blower resistor (B) Wiring diagram

• The RPM of blower motor changes due to the resistance change of switching the blower switch. • Level [3] is the strongest air flow among three levels.

(1) A: B: C: D: E:

Evaporator Diaphragm Heat-sensitive rod Spring Body Needle valve

(a) From receiver (high pressure) (b) To compressor (low pressure) (c) To evaporator (d) From evaporator

• Consists of a diaphragm, heat-sensitive rod, and needle valve (ball). • The refrigerant gas is sealed in the upper portion of the diaphragm. • Refrigerant pressure for the outlet of evaporator is acting on the lower portion of the diaphragm. • The refrigerant gas temperature in the upper portion of the diaphragm changes according to refrigerant temperature of the evaporator outlet. • The open space of needle valve changes according to the gas pressure associated with temperature changes.

SVL97-2

8-9

KiSC issued 09, 2021 A

MECHANISM 3. Air conditioning unit

8. AIR CONDITIONING AND HEATER SYSTEM Evaporator outlet temperature • Low (when cooling load is low)

• • •

High (when cooling load is high)

Specifications

Operation

• •

The gas pressure in the diaphragm chamber decreases The gas volume decreases and the heat-sensitive rod moves to the right The needle valve closes, and the refrigerant amount decreases The gas pressure in the diaphragm chamber increases The gas volume increases and the heat-sensitive rod moves to the left The needle valve opens, and the refrigerant amount increases

3.7 Fin thermistor functions and structures Detects temperature of the evaporator fin.

Rated voltage

DC12 V

Measurement conditions

DC13 ± 0.2 V at 25 ± 5 ℃

Temperature detection

OFF R1

4383 ± 131 Ω (2 ℃)

ON R2

(4095 Ω) (3.35 ℃)

Hysteresis

215 ± 5.0 Ω (1 ℃)

Usage conditions Temperature range

-30 to 80 ℃

Voltage range

DC10 to 16 V

Operating voltage limits

DC8 to 16 V (at 25 ℃)

Temperature detection

10 ℃

15 ℃

20 ℃

25 ℃

30 ℃

Resistance

2.96 kΩ

2.34 kΩ

1.87 kΩ

1.50 kΩ

1.22 kΩ

3.8 Hot water valve functions and structures A valve for adjusting the amount of engine coolant that flows to the heater core.

(a) Open (MAX Hot) (b) Closed (MAX Cool)

• Adjusts the amount of engine coolant to change the temperature of the heater core.

(1) Fin thermistor (2) Thermo-amp

(a) Evaporator fin temperature detection portion

• Detects frost caused by excessive cooling of the evaporator.

8-10

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 4. Condenser

8. AIR CONDITIONING AND HEATER SYSTEM

4. Condenser 4.1 Condenser specifications

Refrigerant IN

Refrigerant OUT

Capacitor

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

Tube Fin Gases Vapor/liquid mix Liquid

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

Gaseous refrigerant Liquid refrigerant Inlet (70 ℃, 158 ℉) Outlet (50 ℃, 122 ℉)

• The refrigerant gas is cooled down while passing the condenser, and turns to liquid.

Height

299.8 mm

Width

420.0 mm

5. Receiver

Thickness

16.0 mm

5.1 Receiver specifications

Fin pitch

3.95 mm

4.2 Condenser functions and structures Exchanges high temperature and pressure refrigerant gas to high pressure liquid refrigerant, with cooling it with fresh air.

SVL97-2

Receiver Capacity

550 cc

Actual capacity

370 cc

Moisture absorption capacity

32 g

Airtight

3.53 MPa (36.0 kg/cm2)

Pressure resistance

5.30 MPa (54.0 kg/cm2)

8-11

KiSC issued 09, 2021 A

MECHANISM 5. Receiver

8. AIR CONDITIONING AND HEATER SYSTEM

5.2 Receiver functions and structures Removes moisture, impurities and air from liquid refrigerant. The receiver stores liquid refrigerant.

6. Pressure switch 6.1 Pressure switch specifications

(1) Pressure switch (1) Dryer (2) Receiver tube (3) Strainer

(4) Receiver tank (A) Refrigerant inlet (B) Refrigerant outlet

[Receiver tank] • The rotating speed of the compressor changes with engine speed, so that the required amount of refrigerant also changes. • The refrigerant is stored or supplied according to the required amount of refrigerant.

Pressure switch Low-pressure side OFF pressure

0.196 ± 0.02 MPa

High-pressure side OFF pressure

3.14 ± 0.2 MPa or higher

Airtight

3.53 MPa

Pressure resistance

5.30 MPa

[Dryer] • Synthetic zeolite absorbs moisture that has entered the circuit. • Replace the receiver in case of expansion valve freezing, it means the dryer is not absorbing moisture. [Strainer] • Strainer collects the contamination to prevent breaking the compressor or clogging the expansion valve. • Replace receiver in case of clogged strainer since the strainer is not cleanable. [Sight glass] • You can visually check the refrigerant amount in the circuit.

8-12

SVL97-2 KiSC issued 09, 2021 A

MECHANISM 6. Pressure switch

8. AIR CONDITIONING AND HEATER SYSTEM

6.2 Pressure switch functions and structures Switch for detecting the pressure (high-low) of the liquid refrigerant

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

Diaphragm Plate spring Pin Plate Contact point Spring Terminal 0.19 MPa (2.0 kgf/cm2, 28.4 psi)

Refrigerant pressure

Operation

No-load (abnormally low pressure)

The refrigerant pressure is less than the spring pressure, causing the spring to raise the plate and the upper contact breaks.

(B)

Contacting (normal)

The refrigerant pressure is greater than the spring pressure, causing the pressure plate to be lowered and the upper contact makes.

(C)

Not contacting (abnormally high pressure)

The refrigerant pressure is greater than the conical spring pressure, causing the pin to be pushed down and the lower contact breaks.

(A)

(b) 3.14 MPa (32 kgf/cm2, 455 psi) D: OFF E: ON P: Pressure PS: Pressure switch

• Stops driving the compressor in case of abnormal pressure with turning off the magnet clutch.

SVL97-2

8-13

KiSC issued 09, 2021 A

8. AIR CONDITIONING AND HEATER SYSTEM

8-14

MECHANISM 6. Pressure switch

SVL97-2 KiSC issued 09, 2021 A

SERVICING 1. Troubleshooting

8. AIR CONDITIONING AND HEATER SYSTEM

SERVICING 1. Troubleshooting 1.1 Troubleshooting the air conditioning system 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)

Not cooling effectively (other)

Not heating effectively

Possible causes

Remedy

Blown fuse

Replace

Main air conditioner relay defective

Replace

A/C blower motor damaged

Replace

A/C blower switch broken

Replace

Wiring harness unplugged or poor contact

Repair

Blown fuse

Replace

Magnetic clutch broken

Repair or replace

A/C switch broken

Replace

Pressure switch broken

Replace

Belt slipping

Adjust or replace

Undercharged

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 blower motor damaged

Replace

A/C blower resistor broken

Replace

Undercharged

Check with a manifold gauge

Refrigerant gas leaking from the cooling circuit

Repair 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

Thermistor broken

Replace

Hot water valve damaged

Replace

Condenser clogged with dirt or debris

Clean

Expansion valve broken

Replace

Hot water valve damaged

Replace (Continued)

SVL97-2

8-15

KiSC issued 09, 2021 A

SERVICING 1. Troubleshooting

8. AIR CONDITIONING AND HEATER SYSTEM Problem and/or situation 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)

Not cooling effectively (both low and high pressure levels too high)

Possible causes

Remedy

Servo motor broken

Check and repair

Blower fan switch broken

Check and repair

Air conditioner main relay broken

Replace

Brushes have poor contact

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 disconnection

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

Undercharged

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

Undercharged

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

Refrigerant overcharged

Check with a manifold gauge (Continued)

8-16

SVL97-2 KiSC issued 09, 2021 A

SERVICING 1. Troubleshooting

8. AIR CONDITIONING AND HEATER SYSTEM

Problem and/or situation Not cooling effectively (both low and high pressure levels too low)

Possible causes

Remedy

Undercharged

Check with a manifold gauge

Servo motor broken

Replace

Temperature control dial broken

Replace

Controller of the wire harness has come 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

Repair

Heater hose is bent or broken

Repair or replace

Drain hose bent or broken

Check and repair

Drain hose clogged

Clean

Cannot control temperature (servo motor or temperature control dial defective)

Water leak (water leak inside the cabin)

1.2 Troubleshooting the compressor Problem and/or situation

Noise (compressor on)

Noise (compressor off)

Possible causes

Remedy

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 or add clamp(s)

Blower damaged

Repair or replace

Magnetic clutch, idler pulley or crank pulley bearings damaged or wearing

Replace

2. Fuse 2.1 Checking the fuses CAUTION • Turn the key switch to [STOP] and carry out the work. • Remove the negative terminal of the battery, and carry out the work. Slow-blow fuse 1. Remove the slow-blow fuse and check the conductivity.

SVL97-2

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

Slow-blow fuse 1 Slow-blow fuse 2 Slow-blow fuse 3 Alternator

(5) Closed cabin (6) Condenser motor

8-17

KiSC issued 09, 2021 A

SERVICING 3. Relay

8. AIR CONDITIONING AND HEATER SYSTEM Normal

Conduction

3. Relay 3.1 Checking the relays CAUTION

Normal

Conduction

• Turn the key switch to [STOP] and carry out the work. • Remove the negative terminal of the battery, and carry out the work.

Fuse 1. Remove the fuse and check the conductivity.

(7) Cover

(8) Fuse box

(9) Blower motor

(10) Compressor clutch

8-18

SVL97-2 KiSC issued 09, 2021 A

SERVICING 4. Air conditioning control panel

8. AIR CONDITIONING AND HEATER SYSTEM

Relay box 1. Remove the relay, and measure the resistance of the coil and contact.

(6) Compressor clutch

(1) Cover

(7) Condenser motor

(2) Fuse box

Coil Normal

91 to 112 Ω

Contact point Normal (3) Blower

Non-conduction

(4) Closed cabin

4. Air conditioning control panel 4.1 Checking the air conditioning control panel CAUTION • Turn the key switch to [STOP] and carry out the work. Air conditioner control panel 1. Remove the connector and air conditioner control panel (5) Relay box

SVL97-2

8-19

KiSC issued 09, 2021 A

SERVICING 5. Compressor

8. AIR CONDITIONING AND HEATER SYSTEM 2. Check the conductivity of the A/C switch.

5. Compressor 5.1 Measuring and checking the compressor ■ Checking the magnetic clutch of the compressor

(1) Air conditioner control panel

1. Start the engine. 2. Turn off the A/C switch, and check for abnormal noise and the idle for the pulley visually. 3. Turn on the A/C switch and fan switch, and check if there is any slipping of the pulley and magnetic clutch. 4. If there is any slipping or abnormal noise, fix the problem.

(2) A/C switch

A/C switch Normal

Conduction

OFF

Non-conduction

(1) Magnetic clutch

3. Check the conductivity of the blower switch.

Blower Switch Lo

Normal

8-20

Conduction

SVL97-2 KiSC issued 09, 2021 A

SERVICING 5. Compressor

8. AIR CONDITIONING AND HEATER SYSTEM

■ Adjusting the clearance of the compressor

Removing 1. Disconnect the negative terminal from the battery. 2. Tilt the radiator.

1. Check the clearance with feeler gauge.

3. Disconnect the magnetic clutch's connector. 4. Disconnect the low-pressure and high-pressure pipes from the compressor, and put on the caps immediately. NOTE • Keep dust and moisture refrigeration cycle. (3) Shim

Clearance

Factory spec

out

the

Clearance 0.30 to 0.65 mm 0.0118 to 0.0255 in.

2. If the measured value is deviated from the factory spec, adjust the shim.

(1) Hose (discharge) (2) Hose (suction)

(1) Magnetic clutch mounting screw (2) Hub plate (3) Shim (4) Snap ring

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

(3) M6 bolt (6T)

Rotor Snap ring Stator Compressor

5.2 Removing/Installing the compressor • Connect the manifold gauge and refrigerant recharging/recycling equipment, and collect refrigerant from the refrigeration cycle.

SVL97-2

8-21

KiSC issued 09, 2021 A

SERVICING 5. Compressor

8. AIR CONDITIONING AND HEATER SYSTEM 5. Loosen the tension pulley and remove the air conditioner belt.

(4) Air conditioner belt (5) Tension pulley (6) Adjustment bolt (4) Air conditioner belt (5) Tension pulley

(a) Adjusting tension (b) Adjusting force

(6) Adjustment bolt

6. Remove the compressor from the bracket.

Adjusting tension (a)

7 to 9 mm 0.27 to 0.35 in.

Adjusting force (b)

50 to 60 N 5.1 to 6.1 kgf 11 to 13.5 lbf

5.3 Oil amount in the compressor A specified amount of compressor oil is sealed in the new compressor. 1. Drain the oil from the old compressor and measure it. 2. Drain all of the oil from the new compressor.

(7) Bolt (M8 × 25) × 2 (8) Bolt (M8 × 35)

(9) Compressor

Installing IMPORTANT • Apply compressor oil to the O-rings of the lines. • After tightening the 2 bolts (7), tighten bolt (8). • After charging the refrigerant, check there is no leakage. Bolt (7) Bolt (8)

Tightening torque

16.7 to 19.6 N⋅m 1.7 to 2.0 kgf⋅m 12.3 to 14.5 lbf⋅ft

1. Assemble and adjust the air conditioner belt.

8-22

SVL97-2 KiSC issued 09, 2021 A

SERVICING 6. Air conditioner unit

8. AIR CONDITIONING AND HEATER SYSTEM

3. Return the same amount of oil as the old compressor. NOTE • Old compressor oil remains in the refrigeration cycle. • If you install the new compressor as is, there will be an excessive amount of oil in the refrigeration cycle. • Compressor oil (ND-OIL8) absorbs moisture easily, so the work should be carried out promptly. • Be careful not to allow the oil to become contaminated with dirt or moisture.

(2) Blower motor connector

Normal

Key switch STOP

Key switch RUN

11 to 14 V

6.1.2 Measuring and checking the blower resistor 1. Disconnect the blower resistor connector. 2. After starting the engine, set the fan switch to [3]. 3. Measure voltage of the wire harness. (1) New compressor (2) Old compressor

(a) Excess (unnecessary) oil

6. Air conditioner unit 6.1 Measuring and checking the air conditioning unit 6.1.1 Measuring and checking the blower motor

(1) Fan Switch

1. Disconnect the blower motor connector. 2. After starting the engine, set the fan switch to [3]. 3. Measure voltage of the wire harness.

(2) Blower register connector

(3) Blower register connector

(1) Fan Switch Normal

SVL97-2

Key switch STOP

Key switch RUN

11 to 14 V

8-23

KiSC issued 09, 2021 A

SERVICING 6. Air conditioner unit

8. AIR CONDITIONING AND HEATER SYSTEM

6.2 Removing/Installing the air conditioning unit • Connect the manifold gauge and refrigerant recharging/recycling equipment, and collect refrigerant from the refrigeration cycle. • Drain the coolant.

(2) Bolt (M8 × 20) × 2

(3) Seat

2. Remove bolts, and cover.

• Dismount the cabin.

(4) Bolt (5) Cover

(6) Cover

3. Remove the cable. Removing 1. Remove four bolts and the seat.

(7) Clamp

(8) Cable

(1) Bolt (M8 × 20) × 2

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SVL97-2 KiSC issued 09, 2021 A

SERVICING 6. Air conditioner unit

8. AIR CONDITIONING AND HEATER SYSTEM

4. Remove the drain hose.

(14) Air Conditioner Unit (15) Stud bolt (M10 × 25) × 2 (16) Nut (M10) (17) Bolt (M10 × 30) × 2 (9) Drain hose

(18) Bolt (M10 × 25) × 2 (19) Bracket

Installing

5. Remove the heater hose. 6. Remove two bolts.

IMPORTANT • Apply compressor oil to the O-rings of the lines. • Ensure that the cable and hose do not become kinked. • After charging the refrigerant, check there is no leakage. Bolt (4) Tightening torque Stud bolt (15)

5.0 to 6.0 N⋅m 0.5 to 0.6 kgf⋅m 3.7 to 4.4 lbf⋅ft 25.0 to 31.0 N⋅m 2.5 to 3.2 kgf⋅m 18.4 to 22.9 lbf⋅ft

Apply a threadlocking adhesive to the stud bolts (15). (10) Heater hose (11) Bolt (M8 × 20)

(12) A/C hose pipe

1. Pass the cable through the bracket.

7. Remove all connectors. 8. Remove bolts and nuts, and remove the air conditioner bracket. 9. Remove the Air Conditioner Unit with the A/C hose pipe. NOTE • Remove the Air Conditioner Unit with care to avoid deformation of the A/C hose pipe.

(a) Cable

(20) Bracket

2. Set the lever to "close" position, and while pulling the cable, fit it to the clamp. 3. Set the air conditioner panel side to the cooling direction, and clamp the cable.

SVL97-2

8-25

KiSC issued 09, 2021 A

SERVICING 6. Air conditioner unit

8. AIR CONDITIONING AND HEATER SYSTEM

6.3 Air conditioning unit parts drawing The Air Conditioner Unit consists of the blower, evaporator, expansion valve, and heater core.

(8) Cable (20) Lever (b) 0 mm (0 in.) (c) 90°

(d) Pull (e) Close direction (f) Open direction

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

Case sub-assy (Lower case) Case sub-assy (Upper case) Blower assy Evaporator assy Core sub-assy, heater

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

Tube and accessories Filter, air (cabin air) Expansion valve Thermistor assy

7. Condenser and receiver 7.1 Measuring and checking the condenser 7.1.1 Measuring and checking the condenser fan motor (8) Cable (21) Air conditioner control panel (b) 0 mm (0 in.)

8-26

(g) Cooling (h) Heating

1. Disconnect the condenser fan motor connector. 2. After starting the engine, turn on the A/C switch and set the fan switch to [3].

SVL97-2 KiSC issued 09, 2021 A

SERVICING 7. Condenser and receiver

8. AIR CONDITIONING AND HEATER SYSTEM

3. Measure voltage of the wire harness.

(1) Fan Switch

(2) A/C switch (1) (2) (3) (4)

Condenser Bolt (M8 × 35) ×4 Flange bolt (M6 × 25) ×2 Bolt (M6 × 12) ×8

(5) A/C hose (discharge) (6) A/C hose (liquid)

3. Remove bolts and flange bolts, and remove the A/C hose. 4. Remove two bolts and the receiver.

(3) Condenser fan motor connector

Normal

Key switch STOP A/C switch OFF

Key switch RUN A/C switch ON

11 to 14 V

7.2 Removing/Installing the condenser and the receiver • Connect the manifold gauge and refrigerant recharging/recycling equipment, and collect refrigerant from the refrigeration cycle. Disconnecting 1. Remove two flange bolts, and the A/C hose. 2. Remove four bolts, and the condenser.

SVL97-2

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

A/C hose (liquid) A/C hose (receiver) Flange bolt (M6 × 25) Bolt (M6 × 25)

(10) Bolt (M8 × 25) ×2 (11) Receiver

Installing IMPORTANT • Apply compressor oil to the O-rings of the lines. • Ensure that the cable and hose do not become kinked. • After charging the refrigerant, check there is no leakage.

8-27

KiSC issued 09, 2021 A

8. AIR CONDITIONING AND HEATER SYSTEM

Bolt (2)

10.0 to 12.5 N⋅m 1.0 to 1.3 kgf⋅m 7.4 to 9.2 lbf⋅ft

Flange bolt (3)

3.9 to 6.9 N⋅m 0.4 to 0.7 kgf⋅m 2.9 to 5.1 lbf⋅ft

Bolt (4)

Tightening torque

SERVICING 7. Condenser and receiver

3.9 to 6.9 N⋅m 0.4 to 0.7 kgf⋅m 2.9 to 5.1 lbf⋅ft

Flange bolt (8)

3.9 to 6.9 N⋅m 0.4 to 0.7 kgf⋅m 2.9 to 5.1 lbf⋅ft

Bolt (9)

3.9 to 6.9 N⋅m 0.4 to 0.7 kgf⋅m 2.9 to 5.1 lbf⋅ft

1. Assemble the receiver.

(10) Bolt (M8 × 25) ×2 (11) Receiver (a) 10.0 mm (0.39 in.)

8-28

(b) 45°

SVL97-2 KiSC issued 09, 2021 A

SERVICING 8. Air conditioning hose

8. AIR CONDITIONING AND HEATER SYSTEM

8. Air conditioning hose 8.1 Removing/Installing the air conditioning hose • Connect the manifold gauge and refrigerant recharging/recycling equipment, and collect refrigerant from the refrigeration cycle. Disconnecting 1. Disconnect low-pressure and high-pressure hoses, and put on the caps immediately. NOTE • Keep dust and moisture out of the refrigeration cycle and air conditioning equipment.

(1) Hose (suction) (2) Hose (liquid, pressure)

(3) Hose (discharge) (4) Hose (liquid)

Connecting IMPORTANT • Do not mix up the high-pressure and low-pressure hoses. • Tighten carefully so as to avoid twisting the hoses. • Apply compressor oil to the O-rings of the lines.

SVL97-2

8-29

KiSC issued 09, 2021 A

SERVICING 9. Heater hose

8. AIR CONDITIONING AND HEATER SYSTEM

9. Heater hose 9.1 Removing/Installing the heater hose • Stop the engine and wait until the radiator and coolant cools down before working. Disconnecting 1. Drain coolant from the radiator. 2. Disconnect the heater hose. NOTE • Coolant will remain in the heater hose and heater core, so when removing the hose, check the situation in the vicinity before draining the coolant.

(1) Coolant valve assy (2) Urea tank

(3) Tape (Gray) (4) Tape (Yellow)

(5) Tape (Black) (6) Tape (Blue)

(7) Tape (Red)

Connecting IMPORTANT • Firmly insert the hose.

8-30

SVL97-2 KiSC issued 09, 2021 A

APPENDICES 1. SERVICE REFERENCE DATA 2. HYDRAULIC CIRCUIT DIAGRAM 3. WIRE HARNESS 4. DISPLAY FLOW CHART 5. CONNECTOR CHART 6. ELECTRICAL CIRCUIT DIAGRAM 1) Open cab specification 2) Closed cab specification (for U.S.) 3) Closed cab specification (for Canada) 7. JOINT CONNECTORS 8. TESTER CODE AND ERROR CODE

KiSC issued 09, 2021 A

1. SERVICE REFERENCE DATA [1] PISTON PUMP FLOW RATE

[2] AUX FLOW RATE

<Condition> Machine: SVL97-2 (Hi-flow model) Hydraulic oil temperature: 50.4 °C (122.7 °F) Engine speed: 2480 rpm AUX mode: R: 9, L: 9

<Condition> Machine: SVL97-2 (Hi-flow model) Hydraulic oil temperature: 50±5 °C (122.7±41 °F) Engine speed: 2480 rpm

(Reference)

100

(Reference)

(b)

Flow rate [L/min]

[3] SPECIFICATIONS

60 40

Engine speed

Hydraulic cylinder (Stroke)

(c)

(a)

Lift arm Bucket

Specifications MIN

1125 to 1175 rpm

MAX

2455 to 2505 rpm

Raise

3.6 to 4.8 sec

Lower

2.9 to 3.9 sec

Crowd

1.9 to 2.7 sec

Dump

1.6 to 2.4 sec

Standard

15.5 mm 0.61 in.

Limit

77.5 mm 3.05 in.

Standard

10.5 mm 0.41 in.

Limit

52.5 mm 2.07 in.

Lift arm Hydraulic cylinder (Drift)

20 0

Items

Bucket 0

Pressure [MPa]

10 11 12 13 14

AUX limit value

Pressure (MPa)

Engine speed (RPM)

Flow rate (L/min)

2.5

2480

2471

2455

2465

(a) 90 L/min (23.3 gal/min) (b) 152 L/min (40 gal/min) (c) ±13 L/min (3.4 gal/min)

Main relief valve

27.5±0.5 MPa 280.5±5.1 kgf/cm2 3771±73 psi

29.5±0.5 MPa 300.9±5.1 kgf/cm2 4279±73 psi

Lift arm

Travel straightness

600 mm 23.6 in.

Distance: 20 m Forward, Backward, High speed

Low speed

Forward

High speed

Forward

Over load relief valve

Bucket AUX

Rod A2 Bottom B2 B3

23.1±0.6 MPa 235.62±6.1 kgf/cm2 3350±90 psi

23.1 MPa 235.6 kgf/cm2 3350 psi

32.5 MPa 331.4 kgf/cm2 4714 psi

37 MPa 377.2 kgf/cm2 5366 psi

Charge relief valve

2.4±0.07 MPa 24.0±0.7 kgf/cm2 350±10 psi

Pilot relief valve

3.5±0.29 MPa 36.0±3.0 kgf/cm2 510±42 psi

3.7 MPa 37.7 kgf/cm2 537 psi

Right HST pump relief valve

Left

Forward Backward Forward

Backward

8.2 to 10.0 sec/20m 5.6 to 6.9 sec/20m

100 L

E/G speed: MAX Oil temp: 50±5 °C Pressure: 9.0 Mpa (92 kgf/cm2, 1300 psi) Forward, Backward

LS relief valve

Backward

HST pump flow rate

Rod A1 Bottom B1

Bucket: Full Time: 10 min

Low speed Measurements

E/G speed: MAX Oil temp: 50±5 °C) (122±41 °F)

0 mm 0 in.

[4] RELIEF PRESSURE Specification

Travel block performance

Travel speed

Items

Remarks

Pilot valve input pressure

High speed

98 L

Travel pilot valve

2.7 MPa 27.5 kgf/cm2 391.5 psi

Attachment pilot valve

3.7 MPa 37.7 kgf/cm2 537 psi

E/G speed: MAX Oil temp: 50±5 °C Pressure: 12.0 Mpa (120 kgf/cm2, 1700 psi) Forward, Backward

E/G speed: MAX Oil temp: 50±5 °C

Backward

SVL97-2 KiSC issued 09, 2021 A

2. HYDRAULIC CIRCUIT DIAGRAM No. Relief Pressure

No. Relief Pressure

27.5 MPa 280.5 kgf/cm 2 3989 psi

32.5 MPa 331.0 kgf/cm 2 4710 psi

29.5 MPa 300.9 kgf/cm 2 4279 psi

32.5 MPa 331.0 kgf/cm 2 4710 psi

29.5 MPa 300.9 kgf/cm 2 4279 psi

32.5 MPa 331.0 kgf/cm 2 4710 psi

29.5 MPa 300.9 kgf/cm 2 4279 psi

32.5 MPa 331.0 kgf/cm 2 4710 psi

29.5 MPa 300.9 kgf/cm 2 4279 psi

2.4 MPa 24.0 kgf/cm 2 350 psi

29.5 MPa 300.9 kgf/cm 2 4279 psi

3.5 MPa 36.0 kgf/cm 2 510 psi

29.5 MPa 300.9 kgf/cm 2 4279 psi

4.9 MPa 50.0 kgf/cm 2 711 psi

23.1 MPa 235.62 kgf/cm 2 3350 psi

98.1 MPa 100.0 kgf/cm 2 14.2 psi

(1)

(3)

HST PUMP HST MOTOR RH PILOT SYSTEM PORT LH Port A B C D A B A B M4 M14 M14 M5 M5 M15 M15 M4

(2)

(4)

(1) TRAVEL P/V

(2) (3) (4)

4 1 1 2 2 3 3 4

3: Hydraulic unlock

2: Parking brake

1: Travel speed shift

A3 SOL 3

A2 SOL 2

A1 SOL 1 T2

Hydraulic Quick Hitch

Pilot Valve (attachment) Bucket Crowd

Bucket Lift Arm Dump Down

LEVER SLIDER

Pilot Valve (travel)

ATTACHMENT P/V

CONTROL VALVE

1 2 3 4

ACTUATO PORT PILOT Port A1 B1 A2 B2 A3 B3 Pa2 Pb1 Pb2 Pa1 Pa3 Pb3

Lift Arm Up

100 mesh

P 1 2

3 4

100 mesh

A: LH-FW

HST Motor

Lift arm

B T

Auxiliary

Bucket

FEMALE DRAIN MALE

3: Lock 2: AUX (M) (Travel)

1: AUX (F)

T B: LH-BW

100 mesh

Regulator

P I PA A

M5 M4 X2 X1

M12

M15

M14

X12

X11 P

A1 B1

Pa1

A2 B2

Pa2

A3 B3

Pa3

PG LSG

PL T

100 mesh

Pcl Pd

PP PLS

M 67.1 kw@2400 rpm

Pump M2 M6

M11

HST Pump

150 mesh

Pb1

Pb2

Pb3

HST Motor Pb

A: RH-BW

B: RH-FW

SVL97-2 KiSC issued 09, 2021 A

3. WIRE HARNESS MAIN HARNESS Air conditioning system specification

(17)

(16)

(70)

(15)

(61)

(71)

Hydraulic quick hitch specification

(64)

(65)

(62)

(63)

(68) (14)

(66)

(69)

(60) 120Ω

(72)

(67)

(12) (11)

(13)

(59)

(53) (54) (10)

(76)

(52)

(55)

(75)

(57)

(56)

(7)

(43)

(45)

(51)

(74)

(6)

(58)

(44)

(50)

(47)

(42)

(49)

(46)

(34)

(18) (48)

(73)

(8)

(35) (9)

(41)

(36) (5) (1)

(23) (37)

(4) (19)

(22)

(3)

(2)

(38) (20)

(28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42) (43) (44) (45) (46) (47) (48) (49) (50) (51) (52) (53) (54)

232C TO_(E-OUT_ROOM) STARTER-SW SW(HYDRAULIC_LOCK) SW(PARKING) SW(WORK_LIGHT) SW(ARM_UP) PILOT CONTROL LEVER RH TO_J/C(CAN2_METER) TO_DIODE(AUX4_J) BONDER(B) SW(ARM_DOWN) BUZZER METER SCR_METER SW(FLOW_SET) SW(SETTING/DISPLAY) ACCEL_SENSOR_H BLOWER_MOTOR THERMOSTAT BLOWER_RESISTER BONDER(E) BONDER(C) BONDER(F) BONDER(D) DUAL_PRESSURE_SW OPC_SW

(55) (56) (57) (58) (59) (60) (61) (62) (63) (64) (65) (66) (67) (68) (69) (70) (71) (72) (73) (74) (75) (76)

TO_(AIRRIDE-) TO_(AIRRIDE+) SEAT_BAR_L_SW SPEAKER_L RADIO_CONVERT SW(A/C) CIGGER_SOCKET SW(BACK_PRESSURE) PILOT CONTROL LEVER LH SW(DPF_INHIBIT) SW(WIPER) SW(HITCH) TO_RESISTOR(OPC) ECU(MAIN) TO_(ENG3) TO_(ENG4) TO_(ENG2) TO_(ENG1) REAR_WORK_L(RH)3 TO_(TAIL_L_H3) TO_(TAIL_L_H2) REAR_WORK_L(RH)2

(40)

(21) (33)

(1) R_WORK_LAMP_R(B) (2) R_WORK_LAMP_R(A) (3) TO_(TAIL_L) (4) E-OUT(ROOF)B (5) E-OUT(ROOF)A (6) SW(ROOM_LAMP) (7) ROOM_LAMP (8) R_WORK_LAMP_L(B) (9) R_WORK_LAMP_L(A) (10) TO_(WIPER_H) (11) SPEAKER_R (12) F_WORK_LAMP_L(B) (13) F_WORK_LAMP_L(A) (14) HORN+ (15) HORN(16) F_WORK_LAMP_R(B) (17) F_WORK_LAMP_R(A) (18) WASHER_MOTOR (19) TO_DIODE(HORN) (20) GND(A) (21) GND(B) (22) BONDER(A_MAIN) (23) R&FBOX (24) SEAT_BAR_R_SW (25) SERVICE_TOOL(CAP) (26) SERVICE_TOOL (27) CAN_TOOL

(39) (32)

(31)

(30)

(24) (25)

(29)

(26) (27)

(28)

SVL97-2 (1/5) KiSC issued 09, 2021 A

ENGINE HARNESS (1) GND(4) (2) GND(3) (3) GND(2) (4) GND(1) (5) TANK_SENSOR (6) WATER_SEPARATOR (7) FUEL_PUMP (8) COOLANT_VALVE (9) SUCTION_HEATER (10) RETURN_HEATER (11) DELIVERY_HEATER (12) POST_NOX_SENSOR (13) TO_RESISTOR(120) (14) TO_(ARM_H2) (15) TO_(ARM_H1) (16) TO_DIODE(1) (17) BONDER(ACU_COMP) (18) PRE_NOX_SENSOR (19) TO_J/C(S_GND2) (20) DEF_PUMP_UNIT (21) ACU (22) BONDER(ACU_HEATER) (23) FUEL_SENSOR (24) TO_(MAIN1) (25) TO_(MAIN3) (26) TO_(MAIN2) (27) TO_(MAIN4) (28) TO_(UNLOAD) (29) TO_J/C(CAN2_H) (30) TO_J/C(CAN2_L) (31) TO_J/C(CAN1_L) (32) TO_J/C(CAN1_H) (33) SOLENOID(Lock) (34) SOLENOID(Unlock) (35) AIR_FLOW_SENSOR (36) SOLENOID(StallGuard) (37) SOLENOID(AUX-R) (38) SOLENOID(AUX-L) (39) FLOAT_SOL (40) SENSOR_OIL_TEMP(TANK) (41) ACCEL_SENSOR_F (42) INTAKE_HEATER_RELAY_C

(43) (44) (45) (46) (47) (48) (49) (50) (51) (52) (53) (54) (55) (56) (57) (58) (59) (60) (61) (62) (63) (64) (65) (66) (67) (68) (69) (70) (71) (72) (73) (74) (75) (76) (77) (78) (79) (80) (81) (82) (83) (84)

INTAKE_HEATER_RELAY_B INTAKE_HEATER_RELAY_A SBF(2) SBF(1) TO_(BAT_H) SBF(3) FUSEBOX BACK_BUZZER FAN_MOTOR RELAY_BOX BONDER(A) ECU(CRS_91P) ECU(CRS_105P) TO_J/C(SHIELD_GND) COOLANT_TEMP_SENSOR G_SENSOR NE_SENSOR OIL_SW ALTERNATOR_B ALTERNATOR_A STARTER_A PRV SCR_TEMP_SENSOR DEF_INJECTOR PCV BOOST_SENSOR INTAKE_AIR_TEMP_SENSOR SENSOR_DOC_EX_TEMP_T0 SENSOR_DOC_EX_TEMP_T1 SENSOR_DPF_EX_TEMP_T2 DPF_DIFF_PRESS_SENSOR EGR_VALVE COMPRESSOR CCV_HEATER1 CCV_HEATER2 CCV_HEATER3 CRS_INJECTOR INTAKE_THROTTLE_VALVE RAIL_PRESSURE_SENSOR HEATER_INTAKE_AIR TO_(RESISTOR) CCV_PRESSURE_SW

(51)

(33)

(50)

(52)

(48)

(31)

(35)

(46)

(44)

(45)

(47)

(43)

(41)

(42) (36)

(56)

(84)

(37) (38)

Air conditioning system specification

(40)

(30)

(39)

(28)

Hydraulic quick hitch specification Only for KCL (Kubota Canada Limited)

(49)

(32)

(34)

(55)

(29)

(17)

(53)

(27)

(54)

(18) (26) (19)

(22)

(16) (25) (13)

120Ω

(20)

(59)

(15)

(63)

(58)

(66)

(24) (11)

(65)

(23) (75) (14)

(12) (21)

(57) (76)

(1)

(62)

(82)

(2)

(72)

(77)

(6)

(3)

(83)

(78)

(10)

(73)

(74)

(64)

(60)

(61)

(9)

(4)

(67)

(71) (70)

(81)

(5) (7)

(8)

(79)

(80)

(68)

(69)

SVL97-2 (2/5) KiSC issued 09, 2021 A

AIR CLEANER INDICATOR HARNESS (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)

TO_(MAIN_HARNESS) STROBE ATTACHMENT LAMP(INDICATOR) FUSE(INDICATOR) TO_(IND2+) TO_(IND2-) TO_(IND_MAIN+) TO_(IND_MAIN-) TO_(IND_L-) TO_(IND_L+) TO_(IND2+_L) TO_(IND2-_L) SW(PRESSURE+) SW(PRESSURE-)

(1)

(2)

(3)

(6)

(8)

(10)

(12)

(14)

(7)

(9)

(11)

(13)

(15)

(4)

(5)

SVL97-2 (3/5) KiSC issued 09, 2021 A

(1) R_WORK_LAMP_R(B) (2) R_WORK_LAMP_R(A) (3) TO_(TAIL_L)

7115-1050-02

(14) HORN+

7113-1020-02

(15) HORN-

7323-2010

7115-1050-02

(5) E-OUT(ROOF)A

7115-1050-02

7323-2010

7323-6234-40

7115-1050-02

7113-1020-02

(31) SW(HYDRAULIC_LOCK) (32) SW(PARKING)

7323-9423

7323-8307

7323-9327

7323-1540

7383-7449-30

7323-5525

7323-7729-40

7323-8307

7383-1080-80

7323-8522-40

7383-1050

7383-7222-10

7323-8322

7383-7222-60

7323-7923-40

7323-8307

(8) R_WORK_LAMP_L(B) (9) R_WORK_LAMP_L(A) (10) TO_(WIPER_H)

7115-1050-02

(21) GND(B)

7009-9228-02

7009-9229-02

(35) PILOT CONTROL (36) TO_J/C LEVER RH (CAN2_METER)

7323-7923-40

7383-7047

7323-8307

7323-1223-40

(66) SW(HITCH)

7323-8307

7113-1020-02

7323-1640

(11) SPEAKER_R

7323-2820

(12) F_WORK_LAMP_L(B) (13) F_WORK_LAMP_L(A)

7115-1050-02

(24) SEAT_BAR_R_SW (25) SERVICE_TOOL (26) SERVICE_TOOL (27) CAN_TOOL (CAP)

7383-8850-30

(48) BLOWER_RESISTER (53) DUAL_PRESSURE_ (54) OPC_SW SW

(61) CIGGER_SOCKET (62) SW(BACK_PRESSURE) (63) PILOT CONTROL (64) SW(DPF_INHIBIT) (65) SW(WIPER) LEVER LH

(23) R&FBOX

7329-1111

7383-8331-40

7323-7729-40

(55) TO_(AIRRIDE-)

7116-2270-02

(67) TO_RESISTOR(OPC) (69) TO_(ENG3)

7323-2820

7322-7340-30

7323-7340-30

(37) TO_DIODE(AUX4_J) (39) SW(ARM_DOWN) (40) BUZZER

7382-3030

7383-7222-60

(56) TO_(AIRRIDE+)

7114-2100

(70) TO_(ENG4)

7382-3040

7323-2820

7323-8520-40

7383-8331-40

7322-7923-40

7323-7740-40

(42) SCR_METER

(41) METER

7383-8389-40

(57) SEAT_BAR_L_SW (58) SPEAKER_L

(71) TO_(ENG2)

7113-1020-02

(28) 232C

7323-2820

7383-4849-40

(59) RADIO_CONVERT

7322-1094

(72) TO_(ENG1)

7382 8745-10

(68) ECU(MAIN)

7154-0089-30

(1) TO_(MAIN_HARNESS) (2) STROBE

7123-6060

7322-9422

(33) SW(WORK_LIGHT) (34) SW(ARM_UP)

(43) SW(FLOW_SET) (44) SW(SETTING/DISPLAY) (45) ACCEL_SENSOR_H (46) BLOWER_MOTOR (47) THERMOSTAT

(60) SW(A/C)

MAIN HARNESS

(6) SW(ROOM_LAMP) (7) ROOM_LAMP

(16) F_WORK_LAMP_R(B) (17) F_WORK_LAMP_R(A) (18) WASHER_MOTOR (19) TO_DIODE(HORN) (20) GND(A)

(29) TO_(E-OUT_ROOM) (30) STARTER-SW

7322-6060

7115-1050-02

(4) E-OUT(ROOF)B

7319-1148-30

(3) ATTACHMENT

PTM06-3S

DTP06-2S-E003

(4) LAMP(INDICATOR) (6) TO_(IND2+)

7119-3020

7113-1020

AIR CLEANER INDICATOR HARNESS (7) TO_(IND2-)

7115-1050

(8) TO_(IND_MAIN+)

7115-1050

(9) TO_(IND_MAIN-)

7113-1020

(10) TO_(IND_L-)

7113-1020

(11) TO_(IND_L+)

7115-1050

(12) TO_(IND2+_L)

7115-1050

(13) TO_(IND2-_L)

7113-1020

(14) SW(PRESSURE+)

7113-1020

(15) SW(PRESSURE-)

7115-1050

SVL97-2 (4/5) KiSC issued 09, 2021 A

(1) GND(4)

(2) GND(3)

7009-1836

(14) TO_(ARM_H2)

(3) GND(2)

7009-1836

(15) TO_(ARM_H1)

7322-6060

7322-6040

(4) GND(1)

7009-1836

(16) TO_DIODE(1)

7323-7729-40

(5) TANK SENSOR

7009-1836

7329-2812-30

ENGINE HARNESS

(6) WATER_SEPARATOR (7) FUEL_PUMP

7323-8321-30

7329-3023

(18) PRE_NOX_SENSOR (19) TO_J/C(S_GND2) (20) DEF_PUMP_UNIT (23) FUEL_SENSOR

7383-0501-30

7383-8850-30

7387-0585-30

7323-9423

(8) COOLANT_VALVE (9) SUCTION_HEATER (10) RETURN_HEATER (11) DELIVERY_HEATER (12) POST_NOX_SENSOR (13) TO_RESISTOR(120)

7387-1868-30

(24) TO_(MAIN1)

7383-8745-10

7329-1317-30

(25) TO_(MAIN3)

7383-3030

7329-1317-30

(26) TO_(MAIN2)

7323-7923-40

(30) TO_J/C(CAN2_L) (31) TO_J/C(CAN1_L) (32) TO_J/C(CAN1_H) (33) SOLENOID(Lock) (34) SOLENOID(Unlock) (35) AIR_FLOW_SENSOR (36) SOLENOID(StallGuard) (37) SOLENOID(AUX-R) (38) SOLENOID(AUX-L) (39) FLOAT_SOL

7383-8850-30

(43) INTAKE_HEATER_ (44) INTAKE_HEATER_ (47) TO_(BAT_H) RELAY_B RELAY_A

7009-1351-02

(63) STARTER_A

7323-2710

(76) CCV_HEATER1

7383-9184-30

7323-2228

(64) PRV

7322-4123-30

7383-2090-30

(48) SBF(3)

7354-5868-30

(65) SCR_TEMP_SENSOR (66) DEF_INJECTOR

7387-1495-40

(77) CCV_HEATER2

7383-9184-30

(45) SBF(2)

7383-5261-30

(78) CCV_HEATER3

7383-9184-30

7323-8321-30

(67) PCV

7389-0944-30

7387-1495-30

7383-8355-30

(51) FAN_MOTOR

7329-3393-40

7323-8321-30

7383-1407

7383-1968-30

7323-8321-30

(56) TO_J/C(SHIELD_GND) (57) COOLANT_TEMP_ (58) G_SENSOR SENSOR

7383-7080-40

7383-8728-10

7383-4673-30

(68) BOOST_SENSOR (69) INTAKE_AIR_ TEMP_SENSOR

(70) SENSOR_DOC_ EX_TEMP_T0

(71) SENSOR_DOC_ EX_TEMP_T1

7383-1032-30

7383-7027-40

7383-7026-30

(79) CRS_INJECTOR (80) INTAKE_THROTTLE_ (81) RAIL_PRESSURE_ (82) HEATER_INTAKE_AIR (83) TO_(RESISTOR) VALVE SENSOR

(46) SBF(1)

7354-5909-30

7383-2090-30

(50) BACK_BUZZER

7387-9921-30

(21) ACU

7009-1351-02

7323-2820

(49) FUSEBOX

7383-7028-10

7329-1317-30

(27) TO_(MAIN4)

7323-8321-30

(59) NE_SENSOR

7383-4673-40

(72) SENSOR_DPF_ EX_TEMP_T2

7383-7023

7383-3040

7383-0501-30

(28) TO_(UNLOAD)

7323-7444-40

7323- 6423-30

(29) TO_J/C(CAN2_H)

7383-8850-30

(40) SENSOR_OIL_TEMP (41) ACCEL_SENSOR_F (42) INTAKE_HEATER_ (TANK) RELAY_C

7383-8728-10

(60) OIL_SW

7323-2710-40

7383-7449-30

7009-1352-02

(73) DPF_DIFF_ (74) EGR_VALVE PRESS_SENSOR

7387-5800-30

7009-1351-02

(61) ALTERNATOR_B (62) ALTERNATOR_A

7383-1740-10

7323-6224-40

(75) COMPRESSOR

7323-8918-30

(84) CCV_PRESSURE _SW

7115-1050-02

(54) ECU(CRS_91P)

(55) ECU(CRS_105P)

7354-5909-30

(52) RELAY_BOX

7154-5199

7383-3500-30

7354-5845-30

7387-9602-30

7389-3066-30

SVL97-2 (5/5) KiSC issued 09, 2021 A

4. DISPLAY FLOW CHART [Normal Mode]

Hour-meter

Engine RPM

AUX Setting

Error message

SW Name Operation

KEY “RUN”

SW1

SW2

SW3

Only when error occurs

Short Press Hold

Symbol

Function Mode Select / Number-UP Mode Select

Short Press Hold

Number-DOWN Return

Short Press

Activate AUX

Hold

[User setting Mode] AUX1

AUX2

Setting Right

Setting Left

Setting neutral

Waiting for AUX Activation

Ready for Setting

Setting Left

Setting Right

Normal Mode

AUX Flow-Setting

Tester Mode

no-1～no-12

AUX knob Setting

AUX Start-up point Setting

AUX3

AUX4

AUX5

KEY “RUN”

[Service Mode] SW3 + KEY “RUN”

Setting Right

Engine RPM: MAX + Hydraulic unlock switch: ON Fine adjustment of AUX feeling

Waiting for AUX Activation Engine RPM: MAX + Hydraulic unlock switch: ON

＜Next Page＞

SVL97-2 (1/2) KiSC issued 09, 2021 A

SW Name Operation SW1

[Service Mode]

SW2

＜Contenued＞ SW3

HST Start-up point Setting

Waiting for travel operation

Ready for Setting

Pressure rising (First time)

Pressure rising (Second time)

Symbol

Short Press Hold Short Press Hold Short Press

Function Mode Select / Number-UP Mode Select Number-DOWN Return Activate AUX

Hold

Pressure rising (Third time)

Finish

Releasing parking brake Fail

Accerator lever/pedal Setting

MAX Position

MIN Position

Error log

Error Code

Error Count

Hour meter of recent error

First hour meter after deleting

Deleting error log

Delete：NO

Delete：YES

Error log (All history)

Error Code

Error Count

Hour meter of recent error

First hour meter after deleting

AUX flow Adjustment

Waiting for AUX Activation

Ready for Setting

Setting 90L

Setting 120L

Setting 150L

Engine RPM: MAX + Hydraulic unlock switch: ON

SVL97-2 (2/2) KiSC issued 09, 2021 A

5. CONNECTOR CHART 232C 2

BAT+_A

COOLANT_TEMP_SENSOR

TO_DIODE(HORN)

F_WORK_LAMP_L(A)

GND(BAT)

INTAKE_HEATER_RELAY_C

J/C(CAN2_METER)

PCV

1 2

TO_RESISTOR(OPC) 1

SEAT_BAR_L_SW

SOLENOID(HydraulicLock)

YAZAKI_62 7123-7740-40

YAZAKI 7003-1210-02

AMP_EJ II 178449-6

SUMITOMO 6098-0017

YAZAKI CA

YAZAKI 7003-2110-02

LA_M6

YAZAKI_RH 7182-9630-30

YAZAKI_090 II 7287-1495-30

YAZAKI_CN(A) 7123-2820

SUMITOMO,DL040 6189-0734

YAZAKI_HS 7283-2090-30

CAP(232C)

BAT+_B

CRS_INJECTOR

DPF_DIFF_PRESS_ SENSOR

F_WORK_LAMP_L(B)

GND(ENGINE)

INTAKE_THROTTLE_VALVE

TO_J/C(CAN2_METER)

POST_NOX_SENSOR

RETURN_HEATER

SEAT_BAR_R_SW

SOLENOID(Lock)

10 9

YAZAKI 7234-2604-40

YAZAKI 7003-1941-02

YAZAKI 7283-1407

AMP 1813271-1

YAZAKI CB

YAZAKI 7003-2112-02

YAZAKI_2.3 II (090 II) 7283-1968-30

YAZAKI_RH 7283-8850-30

HIRSCHMANN 872-860-541

DEUTSCH_DT DT06-2S-CE06

SUMITOMO,DL040 6189-0734

YAZAKI_HS 7283-2090-30

ACCEL_SENSOR_F

BAT-

DEF_INJECTOR

DUAL_PRESSURE_SW

F_WORK_LAMP_R(A)

GND(FRAME)

J/C(CAN1_H)

J/C(SHIELD_GND)

PRE_NOX_SENSOR

ROOM_LAMP

SENSOR_DOC_ EX_TEMP_T0

SOLENOID(Parking)

YAZAKI_2.3 II (090 II) 7283-7449-30

YAZAKI 7003-1210-02

AMP 2098557-1

SUMITOMO 6189-0094

YAZAKI CA

YAZAKI 7003-2110-02

YAZAKI_RH 7182-9631-40

YAZAKI_2.3 II (090 II) 7382-1480-40

HIRSCHMANN 872-860-541

YAZAKI_090 7123-8522-40

YAZAKI_2.3 II (090 II) 7283-7026-30

YAZAKI_HS 7283-2090-30

ACCEL_SENSOR_H

BOOST_SENSOR

DEF_PUMP_UNIT

E-OUT(ROOF)A

F_WORK_LAMP_R(B)

G_SENSOR

TO_J/C(CAN1_H)

TO_J/C(SHIELD_GND)

PRV

R_WORK_LAMP_L(A)

SENSOR_DOC_ EX_TEMP_T1

SOLENOID(StallGuard)

14 13 12 11 10 9

YAZAKI_2.3 II (090 II) 7283-7449-30

SUMITOMO_090 II 3F 6189-0099

DELPHI 15326856

YAZAKI CB

SUMITOMO_TS025 6189-1129

YAZAKI_RH 7283-8850-30

YAZAKI_2.3 II (090 II) 7283-7080-40

YAZAKI_090 II 7287-1495-40

YAZAKI CA

YAZAKI_2.3 II (090 II) 7283-7028-10

AMP 174352-2

AIRRIDE+

BUZZER

DELIVERY_HEATER

E-OUT(ROOF)B

GND(1)

HEATER_INTAKE_AIR

J/C(CAN1_L)

J/C(S_GND2)

RAIL_PRESSURE_ SENSOR

R_WORK_LAMP_L(B)

SENSOR_DPF_ EX_TEMP_T2

SOLENOID(TravelSpeed)

YAZAKI 7114-2100

YAZAKI_CN(A) 7123-2820

DEUTSCH_DT DT06-2S-CE06

YAZAKI CB

YAZAKI 7009-1836

LA_M6

YAZAKI_RH 7182-9631-40

JST 03AHG-B-1B-K

YAZAKI CB

YAZAKI_2.3 II (090 II) 7283-7023

YAZAKI_HS 7283-2090-30

AIRRIDE-

CAN_TOOL

DIODE(1)

EGR_VALVE

GND(2)

HORN+

TO_J/C(CAN1_L)

TO_J/C(S_GND2)

REAR_WORK_L(RH)2

R_WORK_LAMP_R(A)

SENSOR_OIL_TEMP (TANK)

SOLENOID(Unlock)

YAZAKI_250 7116-2270-02

YAZAKI_62 7123-8520-40

YAZAKI 7321-9822

SUMITOMO_DL090 6195-0030

YAZAKI 7009-1836

YAZAKI 7323-2010

YAZAKI_RH 7283-8850-30

YAZAKI CB

YAZAKI CA

AMP_EJ II 178449-6

YAZAKI_HS 7283-2090-30

AIR_FLOW_SENSOR

CAP(CAN)

TO_DIODE(1)

FAN_MOTOR

GND(3)

HORN-

J/C(CAN2_H)

METER

REAR_WORK_L(RH)3

R_WORK_LAMP_R(B)

SERVICE_TOOL

STARTER-SW

2 8

9 10 11 12

1 3

SUMITOMO_TS025 6189-1046

YAZAKI 7234-2601-40

SUMITOMO 6098-0017

DEUTSCH_DT DT06-2S-EP06

YAZAKI 7009-1836

YAZAKI 7323-2010

YAZAKI_RH 7182-9631-40

JAE MX34012SF1

YAZAKI CA

YAZAKI CB

AMP_EJ II 174257-2

YAZAKI_58X 7123-6234-40

ALTERNATOR_A

CCV_HEATER1

DIODE(AUX4_J)

FLOAT_SOL

GND(4)

INTAKE_AIR_TEMP_SENSOR

TO_J/C(CAN2_H)

NE_SENSOR

RESISTOR(120)

SBF(3)

SERVICE_TOOL(CAP)

STARTER_A

120Ω

YAZAKI_58X 7223-6224-40

KOSTAL 09441291

YAZAKI 7321-9822

AMP 174352-2

YAZAKI 7009-1836

YAZAKI_090 II 7283-7027-40

YAZAKI_RH 7283-8850-30

SUMITOMO_TS025 6189-1130

YAZAKI 7382-5053-3R

YAZAKI 7154-5868-30

AMP_EJ II 174259-2

AMP_250 172320-2

ALTERNATOR_B

CCV_HEATER2

TO_DIODE(AUX4_J)

FUEL_PUMP

GND(A)

INTAKE_HEATER_RELAY_A

J/C(CAN2_L)

OIL_SW

TO_RESISTOR(120)

SCR_METER

SOLENOID(AUX-L)

STARTER_B

LA_M8

KOSTAL 09441291

SUMITOMO 6098-0017

YAZAKI 7229-3023

YAZAKI 7009-9228-02

YAZAKI,CN(A) 7123-2228

YAZAKI_RH 7182-9631-40

AMP 172320-1

YAZAKI_58 7123-6423-30

JAE_MX34 MX34005SF1

AMP 174352-2

YAZAKI 7003-1210-02

BACK_BUZZER

COMPRESSOR

DIODE(HORN)

FUEL_SENSOR

GND(B)

INTAKE_HEATER_RELAY_B

TO_J/C(CAN2_L)

OPC_SW

RESISTOR(OPC)

SCR_TEMP_SENSOR

SOLENOID(AUX-R)

SUCTION_HEATER

AMP 174352-2

1 FURUKAWA_RFW P010463

YAZAKI 7321-9822

SUMITOMO,HM090 6180-2451

YAZAKI 7009-9229-02

LA_M6

YAZAKI_RH 7283-8850-30

DEUTSCH_DT DT06-2S-CE05

1 2

120Ω

YAZAKI_CN(A) 7321-9985-0R

AMP_SUPERSEAL1.5 282080-1

AMP 174352-2

DEUTSCH_DT DT06-2S-CE06

SVL97-2 (1/3)

KiSC issued 09, 2021 A

SW(A/C) 3

SW(SETTING/DISPLAY)

TO_(ENGINE_ARM_H1)

TO_(MAIN_H5) 1

COOLANT_VALVE

SUMITOMO_MT/HM090 6180-4181

YAZAKI_58M 7123-6040

YAZAKI_58 7122-1640 CLC_A_24346-79902_1

SW(ARM_DOWN)

SW(WIPER)

TO_(ARM_H2)

TO_(TAIL_L)

10 9

5 1

10 2

TO_(ENG2)

TO_(ENG1)

SBF(1)

YAZAKI_090 II 7283-1080-80

RELAY(1)

60 59 58 57 56 55 54 53 52

49 48 47 46 45 44 43 42

11 12 13 14 15 16

17 18 19 20 21 22

24 25

41 40 39 38 37 36 35 34

30 29 28 27 26 25 24 23

9 10 11 12

19 18 17 16 15 14 13 12 11 10 9

YAZAKI_SDL 7123-8307

YAZAKI_58M 7122-6060

YAZAKI CB

AMP 1-1418448-1

SUMITOMO 6400-0829

YAZAKI 7254-5909-30

YAZAKI_090 II 7182-8745-10

YAZAKI_SWP 7222-7923-40

AMP_040/070_HYBRID_I/O 1747140-1

SW(ARM_UP)

SW(WORK_LIGHT)

TO_(ENGINE_ARM_H2)

TO_(TAIL_L_H2)

LEVER_L

RELAY(2)

SBF(2)

TO_(MAIN1)

TO_(MAIN2)

FUSEBOX

10 9

3 8

YAZAKI_SDL 7123-8307

YAZAKI_58M 7123-6060

YAZAKI CA

SW(BACK_PRESSURE)

TANK_SENSOR

TO_(BAT_H)

TO_(TAIL_L_H3)

5 1

12 11 10 9

10 2

16 15 14 13 12 11

22 21 20 19 18 17

25 24

YAZAKI_58 7122-4123-30

YAZAKI_090 7123-1520

YAZAKI_SWP 7123-7923-40

SUMITOMO 6400-0829

YAZAKI 7254-5909-30

YAZAKI_090 II 7183-8745-10

SW(DPF_INHIBIT)

THERMOSTAT

TO_(E-OUT_ROOM)

WASHER_MOTOR

LEVER_R

RELAY(3)

LEVER_L(STANDARD)

LEVER_R(STANDARD)

YAZAKI_SDL 7123-8307

YAZAKI_4.8(187) 7283-1050

YAZAKI_58 7122-6060

YAZAKI 7323-9327

SW(FLOW_SET)

TO_(AIRRIDE+)

TO_(ENG3)

WATER_SEPARATOR

CCV_PRESSURE_SW

13 14 15

32 31 30 29 28 27

DEUTSCH DT06-4S-CE06

YAZAKI_CN(A) 7123-2820

YAZAKI CB

12 11 10 9

SUMITOMO 6189-0158

10 9

SUMITOMO 6189-0158

SUMITOMO 6189-0156

27 28 29 30 31 32

TO_(REGISTOR)

ACU

1 4

SUMITOMO_DL090 6195-0051

3 2

12 11 10 9

SUMITOMO 6353-0125

YAZAKI_SWP 7123-7923-40

ECU(CRS_91P)

SUMITOMO_DL090 6195-0051

R&FBOX

9 10 11 12 13 14 15 16 17 18 19 20 21

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

75 76 77 78 79 80 81 82 83 84 85 86 87 88 89

1 105

SUMITOMO_HM090 6180-2451

YAZAKI 7114-2100

YAZAKI_8.0(312) 7282-3030

AMP 174352-2

YAZAKI_SWP 7123-7923-40

SUMITOMO 6420-0050

SW(HITCH)

TO_(MAIN_AIRRIDE+)

TO_(ENG4)

CAP(RADIO_CONVERT)

POWER_SOCKET

RELAY(4)

10 9

YAZAKI_SDL 7123-8307

YAZAKI_250 7116-2270-02

YAZAKI_312 7282-3040

SW(HYDRAULIC_LOCK)

TO_(AIRRIDE-)

TO_(MAIN4)

10 9

13 3

YAZAKI_250 7116-2270-02

YAZAKI_312 7283-3040

SUMITOMO_MTW110 6040-9111

DEUTSCH_HD30 HD34-18-14PE

SUMITOMO 6420-0050

SW(PARKING)

TO_(MAIN_AIRRIDE-)

TO_(ENGINE_H5)

RADIO_CONVERT

RELAY_CASSETTE

RELAY(5)

10 9

YAZAKI_SDL 7123-8307

YAZAKI 7114-2100

YAZAKI_SWP 7222-7444-40

SW(ROOM_LAMP)

TO_(ARM_H1)

TO_(UNLOAD)

SUMITOMO_HM090 6187-2801

YAZAKI_58M 7122-6040

YAZAKI_SWP 7123-7444-40

27 28

99 101 98

29 30

102

SUMITOMO_MTW110 6030-9991

5 1

3 5

10 2

31 32 33 34

94 96 93

35 36

11 12

37 38

64 66 63

13 14

39 40

89 91 88

15 16

41 42

17 18

43 44

59 61 58

19 20

45 46

84 86 83

21 22

47 48

23 24

49 50

6 8

60 3

100

9 10

YAZAKI_SDL 7123-8307

69 71 68

ECU(CRS_105P)

74 76 73 75

AMP 3-2109431-2

104 106

1 2

103

54 56 53

25 26

51 52

79 81 78

9 10 11 12 13 14 15 16 17 18 19 20 21

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84

88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105

AMP 2-2109432-2

25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

ECU(MAIN)

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

82 80

SUMITOMO 6400-0829

YAZAKI 7154-0089-30

4 3

44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81

YAZAKI 7154-5798-30

25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

AMP 1473244-1

SVL97-2 (2/3)

KiSC issued 09, 2021 A

ACU

AMP_040/070_HYBRID_I/O 1747140-1

ECU(CRS_91P)

AMP 3-2109431-2

ECU(CRS_105P)

100 101 102 103 104 105

AMP 2-2109432-2

SVL97-2 (3/3)

KiSC issued 09, 2021 A

6. Electrical Circuit Diagram 1) Open cab specification 3.0

BASE:

3.0

EGR 10 MiniFuses

FUSEBOX B/R 7

EngineElements 5 MiniFuses

FUSEBOX B/R 11

FUSEBOX BASE:

0.75

BASE:

0.75

FUSEBOX BASE:

0.50

BASE:

0.5

ECU,SUB-ASSY(E40-V3) BONDER(A)

FUSEBOX

BASE:

ECU(CRS_91P) 0.75 f B/R

BASE:

2.0

B/R

BASE:

2.0

B/R

BASE:

2.0

B/R

B-88

NE-VCC

ECU(CRS_105P) BASE: 0.50 f

BASE:

NE_SENSOR 0.50 f G

BATT

NE-GND

BASE:

0.50

BASE:

0.50

NE(MRE)

BASE:

0.5

SWV23

ECU(CRS_91P)

SWV11

SWV4

NULL

B-3 B-6 B-5

A-47 A-26 A-5

CRS_RELAY

BASE:

2.0

R/W 6

4 5 2

RELAY(1) 10 BASE:

3.00

7 BASE:

2.0

B/R f

Twist 14

1 2 3

2 BASE:

0.75

3 BASE:

0.5

4 BASE:

4 5

J/C(CAN1_L)

J/C(CAN1_L) 1 2 3

JC_7182-9631-40_1

0.5

5 Twist

GND

BR/W

2 BASE:

0.75

BR/W

3 BASE:

0.5

BR/W

4 BASE:

0.5

6 BASE:

BASE:

0.75

EGR_VALVE f BR

BASE:

0.75

0.5

BR/W

VALVE,ASSY(EGR)

BASE:

0.75

BASE:

0.75

BASE:

0.50

G/W

BASE:

0.5

L/W

BASE:

0.50

Y/G

BASE:

0.50

CAN_H

BR/W

CAN_L

GND

POWER(12V)

120 Ohm

+12V

BASE:

CAN_L

2 BASE:

BR/W

0.5

0.50

TO_(ENG1) 0.50 B 13

BASE: B

TO_(MAIN1) BASE: 0.5

TPS

TO_(MAIN1) BASE: 0.50

Twist

Null

BR/W

0.50

BASE:

0.75

BASE:

0.75

BASE:

0.75

BASE:

0.75 f BR/W ECU(CRS_105P)

OUTV1

NULL

OUTV1

NULL

B-87

WATER_SEPARATOR BASE: 0.5 f SB

B-59

CAN2L

B-60

NULL

ADV1

NULL

A-GND12

AIR_ FLOW_ SENSOR

B/R

BASE:

0.75

BASE:

0.75

BASE:

0.75

0.5

L/W

BASE:

0.50

P/B

BASE:

0.50

G/W

BASE:

0.50

Y/G

BASE:

0.75

R/B

BASE:

0.75

B/R

BASE:

ECU(CRS_91P) 0.75 f G

BASE:

0.75

BASE:

0.75

ADE11

ADE13

A-GND12

A-GND3

BASE:

0.75

L/R

ADV5

A-VCC12

BASE:

0.75

A-96 A-75

A-78 A-99 A-58

A-GND-A

A-101

BASE:

OUTE6

BASE: BASE:

INJECTOR INJECTOR1

INJ1-COM INJ2-COM

1.25

BASE:

0.75

B-51

PRV-

BASE:

1.25

B/W

BASE:

0.75

B-41

A-67

ADE5

BASE:

A-GND2

BASE:

A-72 A-93

INJ3-COM

INJECTOR2

INJ4-COM N.C.2

INJECTOR3

BASE: 1.25 f R

INJ1-DRV

BASE: 1.25 f B

INJ2-DRV

BASE:

0.75

BASE:

0.75

A-GND6

BASE:

0.75

A-57 A-97

BASE: 1.25 f B

INJ4-DRV

BASE:

1.25

BASE:

1.25

BASE:

1.25

BASE:

1.25

BASE:

1.25

BASE: 1.25 f W

BASE:

1.25

A-64 A-22 A-1 A-44 A-2 A-23

SI 0.5

1.25

0.5

BASE:

0.5

2 3 4

COOLANT_TEMP_SENSOR BASE: 0.75 f L/R

BASE:

0.5

BRIDGE(1)

L/B

BASE:

0.75

L/B

BASE:

Y/R 0.75 f INTAKE_AIR_TEMP_SENSOR

BASE:

0.75

Y/R

ADE4

BASE:

0.75

A-GND1

BASE:

0.75

ADE3

BASE:

0.75

A-GND4

A-32

JC_7382-1480-40_1

INTAKE_AIR_TEMP_SENSOR 1

ECU(CRS_91P)

BASE:

A-2

GND

A-3

BASE:

1.25

PRV B/W

BASE:

1.25

Pressure Sensor

SIG

CN2

PRV-

B-1

Reducing Valve

PRV+

B-2

BOOST_SENSOR VC

BOOST PRESSURE SENSOR

GND

INTAKE_AIR_TEMP_SENSOR BASE: 0.75 f L

2 0.5

A-1

SI BOOST_SENSOR 0.75 f GR

0.75

A-73

0.75

RAIL,ASSY CN1

RAIL_PRESSURE_SENSOR BASE: 0.75 f R

B/R

BASE:

A-100

SWV9

COM1 COM1

SWV12 COM2 SWV14

COM2 TWV1

TWV4

SWV7

TWV2

SWV8

SENSOR_DOC_EX_TEMP_T0 BASE: 0.75 f Y ECU(CRS_105P) BASE: 0.75 f

ADE7

A-52

BASE:

0.75

ADE8

BASE:

0.75

B/R

NULL

A-GND3

BASE:

0.75

A-GND

ADE9

BASE:

0.75

R/B

Y/R

A-31 A-51 A-30 A-50

BASE:

A-GND3

A-29

NULL

0.75

ECU(CRS_91P) B-4

ECU(CRS_105P)

GND

NULL

B-1

NULL

SWV13

A-VCC4

NULL

OUTV2

NULL

BRIDGE(7)

GND

ECU(CRS_91P) BASE: 2.0

BASE:

B-2

SWE1

2.0 BASE:

NULL

CAN-SLD

NULL

SENSOR_DOC_EX_TEMP_T1

2.0

SENSOR_DOC_EX_TEMP_T0 BASE: 0.75 f W/B

SENSOR_DOC_EX_TEMP_T1 1

SENSOR_DOC_EX_TEMP_T1 BASE: 0.75 f B/R

SENSOR_DPF_EX_TEMP_T2 1

SENSOR_DPF_EX_TEMP_T2 BASE: 0.75 f R/B

GND GND

BASE: 0.75

B-20

NULL

SENSOR_DPF_EX_TEMP_T2 BASE: 0.75 f Y/R

SWV5 NULL

SENSOR_DOC_EX_TEMP_T0

W/B

A-GND3

NULL

BRIDGE(4)

PCV BASE:

SENSOR,WATER_TEMP.

TWV3

A-65

BASE:

1.25

PCV-

A-VCC2

A-79

NULL

BASE:

PCV+

SWV1

OUTE1

BASE:

L/R

ADE1

SWV2

BASE:

BRIDGE(6) A-43

BASE: 1.25 f R

INJ3-DRV

INJECTOR4

BASE: 1.25 f G

BASE:

0.75

PUMP,ASSY(SUPPLY)

PCV

COOLANT_TEMP_SENSOR 0.75 f L

A-VCC1

A-76

OUTV3

A-38

A-66

SWV3

BASE: 1.25 f W

4.7ohm

VOUT

BASE:

A-86

OUTV5

ECU(CRS_105P) 1.25 f G

PRV+

BASE: 1.25 f G

B-34

CRS_INJECTOR N.C.1

0.75

A-3

ASIC

B/R

SOUT4

BASE:

SWV6

J/C(SHIELD_GND)

GND

A-VCC10

VDD

1.25

A-61

0.50

L/R

1.25

A-GND3

0.5

BASE:

A-85

2 3

0.75

BASE:

ECU(CRS_91P)

GND

BASE:

PCV-HI

ADV3

B-17

ECU(CRS_105P) 0.5 f Y/B ECU(CRS_91P) 0.75 f Y/R

DPF_DIFF_PRESS_SENSOR BASE: 0.75 f SB

PCV-LO

A-84

0.50

DPF_DIFF_PRESS_SENSOR

A-GND5

A-105

ECU(CRS_105P) 1.25 f B/W

WATER_SEPARATOR BASE: 1.25 f B/W

ADE2

OUTE5

BASE:

J/C(SHIELD_GND)

GND

ECU(CRS_105P) BASE: 0.75 f

A-80

J/C(SHIELD_GND)

BASE:

NULL

BASE:

TO_J/C(SHIELD_GND) BASE: 0.5 f B

NULL

R/B

BRIDGE(3)

NULL

A-GND13

A-VCC10

NULL

SOUT7

0.75

GND

SOUT5

0.75

G_SENSOR BASE: 0.50

NULL

ADV2

BASE:

OUT

SOUT6

NULL

BASE:

VCC

CAN1L

SENSOR(+)

POWER(12V)

SOUT2

GND

SOUT1

A-VCC11

NULL

BASE: 0.50 ECU(CRS_91P)

G_SENSOR

G_SENSOR f B

CAN1H

B-77

SENSOR(-)

W/B

A-6

CAN2H

B-76

SERVICE_TOOL(CAP)

BASE:

B-70

BASE:

SERVICE_TOOL(CAP)

BASE:

A-27

NULL

WATER_SEPARATOR

G-GND

TO_(MAIN1) BASE: 0.5 32

0.50

ASSY

TO_(ENG1) 0.50 BR 31

TO_(ENG1) 0.50 BR/W 32

BASE:

SERVICE_TOOL

GND

6 Twist

BR/W

H_IC

BASE:

Y/R

0.50

BASE:

0.50

BASE:

GND

0.50

BASE:

R_7382-5053-3R_1 RESISTOR

SERVICE_TOOL CAN_H

TO_RESISTOR(120) 0.5 f 1 BASE:

0.75 0.75

INTAKE_THROTTLE_VALVE INTAKE_THROTTLE_VALVE

Twist 13

0.50

NULL

J/C(CAN1_L) RESISTOR120OHM

BASE:

SOUT3

BR/W

RESISTOR(120)

BASE: BASE:

AIR_FLOW_SENSOR

AIR_FLOW_SENSOR BASE: 0.50 P/B

Twist

TO_J/C(CAN1_L) 1 BASE: 0.75

0.5

6 BASE:

JC_7182-9631-40_1 J/C(CAN1_H)

TO_J/C(CAN1_H) 1 BASE: 0.75

MicroComputer

J/C(CAN1_H)

FORK(1)

RELAY(1) J/C(CAN1_H)

ECU(CRS_105P) BASE: 0.50 f 0.50

NE_SENSOR BASE: 0.5

BRIDGE(5)

0.5

RELAY(1) R/W 8

3.0

0.5

BASE:

OUT

GND

G-VCC

A-59

Null

BASE:

NULL

SWV10

NE_SENSOR VCC

BASE:

NULL

BASE:

0.5

NULL

ADE6

NULL

ADV6

POUT1

ADV7

NULL

OUTV4

NULL

INJ-SLD

NULL

INJ-SLD

NULL

A-GND7

NULL

A-98

NULL

A-103

BASE:

0.75

1.25

JH BASE:

0.75

Y/R

BASE:

1.25

1 2

CCV PRESSURE SWITCH

J/C(S_GND2) 1

NULL

BASE: 0.75

BASE:

Y/R

0.5

GND

Y/R

TO_J/C(S_GND2) BASE: 0.85 B 4

J/C(S_GND2)

BASE:

0.5

B 5

BASE:

0.5

B 6

4 5 6

JC_7182-9631-40_1

BASE:

2.0

R/L

BASE:

0.5

BASE:

0.5

BASE:

0.5

BASE:

0.5

RELAY(40A,ISO) ACU

FUSEBOX BASE: 3.0 B/Y 5

MiniFuses

FUSEBOX 6 BASE:

3.0

Null

RELAY(4)

R/B

3 BASE:

0.85

R/B 1

RELAY(4) 4 BASE: 3.0

4 5

BONDER(ACU_COMP)

2 BASE: 0.5 f G

BASE:

RELAY(4)

FUSEBOX

BASE:

SWITCH(SENSOR)

FUSEBOX f R 9

1.25

FUSEBOX BASE:

0.75

10 MiniFuses FUSEBOX

Twist 10

0.5

BASE:

TANK_SENSOR 0.85 Y

BASE:

0.85

BASE:

0.85

BASE:

0.85

Twist

TANK,ASSY 4 2 1

CAN-H CAN-L

Y/R

Twist

GND

Y/B

Y/R

TO_(ENG1) 0.50 Y/R 25

3 4 5

BASE:

J/C(CAN2_H)

J/C(CAN2_L) J/C(CAN2_L)

Y/R

4 5 6

JC_7182-9631-40_1

0.85

4 BASE:

0.85

5 BASE:

0.85

6 BASE:

SENSOR

Twist

GND

BASE: BASE:

FUSEBOX

2.0

Null

RELAY(5) R 8

0.5

Y/R 6

30 86

RELAY(5) 10 BASE:

RELAY(5)

TO_J/C(CAN2_L) 1 BASE: 0.75

2 BASE:

0.5

3 BASE:

0.85

4 BASE:

0.85

5 BASE:

0.85

6 BASE:

0.50

0.5

1.25

RC_OUT

LEVER_L BASE:

BASE:

AUX_1L_OUT

AUX R3

0.5

G/L

HORN_OUT

BASE:

0.5

SG_OUT

BASE:

0.5

BASE:

0.5

HOLD R

Y/B

W/R

BASE:

0.5

W/B

10 6

BASE:

0.5

G/B

AUX_2L_OUT

BASE:

0.5

AUX_2R_OUT

BASE:

0.5

BASE:

2 5

FrontWorkingLight

R&FBOX 3 BASE:

20 MiniFuses

R&FBOX 1 BASE:

R/G

BASE:

B/Y

GND

SUCTION_HEATER BASE: 2.0 f

B/Y

0.5

VALVE,ASSY 1 2

B/R

VALVE+

TANK HEATER VALVE

Null VALVE-

GND

SW2

IND2

BASE:

3.0

ADR-SW

NULL

ACU_HEATER_RELAY Null

R/L 1

4 5 2

RELAY(3) 4 BASE:

3.0

2 BASE:

0.5

B f

GND

RELAY(3)

POWER_SOCKET

RELAY(AUX1L_C) B

GND

CCV_HEATER2 BASE: 1.25

BASE:

R&FBOX 1.25 B/R 95

BASE:

0.5

Null

B/Y 93

4 5

R&FBOX BASE: 97

1.25

BASE:

0.5

B/L

BASE:

1.25

GND

Null

R&FBOX 1.25 B/R 100 0.5 W/B 98

3 1

TO_(ENG1) 1.25 L 29

BASE:

RELAY(AUX1R_D) 4 5

R&FBOX BASE: 102

1.25

BASE:

0.5

B/L

BASE:

1.25

TO_(ARM_H1)

TO_(MAIN1) hydro-proof BASE: 1.25 L 29

BASE: 28 TO_(MAIN1)

28 TO_(ENG1)

TO_(ENGINE_ARM_H1) BASE: 0.75 f B

BASE:

hydro-proof R 1.25

0.75

BASE:

0.75

BASE:

0.75

BASE:

0.75

BASE:

0.75

L/W

BASE:

0.75

R/G

BASE:

0.75

R/L

BASE:

0.75

L/Y

BASE:

0.75

BASE:

0.75

R&FBOX

BASE:

R&FBOX 1.25 B/R 70

BASE:

0.5

BASE:

R&FBOX 1.25 B/R 75

BASE:

0.5

POWER_SOCKET

Null

4 5

R&FBOX BASE: 72

1.25

L/W

BASE:

0.5

B/L

R&FBOX BASE: 77

1.25

R/G

BASE:

0.5

B/L

Null

hydro-proof TO_(MAIN2) BASE: 1.25 L/W 12

TO_(ARM_H2)

BASE:

TO_(ENG2) 1.25 L/W 12

TO_(ENG2) 1.25 R/G 7

hydro-proof TO_(MAIN2) BASE: 1.25 R/G 7

TO_(ARM_H2)

BASE:

TO_(ENGINE_ARM_H2) L/W BASE: 0.75 f

4 5

TO_(ENGINE_ARM_H2) BASE: 0.75 f R/G

RELAY(AUX3L_H)

0.5

hydro-proof

G/W

BASE:

G/L

2 BASE:

0.5

BASE:

TO_(ENG2) 1.25 L/Y 11

BASE:

TO_(ENG2) 1.25 R/L 10

BASE:

TO_(ENG2) 1.25 BR 9

B/L

TO_(MAIN2) BASE: 1.25

hydro-proof L/Y

TO_(ARM_H2)

TO_(MAIN2) BASE: 1.25

hydro-proof R/L

TO_(ARM_H2)

TO_(MAIN2) BASE: 1.25

hydro-proof BR

TO_(ARM_H2)

GND

BASE:

0.5

BASE:

1.25

BONDER(C)

R&FBOX B/R 90

BASE:

0.5

Y/R

RELAY_CASSETTE 10 BASE: 1.25 R/L

4 5

7 BASE:

0.5

B/L

R&FBOX 92 BASE:

1.25

BASE:

0.5

B/L

BASE:

Null

RELAY(AUX4_J)

Null

4 5

0.50

Y/B

3 2

680

LED(AMBER_GND)

BASE:

0.50

L/R

RESISTANCE(GND)

620

RESISTANCE

BASE:

0.50

Y/B

10 5

Vcc(12V)

hydro-proof

DIODE(AUX4_J)

Null

L/R 0.50

RESISTANCE(GND)

620

ON OFF

SW(HYDRAULIC_LOCK) 0.50 W Vcc(12V) 7

0.50

BASE:

G/W

620

Y/R

BASE:

R&FBOX 0.85 R 60

BASE:

0.5

0.50

Y/R

BASE:

0.50

0.85

Vcc(12V)

GND

OPC_SW BASE:

SWITCH(METER,2) 3

0.50

BASE:

SW(0.74M) SW(ARM_DOWN) SW(ARM_DOWN) 0.50 W BASE: SW_PRESSURE1 SW_PRESSURE2 2 1

SEAT_BAR_L_SW BASE: 2 BASE: GND 1

Vout

R/B

SEAT_BAR_R_SW BASE: Vout 2 BASE: GND 1

FUEL_SENSOR 0.50 LG

(+)

FUEL_SENSOR

0.50

G/W

0.50

(-)

0.50

0.5

B/R

O/L

BASE:

0.5

0.50

L/R

0.50

GND Main Sub

W/R

P/L

SENSOR_OIL_TEMP(TANK) ACCEL_SENSOR_F BASE: 0.5 f P/L

4 2 1

GND

CCW

Main

Sub

BASE:

0.5

LG/R

BASE:

0.5

P/B

BASE:

0.5

P/L

BASE:

0.50

LG/R

BASE:

0.50

1.25

HORNB

BASE:

1.25

0.50

CAN-H

BAT

BONDER(B)

BASE:

0.50

P/B

TO_(MAIN1)

ACCEL_SENSOR_H BASE: 0.5 P/W

4 2

B 2

TO_(ENG1) 0.50 B/W 8

TO_(MAIN1) BASE: 0.5 8

0.5

P/B

BASE:

0.5

LG/B

BONDER(B)

J/C(CAN2_METER)

0.50

BR/W 1

BASE:

0.50

BR/W 2

BASE:

0.5

BR/W 3

BASE:

0.50

BONDER(C)

BASE:

0.50

BASE:

0.5

Twist 4

BASE:

0.5

BR/W

BASE:

0.85

B/W

BONDER(C)

120 Ohm

1 2 3 4 5 6

JC_7182-9630-30_1

TO_J/C(CAN2_METER)

J/C(CAN2_METER)

BASE:

0.50

232C B/W 1

CAP(232C) 1

BASE:

0.50

B/L

BASE:

0.50

BASE:

0.50

Y/R

TRAVEL_SPEED_SW

BASE:

0.5

AUX_HOLD_SW(LEFT)

G/W

BASE:

0.5

B/O

BASE:

0.50

G/W

BASE:

0.50

ECU(MAIN) BASE: 76 BASE: RxD 75 BASE: CAN(H) 45 BASE: CAN(H) 46 BASE: CAN(H) 47 BASE: CAN(L) 48 BASE: CAN(L) 49 BASE: CAN(L) 50

0.50

Y/R

AUX_HOLD_SW(RIGHT)

AUX_SW

PARKING_SW

HYDRAULIC_UNLOCK_SW

BASE:

0.50

BASE:

0.50

R/B

PRESSURE_SW(BACK)

BASE:

0.50

FRONT_WORK_LIGHT_SW

BASE:

0.50

Y/B

DPF_INHIBIT_SW

BASE:

0.5

B/L

USER_SETTING_SW

BASE:

0.5

B/R

0.5

OPC_SW

0.5

G/B

PRESSURE_SW(ARMS_DOWN)

BASE: 0.50 O/B

SEAT_BAR_SW(LEFT)

BASE:

0.50

G/W

SEAT_BAR_SW(RIGHT)

BASE:

0.50

Y/B

STARTER_SW(START)

BASE:

0.5

L/G

FLOAT_OPERATION_SW

BASE:

0.50

W/R

CHARGE_INPUT

BASE:

0.50

B/Y

ENGINE_OIL_PRESSURE_SW

W/Y

+5V_OUTPUT(SENSOR_USE)

BASE: 0.50 L/W

P/L

GND(SENSOR_USE)

BASE:

0.5

O/B

GND(SENSOR_USE)

BASE:

0.5

P/W

GND(SENSOR_USE)

BASE:

0.50

FUEL_SENSOR

BASE:

0.50

W/Y

OIL_TEMP_SENSOR

BASE:

0.5

W/R

AUX_CONTROL1

BASE:

0.5

W/B

AUX_CONTROL2

AUX-RELAY2

BASE: 0.5

B/L

AUX-RELAY1

BASE: 0.5

B/L

23 42

22 GLOW_RELAY

BASE: 0.50 W/B

BACK_BUZZER

BASE: 0.50 Y

WARNING_BUZZER

BASE: 0.50 BR

78 80 31

BASE: 0.50 L/R

DPF_INHIBIT_LED

0.50

LG/R

ACCELERATOR_SENSOR_F-1

0.50

P/B

ACCELERATOR_SENSOR_F-2

BASE:

0.5

LG/B

ACCELERATOR_SENSOR_H-1

0.5

P/B

STARTER_SW(RUN) +B(DIRECT)

BONDER(C)

SOLENOID(AUX-R) BASE: 0.5 f B/L

O/L

SOLENOID(StallGuard) BASE: 0.5 f O/L

SW2

SOLENOID(AUX-L) BASE: 0.5 f O

SOLENOID(AUX-R)

SW1

SW2

SOLENOID(AUX-R) BASE: 0.5 f O

SOLENOID(StallGuard)

SW1

SW2

SOLENOID(StallGuard) BASE: 0.5 O/B

O/B

Null

WATER_PROOF

ON1

3 2

TO_(ENG1)

0.50

R/B

TO_(MAIN1) 17

17 H:

0.5

SOLENOID(Unlock)

f O

(+)

SOLENOID(Unlock)

(-)

5 30

30 TO_(MAIN1)

BASE:

0.50

G/W

10 TO_(ENG1)

10 TO_(MAIN1)

BASE:

0.5

(+)

(-)

0.50

G/R

BASE:

TO_(UNLOAD)

BASE:

TO_(UNLOAD) 0.50 L/W

BASE:

4 TO_(ENGINE_H5)

0.5

B/R

SOLENOID(Lock) H: 0.5 f B

FLOAT_SOL BASE: 0.5

GND

0.5

BASE:

SOLENOID(TravelSpeed)

G/R

0.5

VALVE_UNLOAD2

VALVE_UNLOAD1

SOLENOID(TravelSpeed)

BASE: 0.85 B 2 SOLENOID(HydraulicLock)

VALVE_UNLOAD1

BASE: 0.50 2 SOLENOID(TravelSpeed)

BASE: 0.50 2 SOLENOID(Parking)

VALVE_UNLOAD2

SOLENOID(Parking)

TO_(ENGINE_H5) 2

(-)

2ND_Hydlock_Park_Valve V0621-64114 SOLENOID(HydraulicLock)

TO_(ENGINE_H5)

(+)

GND

SOLENOID(HydraulicLock)

BASE:

0.5

SOLENOID(Unlock)

RD358-74111

VALVE,ASSY

FLOAT_SOL f G/W

SOLENOID(Lock)

SOLENOID(Lock) H: 0.5 f R/B WATER_PROOF

HITCH_Valve

L/W

VALVE_UNLOAD1

SOLENOID(Parking)

VALVE_UNLOAD2

BONDER_A

BACK_BUZZER

BASE:

0.5

B/W

BASE:

0.5

BUZZER1 BUZZER2

BACK_BUZZER

METER

METER N.C(GND)

ACC

BATT

N.C(GND)

CAN_L

N.C(GND)

CAN_H

GND

N.C(GND)

3 4 BASE:

0.50

BONDER(C)

N.C(GND)

+12V_OUT

Y/R

B/L

Vcc

ACCELERATOR_SENSOR_H-2

BASE: 1.25

SW1

SW(HITCH)

TO_(UNLOAD)

BASE: 0.85

PROPORTIONAL SOLENOID SOLENOID(AUX-L)

SOLENOID(AUX-L) BASE: 0.5 f R/G

TO_(ENG1)

TO_(MAIN2) BASE: 0.5 6 TO_(MAIN2) BASE: 0.5 5

BASE: 0.50 R/B

WAKEUP_SIGNAL_OUTPUT

BASE:

0.50

BASE: 0.85 W/B

STARTER_AUTO_RELEASE_RELAY

BASE:

CAN(L)

Twist

Null

AIR_CONDITIONER_RELAY

0.5

CAN(H)

CAN_TOOL

ON2

PARKING_BRAKE_SOLENOID

BASE:

BASE: 0.50 G/R

0.5

0.50 P/B

TRAVEL_SPEED_SOLENOID

BASE:

VCC

R/G

Null

BASE: 0.50 G/W

+5V_OUTPUT(SENSOR_USE)

SW(HITCH)

FLOAT_SOLENOID

O/L

TO_(MAIN2) BASE: 0.5

BASE: 0.50 B/R

HYDRAULIC_LOCK_SOLENOID

0.5

GND

Null

BASE:

0.50

CAN_TOOL

CAP(CAN) 1

SW(HITCH)

STALL_GUARD_FEEDBACK

BASE:

BASE: B/L

BASE: 0.50 O/L

4TH_FUNCTION

BASE: 0.5 3 TO_(MAIN2)

TO_(ENG2) 0.50 O/L TO_(ENG2) 6 0.50 O/B 5

BASE:

0.50 BR

STALL_GUARD_SOLENOID

PRESSURE_SW(ARMS_UP)

BASE:

CAN_TOOL BR/W 1

ON1 N ON2

HYDRAULIC_HITCH_SOLENOID

L/R

TO_(ENG2) 0.5 B/L

BASE:

TO_(MAIN2) BASE: 0.5

0.50 O TO_(ENG2) 3

0.50 R

BASE: 0.50 O

0.50

TxD

AUX_SOLENOID_FEEDBACK

RIDE_CONTROL_SW

0.50

0.50 BR/W

BASE: 0.50 R/G

DISPLAY_CHANGE_SW

BASE:

0.50 L

0.5

TO_(ENG2) 0.50 R/G

BASE:

AUX_SOLENOID(LEFT)

BASE:

0.5

BASE: 0.5

0.50 B/W

AUX_SOLENOID(RIGHT)

O/B

0.50 B/L

TxD

RxD

BASE:

ECU(MAIN)

ECU(MAIN) 0.5 Y

Twist

232C

BASE:

A-1

B-1

HORN

TO_DIODE(HORN) 0.50 B 2 BASE:

R_7321-9985-0R_2

BASE: 2.00 f B

TO_(ENG1)

BONDER(B)

BASE:

SCR_METER BASE: 0.5

RESISTOR

BASE:

W/R

1.25

BASE:

SENSOR(ACCEL.) DC5V

0.5

O/L

CCW

+5V_OUTPUT(SENSOR_USE)

BONDER(C)

BASE:

ACCEL_SENSOR_F

DC5V

DIODE(HORN)

400V

D_7321-9822

CAN-L

R&FBOX 62 BASE:

TO_(MAIN1) TO_(ENG1) BASE: 0.50 LG BASE: 0.50 LG 23 23 TO_(ENG1) FUEL_SENSOR TO_(MAIN1) BASE: 0.50 B BASE: 0.50 B 18 18 TO_(ENG1) BONDER(C) TO_(MAIN1) BASE: 0.5 f W/Y BASE: 0.50 W/Y 22 22

ACCEL_SENSOR_F BASE: 0.5 f O/L

BASE:

BONDER(C)

OIL TEMP. SENSOR

W/Y

TO_RESISTOR(OPC) BASE: 0.50 L 1

BASE:

SW(SETTING/DISPLAY) BASE: 0.5 B/L

SW(0.74M,B) SW(ARM_UP) SW(ARM_UP) 0.50 W BASE: SW_PRESSURE1 SW_PRESSURE2 1 2

Vcc

NULL

SEAT_BAR_R_SW 3

BASE:

SW(0.55M) SW(BACK_PRESSURE) SW(BACK_PRESSURE) 0.50 W BASE: 0.50 SW_PRESSURE1 SW_PRESSURE2 2 1

0.5

DIODE(HORN)

DIODE(HORN) 1

DIODE

Y/R

OPC_SW

OPC_SW 0.50 W

TO_DIODE(HORN) BASE: 0.50 L 1

Y/R

D_7321-9822

Null

G 58

BONDER(C)

Null

SEAT_BAR_L_SW SEAT_BAR_L_SW 0.50 W Vcc 3

BASE: 0.5

0.50

BASE:

RESISTANCE

Null

SW(HYDRAULIC_LOCK)

RESISTANCE(GND)

0.5

HORN_RELAY

SW(HYDRAULIC_LOCK)

Null

BASE:

GND

Null

BASE:

Null

RESISTOR(OPC)

OFF

METER

Null

0.75

TO_(ENGINE_ARM_H1)

RESISTANCE

Null

SW(PARKING) BASE: 0.50

BASE:

1.25 W 4 TO_(ARM_H1)

Twist

SW(PARKING) OFF

TO_(ENGINE_ARM_H2) BASE: 0.75 f BR

BASE:

TO_DIODE(AUX4_J)

DIODE(AUX4_J)

DIODE(AUX4_J) A 2 2 400V

R&FBOX

SW(FLOW_SET) BASE: 0.50

DIODE(7321-9822)

TO_DIODE(AUX4_J) BASE: 0.5 G/B 2

hydro-proof

LED(AMBER)

SWITCH(METER,1)

TO_(ENGINE_ARM_H2) BASE: 0.75 f R/L

HORN+

Null

TO_(ENGINE_ARM_H2) BASE: 0.75 f L/Y

RELAY_CASSET

L/G

Y/R

0.50

0.5

OFF

ON SW(PARKING) BASE: 0.50 W

B/R

1.25

Null

BASE:

RELAY(AUX3R_G)

FLOAT_SW

RELAY_CASSETTE L/Y 5 BASE: 1.25

B/R

0.50

BASE:

1.25

BASE:

0.85

0.50

BASE:

BONDER(E)

0.50

RELAY_CASSETTE BASE: 1.25 B/R 8

SW(DPF_INHIBIT)

Null

0.85

0.5

TO_(ENG1)

TO_(ENG1) BASE: 0.50

1.25

Null

RELAY_CASSETTE BASE: 1.25 B/R 3

Y/R

5 MiniFuses

5 6

8 9 10 11

METER BASE:

0.50

R/B

BASE:

0.50

Y/R

BASE:

0.50

BASE:

0.50

GND Twist 2

GND(POWER)

BASE:

TO_(ENG1) 0.50 B/Y 27

OIL_SW BASE: 0.75 f B/Y WATER_PROOF

TO_(MAIN1) 27

OIL_SW 1

BASE:

TO_(ENG1) 0.50 W/B 2

TO_(MAIN1) 2

INTAKE_HEATER_RELAY_A BASE: 0.5 f W/B BASE:

15.0

INTAKE_HEATER_RELAY A-1

B-1 INTAKE_HEATER_RELAY_B

INTAKE_HEATER_RELAY_A BASE: 3.00 B

A-2

BASE:

C-1

15.0

GND

BASE: 15.0 R HEATER_INTAKE_AIR

INTAKE_HEATER_RELAY_C

HEATER,INTAKE_AIR 1

ALTERNATOR,ASSY B-1

BASE: BASE:

0.75

A-2 A-1

BASE: 0.50 G

ALTERNATOR_B 15.0 R

ALTERNATOR_A 0.75 f W/R

R/W

BASE:

1.25

R&FBOX G 85

BASE:

0.50

Null 3

4 5 2

R&FBOX 87 BASE:

1.25

L/Y

84 BASE:

0.50

BASE:

BONDER(B)

Vcc

ON1

B/W

ON2

OFF

4 1

1.25

F-Light(+) 1

L/Y

F_WORK_LAMP_L(B) BASE: 1.25 L/Y

Null

REAR_WORK_L_RELAY

Vcc

0.50

BASE:

0.50

BUZZER BUZZER BR AV0.5R(+) 1 W AV0.5B(-) 2

TailLamp

TO_(TAIL_L) 1.25 L/Y

Front_WorkLight_L Vcc(R)

GND(W)

B-1

BASE:

R&FBOX 1.25 W/R 80

BASE:

0.50

Null 3

4 5 2

F_WORK_LAMP_R(B) BASE: 1.25 L/Y

R&FBOX 82 BASE:

A-1

1.25

79 BASE:

0.50

R_WORK_LAMP_L(B) BASE: 1.25 Y

R&FBOX

TO_(TAIL_L_H2)

F_WORK_LAMP_R(A) BASE: 0.85 B

GND(W)

A-1

R/W

R_WORK_LAMP_R(B) BASE: 1.25 Y

Rear_WorkLight_L Vcc(R)

A-1

BASE: 1 TO_(TAIL_L_H2)

Vcc(R)

REAR_WORK_L(RH)3

1 REAR_WORK_L(RH)3

BASE: 1.25

1.25

TO_(TAIL_L_H3)

L/Y

1 2

TO_(TAIL_L_H3)

BONDER(A_MAIN)

Rear_WorkLight_R

R_WORK_LAMP_R(A) BASE: 2 f B

GND(W)

B-1

R_WORK_LAMP_L(A) BASE: 0.85 B

GND(W)

B-1

2.0

1 REAR_WORK_L(RH)2

BONDER(A_MAIN)

BONDER(B)

2 10

Vcc(R)

BASE:

BONDER(A_MAIN)

Front_WorkLight_R B-1

REAR_WORK_L(RH)2

F_WORK_LAMP_L(A) BASE: 0.85 B

SW(WORK_LIGHT) OFF

BASE:

ON2ON1OFF 7

BASE:

FRONT_WORK_L_RELAY

SW(WORK_LIGHT) BASE: 0.50 B/W

A-1

TO_(ENG3) BASE: 5.00

BONDER(A_MAIN) 0.50

ROOM_LAMP ROOM_LAMP LAMP(ROOM) BR BASE: LAMP(ROOM)1 LAMP(ROOM)2 1 2

0.50

SW(ROOM_LAMP)

SW(ROOM_LAMP) BASE: 0.50 B

BONDER(A_MAIN)

0.50 BASE: BASE:

0.50

B/W 103

3 1

R&FBOX 106 BASE:

4 5

104 BASE:

R&FBOX R/W 105

SBF(2)

BASE:

3.0

RELAY(2) W/R

BASE:

1.25

GND

NOTAC

W/R

0.50

BONDER(B) BASE:

5.00

ElectricalOutlet 15 MiniFuses

R&FBOX W/R 41

Attachments-1 0 MiniFuses

Null

8 6

3 1

4 5 2

RELAY(2) 10 BASE:

3.0

BASE:

1.25

f W/B WATER_PROOF

BASE:

AirRideSeat 20 MiniFuses

R&FBOX 5.00 W/R 47

TO_(ENG4)

R&FBOX 40 BASE:

1.25

R&FBOX 42 BASE:

1.25

BASE: R&FBOX

RELAY(2)

1.25

TO_(AIRRIDE+) W/H00

BASE:

Attachments-2 20 MiniFuses

R&FBOX 46

1.25

FUSE(INDICATOR) BASE: 2.0 f B/Y 1

1.25 B W/H00 1 TO_(AIRRIDE-)

TO_(E-OUT_ROOM) BASE: 3.00 G 2 W/H00 TO_(MAIN_INDICATOR) W/H22 5

(+)

(-)

GND

W/H22

TO_(MAIN_INDICATOR)

AIRRIDE+

TO_(MAIN_AIRRIDE+) W/H00 BASE: 1.25 V 1 BASE: 1.25 B 1 W/H00 TO_(MAIN_AIRRIDE-)

AirRideSeat

W/H00

TO_(E-OUT_ROOM)

(+)

1 2 AIRRIDE-

TO_(MAIN_INDICATOR) BASE: 2.0 f G 2 W/H22

TO_(E-OUT_ROOM) W/H00 5

FUSE(INDICATOR) 005 AutoFuses

FUSE(INDICATOR) BASE: 2

ASSY_INDICATOR SW(PRESSURE-)

SW(PRESSURE+) BASE: 0.85 Y/R A-1

LAMP(INDICATOR) BASE: 0.5 B/L

B-1

LAMP(PTO,AUTO) 1

LAMP(INDICATOR)

15.0 BASE:

BASE:

3.0

STARTER_A W

BASE:

60.0

TO_(IND_L+) W/H23

E-OUT(ROOF)A BASE: 2.00 R/W 2.00

E-OUT(ROOF)B

TO_(IND_L-) BASE: 0.5 1 W/H23

B/L

TO_(MAIN_INDICATOR) BASE: 2.0 f B 4 W/H22

(-)

hydro-proof

BASE:

TO_(IND_MAIN+) BASE: 0.5 Y/R 1 W/H23

hydro-proof TO_(IND2-_L) BASE: 0.85 B/L 1 W/H24

TO_(IND2+_L) hydro-proof BASE: 0.85 Y/R 1 W/H24

TO_(IND_MAIN-) W/H23

TO_(IND2-) BASE: 0.5 1 W/H22

TO_(E-OUT_ROOM) BASE: 3.00 B 4 W/H00

B/L

BONDER(B)

BASE:

ATTACHMENT 2 B 1

BASE:

2.0

CAP(ATTACHMENT) CAP(ATTACHMENT) 1

G 2

FromRoom1 1 FromRoom2 2

TO_(E-OUT_ROOM) BASE: 0.50 BR 3

TO_(MAIN_INDICATOR) BASE: 0.85 Br 3 W/H22

E-OUT(ROOF)

W/H00

TO_(IND2+) 0.5 Y/R 1 W/H22

CIGGER_SOCKET

TO_(E-OUT_ROOM) TO_(MAIN_INDICATOR) BONDER(C) BASE: 3.00 B/Y BASE: 2.0 f B/Y 1 1 W/H00 W/H22

R&FBOX 48 BASE:

TO_(MAIN4) BASE: 1.25

CIGGER_SOCKET BASE: 1.25 G

BONDER(A_MAIN)

R&FBOX

SBF(2) R

5.00

STARTER_RELAY

ClosedCAB/SBF-50A 50 Bolt-on_type

ACU/SBF-40A 40 Plug-in_type

Main/SBF-60A 60 Bolt-on_type

SBF(2)

5.00

ArmHarness 20 MiniFuses

R&FBOX

CCV_HEATER/SBF-30A 30 Bolt-on_type

BASE:

Null

3.0 NOTAC:

5.0 SBF(2) BASE:

SBF(2) BASE:

8.0

B/Y

W/R

ELECTRICAL_OUTLET_RELAY

W/R

BASE: 0.85

TO_(MAIN3)

BASE:

BASE: 3.0

SBF(2)

COOLANT_VALVE BASE: 0.5

NULL

BASE: 0.50

R/W 5.0

TUBE

NULL

SW(WORK_LIGHT) 5.00

SUCTION_HEATER H-DRV f R 1

BASE:

ACCEL_SENSOR_H BASE: 0.5 O/L

BASE:

R/W 3.0 BASE:

R&FBOX 5 BASE:

RoomLight&Strobe

BASE:

2.0

GND

RETURN_HEATER BASE: 2.0 f

0.50

SW(FLOW_SET) BASE: 0.50 W

BASE: 0.5 R&FBOX 7 BASE:

5 MiniFuses RearWorkingLight

BASE:

B/Y

BASE:

SENSOR_OIL_TEMP(TANK)

Horn

2.0

TUBE

BASE:

DELIVERY_HEATER BASE: 2.0 f

R&FBOX 9 BASE:

15 MiniFuses

BASE:

0.5

B/R

0.50

R&FBOX 13 BASE:

5 MiniFuses

TO_(MAIN1)

BASE:

RETURN_HEATER H-DRV f G 1

GND

BASE:

0.50

R&FBOX 11 BASE:

0.50

B/R

GND

BASE:

0.5

TO_(MAIN1)

1.25

P R&FBOX 30 BASE:

5 MiniFuses METER(+B)

BASE:

TUBE

DELIVERY_HEATER H-DRV Y 1

2.0

BASE:

L/R

BONDER(C)

15 MiniFuses ECU-main(+B)

R/G

G/R

OFF

R&FBOX 32 BASE:

AUX_ElectricalPower

W/R

0.5

IND1

SENSOR

B/O

R 0.50

SEAT_BAR_R_SW BASE: 0.50 W

BASE: BASE:

0.5

NULL

GND

BASE:

0.5

Null

BASE: 0.85

R&FBOX 34 BASE:

BASE:

0.75

IND4

ON OFF

BASE:

2.0

U-LEV

BASE:

Vcc(12V)

B/W

BASE:

R&FBOX

0.5

BASE:

L/W

0.50

BASE:

5.00

BASE:

NOX

BAT

BASE:

SIGNAL

R&FBOX 36 BASE:

SW(SETTING/DISPLAY) BASE: 0.5 W

BASE:

SW1

TO_(ENG1) BASE: 0.50 20 BASE: 0.50 21 TO_(ENG1)

SW(DPF,INHIBIT)

BASE:

R&FBOX R/W 2

SW0

GND

R&FBOX

BASE:

5.0

GND

2.0

RELAY(3) 3.0 B/Y 3

B/W

BONDER(C)

BASE:

0.5

BASE:

BRIDGE(2)

NULL

HOLD_R_OUT

Y/R

0.50

O/B

0.5

BONDER(F)

R&FBOX R/W 8

0.5

BASE:

TO_(MAIN1) 0.50 L/W 20 BASE: 0.50 G/R TO_(MAIN1) 21

R&FBOX 50 BASE:

TO_(MAIN1) BASE: 0.50 L/R WATER_PROOF 3

R&FBOX R/W 12

BASE:

0.50

0.5

5.0

NULL

2.0

RELAY(AUX2R_F)

BASE:

HOLD_L_OUT

SIGNAL

BASE:

GND

BASE:

B/W

HOLD L

BASE:

0.85

AUX4_OUT

FLOAT

SWITCH(AC) 5 R&FBOX MiniFuses

0.5

BASE:

GND

R&FBOX 1.25 P 29

BASE:

IND3

NULL

0.50

R&FBOX 52 BASE:

ECU(AC) 20 MiniFuses

GND

0.75

TO_(ENG1) BASE: 0.50 9

R&FBOX

25 BASE:

5 MiniFuses

L/R

0.5

0.75

BASE:

NULL

BASE: 0.50

BASE:

0.5

BASE:

EGT2

hydro-proof

NULL

BASE:

CAN-L

BASE:

LEVER_R BASE:

1.25 GND

CAN-H

BONDER(C)

BASE: B

PUMP

BAT

AUX L2

5 MiniFuses FuelPump

FUEL_PUMP BASE: 0.50

0.5

0.75

TO_(MAIN2) BASE: 0.50 TO_(MAIN2) BASE: 0.50

AUX 4

SIGNAL

FUEL_PUMP

BASE:

OUT1

Control_Elements

R&FBOX

IG 18 CAN_SW 42

BASE:

U-TEMP

BONDER(D) BASE:

NULL

0.5

PUMP,ASSY DEF_PUMP_UNIT DCU_Heater_Gnd 0.75 f B/Y 1 0.5 GR Urea_Pressure 2 0.5 W XDRP 3 3PH_BLDC_B_Phose_V 0.75 f L 4 3PH_BLDC_A_Phose_U 0.75 f Y 5 Null 6 Null 7 0.85 B/W DCU_Heater_Power 8 Null 9 0.5 f B/W XDRG 10 3PH_BLDC_C_Phose_W 0.75 f G 11 Motor_Case_Gnd 0.85 B 12 Null 13 Null 14

B/W

TO_(ENG2) 0.5 Y 1 TO_(ENG2) BASE: 0.5 G 2

5 MiniFuses BACK-BUZZER

R&FBOX 3.0 R/L 31

0.5

SENSOR(NOX,POST)

BASE:

HTREL

0.5

BASE:

BASE: 0.50 W

5 MiniFuses CRS-ECU(AC)

R&FBOX

0.85

Y/R

BASE:

0.5

TO_(ENGINE_H5) BASE: 0.85 B 3

GND

OUT2

STARTER

R&FBOX R/L 35

ADR-SW

0.5 0.5

BASE:

TO_(UNLOAD) BASE: 0.85 B

CCW

AUX

VCC

SW(DPF_INHIBIT) BASE: 0.50 W

3.0

NULL

5 MiniFuses

BASE:

BASE: BASE:

B/W

TO_(MAIN1) f Y 9

3.0

R&FBOX R/L 51

0.75

BR/W

NULL

0.5

GND

NULL

BASE:

R&FBOX B/W 26

BASE:

CAN1(+) 17 CAN1(-) 16

0.5

RELAY(AUX2L_E)

0.50 BASE:

3.00

GND

W/B

BASE:

HORN

AUX R2

BASE:

0.85

SCR_TEMP_SENSOR BASE: 0.5 f B/W

BASE:

GND

W/B

0.5

SENSOR(THERMO)

SIG

BRIDGE(8)

0.85

R/W

POST_NOX_SENSOR 0.85 Y

TH(+)

0.5

TO_(ENG1) BASE: 4

3.0

Twist BASE:

CAN2(+) 28 CAN2(-) 27

TO_(MAIN1) f W/B 4

BASE:

MREL2

BASE:

1.25

B/W

0.5

AUX_3R_OUT

Y/B

3.00

SENSOR

B/Y

GLIP(RH,MULTI)

LEVER_R BASE: 0.5 W/Y

START

OFF BASE:

0.85

MREL1

0.5

R&FBOX

STARTER-SW

STARTER-SW 3.0 R/L

BASE:

GND GND GND GND GND GND

NOX

BAT

O/B

0.5

2nd

BASE:

0.5

BASE:

CCV_HEATER1 BASE: 1.25

HEATER

AUX_3L_OUT

0.5

BASE:

AUX_1R_OUT

AUX L3

0.85

CAN-L

BASE:

AUX R1

HEATER

CCV_HEATER1 L/W + 2

0.85

BASE:

Twist

CCV_HEATER2

AUX L1

BASE:

DEF_INJECTOR BASE: 0.5

L/W

BAT

0.85

INJECTOR

GND GLIP(LH,MULTI)

LEVER_L 0.5 W

BASE:

1.25

7 BASE:

BASE:

0.5

57 SGND 44 U-PRES 56 S5V 36 U 2 V 21 W 32 HT4 20 HT2 1 HT3 3 HT1 22

CAN-H

GND

BASE: 4

0.5

BASE:

EGT1

SCR_TEMP_SENSOR

0.5

BASE:

2.0

0.85

BASE:

SENSOR(NOX,PRE)

G/B

2 BASE:

0.50

BASE:

G G

BASE:

BASE: 0.5

0.5

3 BASE:

CCV_HEATER_RELAY

CCV_HEATER 20 FUSEBOX MiniFuses FUSEBOX

3.0

2 BASE:

J/C(CAN2_L)

NOTAC:

PRE_NOX_SENSOR 0.85 Y

GND

2 0.50

J/C(CAN2_H)

BASE:

TO_J/C(CAN2_H) 1 BASE: 0.75 f

JC_7182-9631-40_1

BASE:

TO_(ENG1) 0.50 Y/B 24

TO_(MAIN1) BASE: 0.5

TO_(MAIN1) BASE: 0.75

J/C(CAN2_H)

BASE:

f f

TH(-)

GND BASE: 0.5

0.5 0.5

TULC

POWER

BASE: BASE:

INJ(+)

DEF_INJECTOR

BRIDGE(9)

R/L

B/Y

R/L

B/Y

2.0

0.5

2.0

BASE:

J/C(S_GND2)

ACU BASE:

R/L

INJ(-)

2.0

3.0

ACU

2.0

MiniFuses

BONDER(ACU-HEATER) BASE:

BASE:

FORK(2)

FUSEBOX 4 BASE:

BASE:

ECU,ASSY(ACU,V38BB1)

ACU_HEATER

FUSEBOX BASE: 3.0 B/Y 3

CAP(STROBE)

STROBE BASE: 0.85 B 1

CAP(STROBE) 1

hydro-proof BASE: 0.85

Br 3

1 2 3

ASSY_STARTER A-1

B/R B-1 STARTER_B

15.0 SBF(1) BASE:

Alternator/SBF-120A 120 Bolt-on_type SBF(1) R

15.0 SBF(1) BASE:

Heater/SBF-100A 100 Bolt-on_type SBF(1) R

3.0 SBF(1) BASE:

Engine/SBF-30A 30 Plug-in_type

R/W

SBF(1)

BAT+_A BASE:

BAT+_B

60.0

B/R

TO_(BAT+) 8.00 R 2 BASE:

TO_(BAT+) 8.00 R 1

TO_(BAT_H)

BASE:

8.00

BASE:

TO_(BAT_H)

BASE:

8.00

BASE:

+ BATTERY(31) BATTERY

TO_(MAIN4) 5.00 B

TO_(ENG4) BASE: 5.00 1

BATB/Y 60.0

BONDER(D)

GND BASE:

3.00

5.0

TO_(ENG3) BASE: 5.00 1

3.00

BONDER(B)

BONDER(C) 3.00

GND

BONDER(B)

GND 3.00

BONDER(D)

GND

BASE:

BONDER(D)

BASE:

TO_(MAIN3) 5.00 B

GND

GND GND

BASE:

GND BASE:

BASE:

GND(FRAME) GND(ENGINE) ENGINE BASE: 60.0 B/Y 1

GND

FRAME

5.0

BONDER(A_MAIN)

Composition Specification Code BASE

Notes All-Use

Air Conditioner

Hydraulic Quick Hitch

Radio

NOTAC

Not Air Conditioner

W/H00 W/H00 W/H09 W/H09 W/H09 W/H13 W/H17 W/H20 W/H32 W/H33 W/H34

V0631-53314 V0631-53364 V0631-53416 V0631-53426 V0631-53466 V0521-53351 V0621-53492 V0511-53394 V0631-53243 V0631-53251 V0631-53261

W/H(MAIN) W/H(MAIN,C) W/H(ENGINE) W/H(ENGINE,H,F) W/H(ENGINE,C) W/H(ARM) W/H(UNLOAD_VALVE) W/H(WIPER) CORD,BATTERY(+) CORD,BATTERY(-) CORD,BODY_EARTH

BONDER(D)

KiSC issued 09, 2021 A

2) Closed cab specification (for U.S.)

f L

BASE: 0.75

f L

ECU,SUB-ASSY(E40-V3) BONDER(A)

FUSEBOX BASE: 0.50 12

BASE: 0.5

f SB

ECU(CRS 91P) BASE: 0.75 f B/R

FUSEBOX

BASE: 2.0

B/R

BASE: 2.0

B/R

BASE: 2.0

B/R

NE-VCC

ECU(CRS 105P) BASE: 0.50 f G

NE SENSOR BASE: 0.50 f G

BATT

NE-GND

BASE:

BASE: 0.50

NE(MRE)

SWV23

BASE: 0.5 f L ECU(CRS 91P)

SWV11

SWV4

NULL

B-88 B-3 B-6 B-5

A-47 A-26 A-5

NULL

SWV10

CRS RELAY

f R/W 6

RELAY(1) 10 BASE: 3.00

4 5

B/R

BASE: 2.0

RELAY(1) 14 Twist

1 2

2 BASE:

0.75

f BR

3 BASE:

0.5

f BR

4 BASE:

0.5

f BR

0.5

BASE: 0.75

BASE:

CAN L

GND

BASE: 0.75 f L

NULL

OUTV1

NULL

B-87

B-59

NULL

POWER(12V)

SOUT2

0.75 f BR/W ECU(CRS 105P)

B-60

SOUT6 CAN1L SOUT5 NULL SOUT3 NULL SOUT7

NULL

TO J/C(CAN1 L) 1 BASE: 0.75

f BR/W

2 BASE:

0.75

f BR/W

3 BASE:

0.5

f BR/W

4 BASE:

0.5

f BR/W

3 4 5

6 BASE:

0.5

BASE: 0.50

G/W

BASE: 0.5

L/W

BASE: 0.50

Y/G

BASE: 0.50

SENSOR(+) VO

AIR FLOW SENSOR

GND

POWER(12V)

RESISTOR120OHM 1

120 Ohm

TO RESISTOR(120) 1 BASE: 0.5 f BR

2 BASE:

0.5

13 Twist

f BR/W

CAN L

GND

BASE:

0.50

BASE:

0.50

Y/R

BASE:

0.50

BR/W

BASE:

0.50

TO (ENG1) BASE: 0.50 BR/W 32

TO (ENG1) BASE: 0.50 B 13

TO (MAIN1) BASE: 31

TO (MAIN1) BASE: 0.5 32

TO (MAIN1) BASE: 0.50

0.5

Null

f BR

BASE: 0.75

f G

BASE: 0.75

f L

WATER SEPARATOR

f BR/W

WATER SEPARATOR BASE: 0.5 f SB

W/B

f B/R

ADV2

NULL

A-GND13

BASE:

0.5

L/W

BASE:

0.50

P/B

BASE:

0.50

G/W

BASE:

0.50

Y/G

BASE:

0.75

R/B

BASE:

0.75

B/R

BASE:

ECU(CRS 91P) 0.75 f G

BASE:

0.75

BASE:

0.75

ADE13

A-GND12

A-GND3

BASE:

0.75

f L/R

ADV5

A-VCC12

BASE:

0.75

f SB

A-80 A-96 A-75

A-78 A-99 A-58

A-GND-A

A-101

A-GND5

A-105

OUTE6

A-84 B-17 B-34

BASE:

WATER SEPARATOR BASE: 1.25 f B/W

BASE:

1.25

f R

BASE:

0.75

f B

BASE:

1.25

f B/W

BASE:

0.75

f W

BASE:

COOLANT TEMP SENSOR 0.75 f L

BASE:

0.75

BASE:

1.25

PRV f B/W

BASE:

1.25

f R

A-93

BASE:

0.75

f B

BASE:

0.75

f W

A-GND6

BASE:

0.75

f R

A-57 A-97

B-41

INJ1-COM

INJECTOR1

INJ2-COM INJ3-COM

INJECTOR2

INJ4-COM N.C.2 INJ1-DRV

INJECTOR3

INJ2-DRV INJ3-DRV

INJECTOR4

INJ4-DRV

1 2 3 4 5

BASE: 1.25 f

R 2

6 7 8 9

BASE: 1.25 f

BASE: 1.25

A-43 A-64 A-22 A-1

0.5

f B4

f B6

BOOST SENSOR BASE: 0.75 f GR

ADE3

f L/B

BASE: 0.75

L/B

BASE: 0.75

Y/R

A-61

BASE:

0.75

A-GND4

BASE:

0.75 f Y/R INTAKE AIR TEMP SENSOR

ADE4

BASE:

0.75

f G

BASE:

0.75

f L

A-79

A-73

A-GND1

A-32

INTAKE AIR TEMP SENSOR 1

ECU(CRS 91P)

4 5 6 7 8

J/C(SHIELD GND)

A-1

SIG

A-2

Pressure Sensor

GND

A-3

CN2

PRV-

B-1

Reducing Valve

PRV+

B-2

BOOST SENSOR

BOOST PRESSURE SENSOR

GND

INTAKE AIR TEMP SENSOR BASE: 0.75 f L

BASE: 0.5

SWV9

COM1 SWV12 COM2 SWV14

COM2 TWV1

A-2 A-23

TWV4

SWV7

TWV2

SWV8

ADE7

BASE:

0.75

f Y

ADE8

BASE:

0.75

f B/R

NULL

A-GND3

BASE:

0.75

f GR

A-GND

ADE9

BASE:

0.75

f R/B

NULL

A-GND3

BASE:

0.75

f Y/R

A-31 A-51 A-30 A-50 A-29

NULL

GND

B-4

BASE: 2.0

f B

ECU(CRS 105P)

NULL

B-1 B-2

SWE1

NULL

SWV13

A-VCC4

NULL

OUTV2

NULL

BRIDGE(7)

GND

BASE:

NULL

CAN-SLD

NULL

f B

SENSOR DPF EX TEMP T2 BASE: 0.75 f R/B

GND GND

BASE: 0.75

B-20

NULL

f B

2.0

SENSOR DOC EX TEMP T1 BASE: 0.75 f B/R

SENSOR DPF EX TEMP T2

SENSOR DPF EX TEMP T2 BASE: 0.75 f Y/R

ECU(CRS 91P) BASE: 2.0

SENSOR DOC EX TEMP T0 BASE: 0.75 f W/B

SENSOR DOC EX TEMP T1

SWV5 NULL

ECU(CRS 91P)

ECU(CRS 105P) BASE: 0.75 f W/B

A-52

A-GND3

A-65

SENSOR DOC EX TEMP T0

SENSOR DOC EX TEMP T0 BASE: 0.75 f Y

TWV3

BASE:

0.5

BASE:

f GR

A-100

NULL

BRIDGE(4)

BASE: 0.5

0.75

OUTE1

COOLANT TEMP SENSOR BASE: 0.75 f L/R

RAIL PRESSURE SENSOR BASE: 0.75 f R

BASE:

COM1

A-44

BASE: 1.25

BRIDGE(6)

ECU(CRS 105P) BASE: 1.25 f G BASE: 1.25

SENSOR,WATER TEMP. 1

PCV BASE: 1.25 f B/R

A-VCC2

SWV3

BASE: 1.25 f

PCV-

BRIDGE(1)

OUTV5

CRS INJECTOR

N.C.1

INJECTOR

PCV+

SWV1

SOUT4

BASE: 0.5

0.50

A-76

PUMP,ASSY(SUPPLY)

PCV

f L/R

A-VCC1

2 BASE:

A-72

SWV2

A-38

SERVICE TOOL(CAP)

A-67

A-GND2

SERVICE TOOL(CAP) 1

A-66

ADE1

f B3

RAIL,ASSY CN1

PRV+

ADE5

ECU(CRS 105P) BASE: 0.5 f Y/B ECU(CRS 91P) BASE: 0.75 f Y/R

4.7ohm

VOUT

f B/R

ECU(CRS 91P)

GND

2 1

f GR

A-86

OUTV3

f LG

1.25

PRV-

0.5

ASIC

1.25

A-VCC10

A-3

BASE: 0.75

GND

BASE:

A-GND3

BASE:

VDD

BASE:

A-85

SWV6

f L/R

PCV-HI

B-51

ECU(CRS 105P) 1.25 f B/W

BASE: 0.75

PCV-LO ADV3

DPF DIFF PRESS SENSOR

DPF DIFF PRESS SENSOR BASE: 0.75 f SB

ADE2

OUTE5

f B2

GND

ECU(CRS 105P) BASE: 0.75 f LG

0.50

0.75

J/C(SHIELD GND)

BASE:

ADE11

7 Twist

BASE: 0.50

ASSY

GND

TO (ENG1) BASE: 0.50 BR 31

6 Twist

SERVICE TOOL

TPS

H IC

RESISTOR SERVICE TOOL

BASE: 0.75

NULL

INTAKE THROTTLE VALVE BASE: 0.75 f R/B

A-VCC11

NULL

J/C(CAN1 L) INTAKE THROTTLE VALVE

NULL

f BR/W

RESISTOR(120)

BRIDGE(3)

A-GND12

NULL

SENSOR(-)

TO J/C(SHIELD GND) BASE: 0.5 f B1

NULL NULL

NULL

BASE: 0.5

NULL

ADV6

POUT1

ADV7

NULL

OUTV4

NULL

INJ-SLD

NULL

A-98

BASE:

ADE6

NULL

INJ-SLD

NULL

A-GND7

NULL

A-103

BASE:

0.75

1.25

JH BASE:

0.75

Y/R

BASE:

1.25

1 2

CCV PRESSURE SWITCH

J/C(S GND2) 1

NULL

GND

Y/R

ACU HEATER 30 MiniFuses

BASE: 3.0 B/Y 3 FORK(2)

FUSEBOX 4 BASE: 3.0

BONDER(ACU-HEATER)

R/L

RELAY(40A,ISO) ACU 20 MiniFuses

FUSEBOX BASE: 3.0 B/Y 5

FUSEBOX 6 BASE: 3.0

Null

RELAY(4)

R/B

3 BASE:

0.85 R/B 1

FUSEBOX

4 5

RELAY(4) 4

BASE: 3.0

BASE: 0.5 f G

BONDER(ACU COMP)

BASE: 0.5

f G

RELAY(4)

SWITCH(SENSOR) 10 MiniFuses FUSEBOX

FUSEBOX BASE: 1.25 f R 9

FUSEBOX 10 BASE: 0.75

f R

TANK SENSOR BASE: 0.85 Y Twist

BASE: 0.85

4 2 1

TANK,ASSY

CAN-H

Twist

J/C(CAN2 H) 2 3 4 5

TO (ENG1) BASE: 0.50 Y/R 25

TO (ENG1) BASE: 0.50 Y/B 24

J/C(CAN2 H) 1

TO (MAIN1) BASE: 0.5

TO (MAIN1) BASE: 0.75

Y/B

Y/R

GND

TO J/C(CAN2 H) 1 BASE: 0.75

2 BASE:

0.5

3 BASE:

0.85

4 BASE:

0.85

5 BASE:

0.85

6 BASE:

0.50

SENSOR

GND

Twist

J/C(CAN2 L) 1

2 3 4 5 6

FUSEBOX

BASE:

RELAY(5) 2.0 R 8

BASE:

0.5

Null

Y/R 6

4 5

Twist

2 BASE:

0.5

3 BASE:

0.85

4 BASE:

0.85

5 BASE:

0.85

6 BASE:

0.50

L/W

7 BASE:

0.5

BAT

RC OUT

LEVER L BASE:

AUX R3

HORN

AUX 3R OUT

BASE:

0.5

G/L

SG OUT GND

NULL

AUX 4

BAT

0.5

10 6 4

AUX R2

BASE:

0.5

BASE:

0.5

BASE:

0.5

W/B

BASE:

0.5

G/B

AUX 2R OUT

BASE:

0.5

BASE:

0.5

B/O

FLOAT SW

BASE:

0.5

L/G

GND

BASE:

0.5

NULL

BASE:

0.5

GND

NULL

BASE:

0.5

GND

SW0

BASE:

0.5

GND

SW1

BASE:

0.5

BASE: 0.5

0.75

NULL

VALVE-

ACU HEATER RELAY

Null

R/L 1

RELAY(3) 4 BASE: 3.0

4 5

2 BASE:

0.5

GND

Twist

POWER SOCKET

CCV HEATER2 BASE: 1.25

BASE:

R&FBOX 1.25 B/R 95

BASE:

0.5

Null

B/Y 93

4 5 2

R&FBOX 97 BASE: 1.25

94 BASE:

B/L

0.5

BASE:

1.25

GND TO (ENG1) 1.25 L 29

BASE: Null

R&FBOX 1.25 B/R 100 0.5 W/B 98

3 1

4 5 2

TO (ARM H1)

TO (MAIN1) BASE: 1.25 29

hydro-proof

1 3

hydro-proof

R&FBOX 102 BASE: 1.25

99 BASE:

B/L

0.5

BASE:

1.25

BASE:

1.25

28 TO (MAIN1)

28 TO (ENG1)

TO (ENGINE ARM H1) BASE: 0.75 f B 2 BASE: 0.75 f L 1 BASE: 0.75 f R 3

BASE:

R&FBOX 1.25 B/R 70

BASE:

0.5

BASE:

R&FBOX 1.25 B/R 75

BASE:

0.5

3 1

0.50

0.5

5 2

R&FBOX 72 BASE: 1.25

L/W

69 BASE:

0.5

B/L

R&FBOX 77 BASE: 1.25

R/G

74 BASE:

B/L

BASE:

TO (ENG2) 1.25 L/W 12

BASE:

TO (ENG2) 1.25 R/G 7

TO (MAIN2) BASE: 1.25 12

hydro-proof L/W

TO (ARM H2)

4 5

TO (MAIN2) BASE: 1.25

hydro-proof R/G

TO (ARM H2)

0.5

R&FBOX 11 BASE:

0.50

Y/B

0.50

Y/B

10 5

R&FBOX 13 BASE:

R&FBOX 9 BASE:

0.85

0.50

BASE:

620

R&FBOX 5 BASE:

0.85

1.25

R&FBOX 1 BASE:

1.25

0.50

Null

0.5

G/L 6

BASE: BASE:

0.5

Y/R 88

Null

RELAY CASSETTE 5 BASE: 1.25 L/Y

4 5

2 BASE:

0.5

BASE:

TO (ENG2) TO (MAIN2) BASE: 1.25 L/Y 11 11

BASE:

TO (ENG2) 1.25 R/L 10

BASE:

TO (ENG2) 1.25 BR 9

B/L

RELAY CASSETTE 10 BASE: 1.25 R/L

7 BASE:

0.5

B/L

R&FBOX 92 BASE: 1.25

4 5

TO (ENGINE ARM H2) BASE: 0.75 f 1

1.25

L/Y

TO (ARM H2) hydro-proof 4

TO (ENGINE ARM H2) BASE: 0.75 f L/Y 4

TO (MAIN2) BASE: 1.25

R/L

TO (ARM H2) hydro-proof 3

TO (ENGINE ARM H2) BASE: 0.75 f R/L 3

TO (MAIN2) BASE: 1.25

TO (ARM H2) hydro-proof 5

BASE:

0.5

B/L

BASE:

HORN RELAY

0.50

BASE:

R&FBOX 0.85 R 60

BASE:

0.5

G 58

BASE: 0.85

BASE:

0.50

BASE:

TRAVEL SPEED SW

BASE:

0.5

AUX HOLD SW(LEFT)

G/W

BASE:

0.5

B/O

AUX HOLD SW(RIGHT)

BASE:

0.50

G/W

AUX SW

BASE:

0.50

0.5

Vcc(12V)

R/B

PRESSURE SW(BACK)

BASE:

0.50

FRONT WORK LIGHT SW

BASE:

0.50

Y/B

DPF INHIBIT SW

OPC SW

BASE:

0.5

B/L

USER SETTING SW

BASE:

0.5

B/R

DISPLAY CHANGE SW

GND

3 4

BASE:

SW(0.74M)

BASE: BASE:

L/R

SW(ARM DOWN) BASE: 0.50 L

SW PRESSURE2

BASE:

B/R

SW(ARM UP) BASE: 0.50

SW PRESSURE1

Vout

SEAT BAR L SW BASE: 0.50 G

BASE: 0.50

Vcc

SEAT BAR R SW BASE: 0.50 2 BASE: 0.50 GND 1

FUEL SENSOR

(+)

(-)

TO (MAIN1) BASE: 0.50 LG 23 TO (MAIN1) FUEL SENSOR BASE: 0.50 B 18 TO (MAIN1) BASE: 0.5 f W/Y 22

OIL TEMP. SENSOR

0.5

f O/L

2 7

BASE:

0.5

ACCEL SENSOR F

DC5V

CCW

GND Main

SENSOR(ACCEL.)

DC5V

TO (ENG1) BASE: 0.50 LG 23 TO (ENG1) BASE: 0.50 B 18 BONDER(C) TO (ENG1) BASE: 0.50 W/Y 22

CCW

GND Main

Sub

ACCEL SENSOR F BASE: 0.5 f P/L

4 2 1

BASE:

0.5 f LG/R

BASE:

0.5 f P/B

BASE:

0.5

P/L

BASE:

0.50

LG/R

BASE:

0.50

P/B

B-1

ACCEL SENSOR H BASE: 0.5 P/W

4 2 1

0.5 0.5 0.50

0.50

BR/W

0.5

0.50

BASE: 0.5

B/L

AUX SOLENOID(LEFT)

BASE: 0.50

R/G

AUX SOLENOID FEEDBACK

BASE: 0.50

0.5

P/B

BASE:

0.5

LG/B

BR/W

BASE: 0.85

0.50

A-2

Twist

BASE: 0.50

O/L

STALL GUARD FEEDBACK

BASE: 0.50

O/B

HYDRAULIC HITCH SOLENOID

P/B

A-1

BASE: 0.50

0.50

G/W

SEAT BAR SW(RIGHT)

BASE: 0.50

G/W

TRAVEL SPEED SOLENOID

BASE: 0.50

G/R

Y/B

STARTER SW(START)

BASE:

0.5

L/G

FLOAT OPERATION SW

0.50

BR/W

ENGINE OIL PRESSURE SW

BASE: 0.5

B/L

AUX-RELAY1

BASE: 0.5

B/L

STARTER AUTO RELEASE RELAY

BASE: 0.85

W/B

GLOW RELAY

BASE: 0.50

W/B

BACK BUZZER

BASE: 0.50

WARNING BUZZER

BASE: 0.50

0.5

O/L

+5V OUTPUT(SENSOR USE)

W/Y

+5V OUTPUT(SENSOR USE)

78 80

BASE:

0.5

P/L

GND(SENSOR USE)

BASE:

0.5

O/B

GND(SENSOR USE)

BASE:

0.5

P/W

GND(SENSOR USE)

BASE:

0.50

FUEL SENSOR

BASE:

0.50

W/Y

OIL TEMP SENSOR

BASE:

0.5

W/R

AUX CONTROL1

BASE:

0.5

W/B

AUX CONTROL2

0.85

AUX-RELAY2

0.5

WAKEUP SIGNAL OUTPUT

BASE: 0.50

R/B

DPF INHIBIT LED

BASE: 0.50

L/R

25 6

LG/R

ACCELERATOR SENSOR F-1

BASE:

0.50

P/B

ACCELERATOR SENSOR F-2

L/Y

BASE:

0.75

BASE:

0.75

BASE:

1.25

HORNB

BASE:

1.25

Twist

L M N P

HORN T1

A-1

B-1

J/C(CAN2 METER)

BASE:

0.50

BR/W 1

BASE:

0.50

BR/W 2

BASE:

0.5

BR/W 3

BASE:

0.50

BASE:

0.50

BASE:

0.5

1 2 3 4 5

6 J/C(CAN2 METER)

TO J/C(CAN2 METER)

BASE:

0.5

LG/B

ACCELERATOR SENSOR H-1

P/B

BASE:

0.50

BASE:

0.50

Y/R 4

232C RxD

5Twist

TxD

BASE:

CAN TOOL 0.50 BR/W 1

CAP(CAN) 1

BASE:

0.50

CAN TOOL CAN(H)

CAN(L)

GND

CAN TOOL

VCC

TO (MAIN2) BASE: 0.5

BASE:

TO (ENG2) 0.50 O/L 6

BASE:

0.50

TO (MAIN2) BASE: 0.5

O/B 5 TO (ENG2)

R/G

B/L

SOLENOID(AUX-R) BASE: 0.5 f B/L

O/L

SOLENOID(StallGuard) BASE: 0.5 f O/L

BASE: 0.5 5 TO (MAIN2)

SOLENOID(AUX-L)

SOLENOID(AUX-L) BASE: 0.5 f R/G

SW1

SW2

SOLENOID(AUX-L) BASE: 0.5 f O

SOLENOID(AUX-R)

SW1

SW2

SOLENOID(AUX-R) BASE: 0.5 f O

SOLENOID(StallGuard) 1

SW1

SW2

SOLENOID(StallGuard) BASE: 0.5 O/B

O/B

Null

SW(HITCH) Null

P/B

ON1

Null

WATER PROOF

Vcc

3 2

TO (ENG1)

0.50

R/B

TO (MAIN1)

17 H: 0.5 f O SOLENOID(Unlock)

(+)

SOLENOID(Unlock)

(-)

5 TO (ENG1) 30

SOLENOID(Lock) H: 0.5 f R/B WATER PROOF

30 TO (MAIN1)

SOLENOID(Lock)

(+)

H: 0.5 f B SOLENOID(Unlock)

(-)

GND

SOLENOID(Lock) H: 0.5 f B

GND

HITCH Valve

BASE: 0.50

G/W

10 TO (ENG1)

BASE:

10 TO (MAIN1)

0.5

0.50

BASE:

G/R

(+)

(-)

4 TO (UNLOAD)

4 TO (ENGINE H5)

TO (UNLOAD) 0.50 L/W 2

FLOAT SOL BASE: 0.5

f B

GND

0.5

B/R

VALVE UNLOAD1

BASE:

0.5

BASE:

VALVE UNLOAD2

SOLENOID(HydraulicLock)

BASE:

VALVE,ASSY

FLOAT SOL f G/W

2ND Hydlock Park Valve SOLENOID(HydraulicLock)

TO (ENGINE H5)

BASE:

VALVE UNLOAD1

SOLENOID(TravelSpeed)

BASE:

VALVE UNLOAD2

SOLENOID(HydraulicLock)

SOLENOID(TravelSpeed)

G/R

0.85

0.50

BONDER A

SOLENOID(TravelSpeed)

TO (ENGINE H5)

BASE:

0.5

SOLENOID(Parking)

L/W

VALVE UNLOAD1

SOLENOID(Parking)

BASE:

VALVE UNLOAD2

0.50

SOLENOID(Parking)

BACK BUZZER

28 9

ACCELERATOR SENSOR H-2

BASE:

0.5

B/W

BASE:

0.5

1 2

BACK BUZZER

Null 3

G 83

BASE:

1.25

STARTER SW(RUN)

BASE:

0.85

Y/R

+B(DIRECT)

BASE:

2.00

f B

GND(POWER)

TO (ENG1) BASE: 0.50 B/Y 27

TO (MAIN1)

OIL SW

OIL SW BASE: 0.75 f B/Y WATER PROOF

R&FBOX 87 BASE: 1.25 L/Y

4 5

BUZZER1 BUZZER2

METER

2 3 4 BASE: 0.50

BONDER(C)

METER

N.C(GND)

ACC

N.C(GND)

BATT

N.C(GND)

CAN L

N.C(GND)

CAN H

GND

N.C(GND)

METER BASE:

0.50

R/B

BASE:

0.50

Y/R

BASE:

0.50

BASE:

0.50

8 9

10 11

GND Twist 2

BASE:

TO (ENG1) 0.50 W/B 2

TO (MAIN1)

INTAKE HEATER RELAY

INTAKE HEATER RELAY A BASE: 0.5 f W/B

BASE:

15.0

A-1

B-1

INTAKE HEATER RELAY A BASE: 3.00 B

A-2

BASE:

C-1

15.0

GND

INTAKE HEATER RELAY C

BASE:

15.0

HEATER,INTAKE AIR

BASE:

BUZZER 0.50 BR

BASE:

0.50

BUZZER

Vcc

SW(WORK LIGHT) ON1

0.50

B/W

Vcc

ON2

Null

REAR WORK L RELAY

Null

R&FBOX BASE: 1.25 W/R 80

6 BASE: 0.50

AV0.5R(+)

AV0.5B(-)

BASE: 1.25

Vcc(R)

GND(W)

A-1

B-1

Vcc(R)

A-1

R&FBOX

R WORK LAMP L(B) BASE: 1.25 Y

Rear WorkLight L Vcc(R)

A-1

BONDER(A MAIN)

Rear WorkLight R Vcc(R)

TO (ENG3) BASE: 5.00 R/W

0.50

ROOM LAMP ROOM LAMP LAMP(ROOM) LAMP(ROOM)1 LAMP(ROOM)2 BR BASE: 0.50 1 2

A-1

SW(ROOM LAMP)

TO (TAIL L H2)

TO (TAIL L H3)

SPEAKER

SPEAKER R RA: 0.5

Y/R

RA: 0.5

SPEAKER

SW(ROOM LAMP) BASE: 0.50 B

TO (TAIL L H3)

L/Y

R WORK LAMP R(A) BASE: 2 f B

GND(W)

B-1

BASE: 1.25

R WORK LAMP L(A) BASE: 0.85 B

GND(W)

B-1

REAR WORK L(RH)3

BASE: 1.25

TO (TAIL L H2)

F WORK LAMP R(A) BASE: 0.85 B

GND(W)

REAR WORK L(RH)3

BASE: 2.0 f B 1 REAR WORK L(RH)2

BONDER(A MAIN)

Front WorkLight R B-1

REAR WORK L(RH)2

F WORK LAMP L(A) BASE: 0.85 B

BONDER(A MAIN)

BONDER(B)

Front WorkLight L

79 BASE: 0.50 B

2 10

F-Light(+) 1

L/Y

F WORK LAMP R(B) BASE: 1.25 L/Y

R&FBOX 82 BASE: 1.25 Y

TailLamp

TO (TAIL L) BASE: 1.25 L/Y

84 BASE: 0.50 B

F WORK LAMP L(B) BASE: 1.25 L/Y

SPEAKER L RA: 0.50

W/B

RA: 0.50

RADIO CONVERT RA: 0.5 Y/R 4

RA: 0.5 BR

CAP(RADIO CONVERT) 4

RA:

0.5

0.50 W/B 5

0.50

W 2

RA:

1.25

RA:

0.5

BR 6

RA:

1.25

RA: RA:

BONDER(B)

ElectricalOutlet 15 MiniFuses

R&FBOX W/R 41

5.0

AC: 0.5

BASE: 5.00

3 BASE:

RELAY(2) 3.0 W/R 8

GND

ClosedCAB/SBF-50A 50 Bolt-on type

CCV HEATER/SBF-30A 30 Bolt-on type

B 6

RELAY(2) 10 BASE: 3.0

4 5

7 BASE: 1.25

f W/B WATER PROOF

R&FBOX

Null 3 1

4 5 2

R/W

54 AC: 0.50

1 BASE: 1.25 B W/H00 1 TO (AIRRIDE-)

BONDER(A MAIN)

Attachments-2 20 MiniFuses

R&FBOX

TO_(E-OUT_ROOM) BASE: 3.00 G 2 W/H00

W/H22

SBF(2) BASE: 15.0 R

AC: 1.25 G/W

ASSY STARTER

CompressorClutch 10 MiniFuses

R&FBOX 21 AC: 1.25

BlowerMotor 20 MiniFuses

R&FBOX AC: 5.00 R 16

LAMP(INDICATOR) BASE: 0.5 B/L

AIRRIDE+

AIR RIDE SEAT (+)

1 2 AIRRIDE-

BASE:

2.00

R/B

TO (MAIN1) AC: 0.5 5

R&FBOX 15 AC: 2.00 f R

Condensor Motor/SBFPlug-in type

RELAY(1) 3

SBF(3) AC: 3.0 B/Y 2 AC: 0.5 f B/L

SBF(3)

4 5 2

RELAY(1) 5 AC: 2.0 f

FAN MOTOR W

2 AC: 0.5 f Y/L

FAN MOTOR 1

FAN2

W/H23

LAMP(PTO,AUTO) 1

LAMP(INDICATOR)

TO_(IND_L-) BASE: 0.5 1 W/H23

B/L

TO_(MAIN_INDICATOR) BASE: 2.0 f B 4 W/H22

TO_(E-OUT_ROOM) BASE: 0.50 BR 3

TO_(IND2+_L) hydro-proof BASE: 0.85 Y/R 1 W/H24

TO_(IND_MAIN-) W/H23

TO_(IND2-) BASE: 0.5 1 W/H22

TO_(E-OUT_ROOM) BASE: 3.00 B 4 W/H00

B/L

BONDER(B)

BASE:

ATTACHMENT 2 B 1

BASE:

2.0

TO_(MAIN_INDICATOR) BASE: 0.85 Br 3

W/H00

CAP(ATTACHMENT) CAP(ATTACHMENT) 1

G 2

CAP(STROBE)

STROBE BASE: 0.85 B 1

CAP(STROBE) 1

hydro-proof BASE: 0.85

Br 3

1 2 3

W/H22

Vcc ON

9 6

Vcc WS WS1

30mA

Null

WS2 Null Null

Null

3 2

SW(WIPER) AC: 1.25

G/W

AC:

1.25

L/W

AC:

0.50

AC:

0.50

WASHER MOTOR AC: 0.50 W

10 5

WASHER MOTOR (+)

(-)

WASHER MOTOR AC: 0.50 B

BONDER(A MAIN) TO (WIPER H) TO (WIPER H)

TO (MAIN H5) TO (MAIN H5)

TO (WIPER H) TO (MAIN H5) AC: 1.25 G/W @termi 1 AC: 1.25 L/W @termi 4 AC: 1.25 G @termi 3

WIPER MOTOR AC: 0.75 f G AC: 0.75

f W

AC: 0.75

f R

WIPER MOTOR 1 4 3

(+B) (S)

(+1)

WIPER MOTOR AC: 0.75 2

(-)

f B

TO (MAIN H5)

TO (WIPER H) AC: 0.85

2@termi

BONDER(A MAIN)

f R/B

COMPRESSOR RELAY Null

RELAY(2) AC: 0.5 f R/B 3 AC: 0.5

Y/L 1

4 5

RELAY(2) 5 AC: 1.25 f

2 AC: 0.5

B/L

TO DIODE(1) AC: 1.25 f L 1

DIODE(7321-9822)

DIODE(1) 1

CLUTCH,ASSY.MAGNET

COMPRESSOR AC: 1.25 f L AC: 0.5

RELAY(1)

Y/L AC:

0.5

Y/L

DIODE(1)

TO DIODE(1)

AC: 1.25

FAN MOTOR AC: 2.0 f B

GND

DIODE

RELAY(2)

FAN1

TO_(IND_L+)

FromRoom1 1 FromRoom2 2

CONDENSER RELAY SBF(3) AC: 5.0 R 1

ACC

E-OUT(ROOF)

E-OUT(ROOF)B

TO_(E-OUT_ROOM)

TO_(IND_MAIN+) BASE: 0.5 Y/R 1 W/H23

hydro-proof TO_(IND2-_L) BASE: 0.85 B/L 1 W/H24

B-1

hydro-proof

G/W

TO (ENG1) AC: 1.25 R/B 5

TO_(IND2+) 0.5 Y/R 1 W/H22

(-)

R&FBOX Null

ASSY_INDICATOR SW(PRESSURE-)

SW(PRESSURE+) BASE: 0.85 Y/R A-1

R/B

R AC: 3.0

TO (ENG4) AC: 5.00 4

R&FBOX 19 AC: 1.25

15 MiniFuses

GND

AC: 0.5

Wiper

R&FBOX AC: 3.0 R/W 20

(+)

(-)

E-OUT(ROOF)A BASE: 2.00 R/W

W/H00

OFF

WS1 ON OFF WS2

SW(WIPER) AC: 1.25 G

A-1

(+)

TO_(MAIN_INDICATOR) BASE: 2.0 f G 2 W/H22

FUSE(INDICATOR) BASE: 2

SW(WIPER)

R&FBOX

STARTER A 3.0 W

TO (MAIN AIRRIDE+) W/H00 BASE: 1.25 V 1 BASE: 1.25 B 1 W/H00 TO (MAIN AIRRIDE-)

TO_(E-OUT_ROOM) W/H00 5

TO_(MAIN_INDICATOR)

BONDER(B)

SPEAKER R(+)

CIGGER SOCKET

CIGGER SOCKET BASE: 1.25 G

TO (AIRRIDE+) W/H00

R&FBOX 48 BASE: 1.25 V

TO_(MAIN_INDICATOR) W/H22 5 R&FBOX 57 AC: 3.0

TO_(E-OUT_ROOM) TO_(MAIN_INDICATOR) BONDER(C) BASE: 3.00 B/Y BASE: 2.0 f B/Y 1 1 W/H00 W/H22

CAB RELAY R&FBOX AC: 3.0 R 55

BASE: 1.25 B

AirRideSeat 20 MiniFuses

R&FBOX BASE: 5.00 W/R 47

RELAY(2)

AC: 0.5 B/W 53

NOTAC

R&FBOX 42 BASE: 1.25 G

Attachments-1 0 MiniFuses

STARTER RELAY

Null

104 BASE: 0.50

R&FBOX 40 BASE: 1.25 W

W/R

SPEAKER L(-)

BASE: 0.85

R&FBOX 106 BASE: 5.00

TO (MAIN4) BASE: 1.25 2

G/W

TO (ENG4)

BONDER(D)

FUSE(INDICATOR) 005 AutoFuses

FUSE(INDICATOR) BASE: 2.0 f B/Y 1

AC: 1.25

R&FBOX

SBF(2) AC:

SBF(2) BASE: 5.0

ArmHarness 20 MiniFuses

RA: 1.25

B/W 103

SPEAKER R(-)

CAP(RADIO CONVERT)

0.50 BASE: 0.50

B/W

R&FBOX R/W 105

B/Y

BASE: 5.00

Null

GND

BASE:

R AC: 3.0

ELECTRICAL OUTLET RELAY

SPEAKER L(+)

BONDER(A MAIN)

W/R

ACU/SBF-40A 40 Plug-in type

0.50

0.5

B/L 2

TO (UNLOAD)

BASE:

0.50

BASE: 0.5 3 TO (MAIN2) TO (MAIN2) BASE: 0.5 8

AC:

BASE:

O 3 TO (ENG2) TO (ENG2) 0.5 B/L 8

AIR CONDITIONER RELAY

CHARGE INPUT

BASE:

0.50

ON2

L/W

B/Y

0.50

H: 0.50

BASE: 0.50

W/R

BASE:

PARKING BRAKE SOLENOID

0.50

BASE:

TO (ENG2) 0.50 R/G 4

B/R

FLOAT SOLENOID

BASE:

0.50

BASE: 0.50

HYDRAULIC LOCK SOLENOID

PRESSURE SW(ARMS DOWN)

SEAT BAR SW(LEFT)

BASE:

PRESSURE SW(ARMS UP)

BONDER(B)

@termi 3

W/R

0.75

FRONT WORK L RELAY

BASE:

SBF(2) BASE: 8.0

BASE:

SW(HITCH)

BONDER(A MAIN)

Main/SBF-60A 60 Bolt-on type SBF(2)

AC: 0.5 1 TO (ENG1)

GND

Y/L

f B/L

BLOWER RELAY

BASE:

AC:

0.5

f B/L

26 TO (MAIN1)

Null

GND

A-3

A-1

THERMOSTAT AC: 0.5 Y/L

DUAL PRESSURE SW AC: 0.5 B/L

64 AC:

BLOWER MOTOR BLOWER MOTOR BLOWER MOTOR(+) BLOWER MOTOR(-) AC: 2.00 f P/L M 1 2

BAT+ A BASE: 60.0

GND

BATTERY(31) -

BASE: 5.00

GND

BASE: 5.00 B

TO (MAIN4) 1

TO (ENG4) BASE: 5.00 1

GND

TO (ENG3) BASE: 5.00 @termi 1

TO (MAIN3)

BASE: 3.00

BONDER(D)

BONDER(B) BASE: 3.00

BONDER(D)

BASE: 5.0

GND

BONDER(C)

GND

BONDER(B)

GND BASE: 3.00

BONDER(A MAIN)

2 4 1 3

OFF Lo Me Hi SW(A/C) B/Y

AC: 1.25

B/Y

AC: 1.25

AC:

2.00

f L/Y

AC: 2.00

AC:

2.00

f G/R

AC: 2.00

L/Y G/R

AC: 0.85

BR/W

AC: 1.25

B/Y

GND(Blower)

7 3 8 4 5

SW(A/C) AC: 2.00 f B

BONDER(C)

Me Hi (+) SIGNAL

GND(A/C)

AC: 0.5

Y/L

Null

BASE: 3.00 B

GND

Y/L

ASSY SWITCH,A/C

BONDER(D)

GND B

BLOWER MOTOR AC: 2.00 f G/R

THERMOSTAT AC: 0.50 B/Y

Null

R B/Y

AC: 0.5

BLOWER RESISTER BLOWER RESISTER

BASE: 5.0

0.50

AC: 0.50 BR/W

f B/R

A-5

Null

A-2

PIPE SUCTION2

R&FBOX 67 AC: 2.00 f

B/Y

A-4

MGC

R/B 63

B/Y

THERMISTOR

B-2

0.5

R&FBOX

DUAL PRESSURE SW

PIPE SUCTION1

AC:

Null 30

AC: 0.50

B-1 THERMOSTAT

A/C

B/L

R&FBOX 2.00 f P/L 65

AC: 0.50

TO (BAT+) TO (BAT H) BASE: 8.00 R @termi 2

THERMOSTAT

0.5

26 TO (ENG1)

DUAL PRESSURE SW AC: 0.50 BR/W

THERMISTOR

AC:

AC: 2.00 f G/R

SBF(1) R 8.00

R/L

CAP(232C) 1

Null

BATB/Y

J/C(CAN2 METER)

232C B/W 1

+12V OUT

BASE: 60.0

0.75

SW(HITCH)

STALL GUARD SOLENOID

4TH FUNCTION

TO (ENG1)

R&FBOX BASE: 1.25 G 85

Alternator/SBF-120A 120 Bolt-on type

Heater/SBF-100A 100 Bolt-on type SBF(1) R 8.00

BASE:

ON1 N ON2 41

BASE:

BASE: 0.5

RIDE CONTROL SW

L/R

B/W

G/B

0.50

O/B

B/L

0.50

0.5

AUX SOLENOID(RIGHT)

BASE:

f R/G

3 Twist ECU(MAIN) BASE: TxD 76 BASE: RxD 75 CAN(H) BASE: 45 CAN(H) BASE: 46 CAN(H) BASE: 47 CAN(L) BASE: 48 CAN(L) BASE: 49 CAN(L) BASE: 50

BONDER(C)

AC: 0.5

TO (BAT+) TO (BAT H) BASE: 8.00 R @termi 1

0.75

ALTERNATOR,ASSY

SBF(1)

BAT+ B

BASE:

HEATER INTAKE AIR

SBF(1) BASE: 15.0 R

SBF(1) BASE: 3.0 R/W

Engine/SBF-30A 30 Plug-in type

f L/W

TO DIODE(HORN) 2 BASE: 0.50 B

232C

TO (MAIN1)

GND

0.75

BONDER(B)

DIODE(HORN) 2

INTAKE HEATER RELAY B

TO (MAIN4) AC: 5.00 R 4

BASE:

BASE: 0.5

BAT

SENSOR OIL TEMP(TANK) BASE: 0.5 f P/L

O/L

Sub

GND(ENGINE) ENGINE B/Y 1

BONDER(C)

+5V OUTPUT(SENSOR USE)

BONDER(C)

G/W

SCR METER BASE: 0.5

CAN-H

120 Ohm

0.50

BASE:

BONDER(C)

Vout

f B/W

BASE:

Vcc

TO (MAIN1) BASE: 0.5 8

SW PRESSURE2

0.5

0.50

BONDER(B)

SW(SETTING/DISPLAY) BASE: 0.5 B/L

SW(0.74M,B) SW PRESSURE1

BASE:

SWITCH(METER,2)

0.50

SW(BACK PRESSURE) BASE: 0.50 R/B

SW PRESSURE2

W/R

OPC SW BASE:

SEAT BAR L SW

7 ACCEL SENSOR F BASE: 0.5 f O/L

Y/R

0.50

BASE: 0.50

59 BASE:

PARKING SW

BASE:

SW PRESSURE1

OPC SW

SW(0.55M)

SW(ARM UP) 0.50 W

SENSOR OIL TEMP(TANK) BASE: 0.5 f W/Y

Y/R

HYDRAULIC UNLOCK SW

Null

Y/R

B-1 STARTER B

GND(FRAME) BASE: 60.0

BONDER(B)

CAN-L

R&FBOX 62 BASE: 1.25

0.50

RESISTANCE

ECU(MAIN)

ECU(MAIN) 0.5 Y

0.50

2 RESISTOR(OPC)

BASE:

Null

OPC SW 0.50 W

BASE: 0.50

BASE:

Null

620

BASE: 0.75 f W 4 TO (ENGINE ARM H1)

DIODE(HORN)

RESISTOR

TO RESISTOR(OPC) BASE: 0.50 L 1

BASE:

SW(HYDRAULIC LOCK)

Null

0.50

SW(HYDRAULIC LOCK) OFF

RESISTANCE(GND)

FUEL SENSOR BASE: 0.50 LG

BASE: 60.0 f B/R

FRAME

0.75

BONDER(C)

Vcc(12V)

R&FBOX

SEAT BAR R SW

SEAT BAR R SW 0.50 W 3

B/R

W/R

BASE:

TO (ENGINE ARM H2) BASE: 0.75 f BR

NULL

Null

BATTERY

1.25 W 4 TO (ARM H1)

DIODE(HORN) 1

GND

hydro-proof

SW(ARM DOWN) BASE: 0.50 W

BASE: 1.25 f

R/G

DIODE

TO (ENG1) BASE: 0.50 B/W 8

BASE: 0.50

TO DIODE(HORN) BASE: 0.50 L 1

TO DIODE(AUX4 J) 1 BASE: 0.5 Y/R

METER

Null

DIODE(AUX4 J) 1 1

DIODE(AUX4 J)

DIODE(7321-9822)

DIODE(AUX4 J) A 2 2

R WORK LAMP R(B) BASE: 1.25 Y

0.75

TO (ENGINE ARM H2) BASE: 0.75 f L/W 2

BASE: 0.50 Y/R

R&FBOX 3 BASE:

hydro-proof

SW(FLOW SET) BASE: 0.50 G/W

SW(PARKING) BASE: 0.50

RESISTANCE

Null

BASE: R&FBOX 7 BASE:

TO DIODE(AUX4 J) BASE: 0.5 G/B 2

SW(PARKING)

Null

BONDER(E)

1.25

Null

0.50

R&FBOX 1.25 B/R 90

hydro-proof

BASE:

Null

BASE:

RELAY(AUX4 J)

RESISTANCE

RESISTANCE(GND)

RELAY CASSET

620

OFF

SBF(2)

POWER SOCKET

Null

RELAY CASSETTE BASE: 1.25 B/R 3

BASE:

RESISTANCE(GND)

Null

BASE:

0.75

Null

BASE:

RELAY CASSETTE BASE: 1.25 B/R 8

L/R

OFF

TO (MAIN3)

B/R

TANK HEATER VALVE

Null

RELAY(3)

hydro-proof

0.50

Null

R/W

3.0

RELAY(AUX3L H)

BASE:

OFF

SW(WORK LIGHT) BASE: 0.50 B/W

BASE:

VALVE+

IND2

ADR-SW

ON2ON1OFF 5.00

SUCTION HEATER BASE: 2.0 f B/Y

IND1

GND

SW(WORK LIGHT) BASE:

GND

SW2

GND

G BASE:

TUBE

H-DRV

GND

RELAY(AUX1L C)

CCV HEATER1 BASE: 1.25

BASE: 0.50

ALTERNATOR A 0.75 f W/R

R&FBOX

LED(AMBER GND)

Vcc(12V)

ACCEL SENSOR H BASE: 0.5 O/L

BASE:

GND

RETURN HEATER BASE: 2.0 f B/Y

VALVE,ASSY

COOLANT VALVE BASE: 0.5 R/G

BASE: 3.0

L R/W BASE: 5.0

R/W

GND

B/R

TO (ENG1) BASE: 0.50 L/R

BASE:

BASE: 3.0

NULL

BASE:

680

GND

ALTERNATOR B 15.0 R

0.5

BASE:

NULL

RELAY(AUX1R D)

LED(AMBER)

ON SW(PARKING) BASE: 0.50 W

SEAT BAR L SW BASE: W 0.50

BASE:

SENSOR

BONDER(C)

BASE:

Null

OFF

P R&FBOX 30 BASE:

BASE: 0.50 12 TO (ENG1)

NULL

TUBE

H-DRV

SUCTION HEATER BASE: 2.0 f R

NULL

BASE: 0.50 19 TO (ENG1)

Null

SWITCH(METER,1)

SW(FLOW SET) BASE: 0.50 W

BASE:

12 TO (MAIN1)

BASE:

DELIVERY HEATER BASE: 2.0 f B/Y

BASE: 0.50 B/R TO (MAIN1) 19

BASE:

W/R

G/R

0.50

SW(SETTING/DISPLAY) BASE: 0.5 W

0.5

GND

BASE:

L/W

BASE:

SW(BACK PRESSURE) BASE: 0.50 W

0.75

BASE:

NULL

BASE:

TUBE

H-DRV

RETURN HEATER BASE: 2.0 f G

BASE: 0.50 21 TO (ENG1)

BASE:

HTREL

BASE: 0.50 G/R TO (MAIN1) 21

0.50

BONDER(C)

R&FBOX

B/R

NULL

BAT

BONDER(F)

RoomLight&Strobe 5 MiniFuses

0.5

TO (ENG1) BASE: 0.50

BASE:

R&FBOX BASE: 5.00 R/W 2

BASE:

OFF

SIGNAL

FrontWorkingLight 20 MiniFuses

R/G

IND4

SW(DPF INHIBIT)

Null

BONDER(C)

MiniFuses RearWorkingLight 15 MiniFuses

0.5

L/R

R&FBOX 32 BASE: 1.25

BASE:

TO (MAIN1) BASE: 0.50 L/W

R&FBOX 34 BASE: 0.50

Horn

TH(+)

DELIVERY HEATER BASE: 2.0 f Y

Vcc(12V)

BASE:

R&FBOX BASE: 5.0 R/W 8

PUMP,ASSY DEF PUMP UNIT DCU Heater Gnd 0.75 f B/Y 1 0.5 GR Urea Pressure 2 0.5 W XDRP 3 3PH BLDC B Phose V 0.75 f L 4 3PH BLDC A Phose U 0.75 f Y 5 Null 6 Null 7 0.85 B/W DCU Heater Power 8 Null 9 0.5 f B/W XDRG 10 3PH BLDC C Phose W 0.75 f G 11 Motor Case Gnd 0.85 B 12 Null 13 Null 14

f B/W

HORN+

B/W

SW(HYDRAULIC LOCK) BASE: 0.50 W

R&FBOX R/W 12

U-LEV

ON OFF

BASE: 5.0

2.0

R&FBOX

SIGNAL

R&FBOX 36 BASE: 0.50

AUX ElectricalPower 15 MiniFuses ECU-main(+B) 5 MiniFuses METER(+B) 5 MiniFuses

BASE:

0.5

NOX

B/W

SW(DPF,INHIBIT)

SWITCH(AC) 5 R&FBOX MiniFuses

RELAY(3) BASE: 3.0 B/Y 3

G/W

BASE:

GND

R&FBOX BASE: 1.25 P 29

BASE: 0.5

0.5

RELAY(AUX3R G)

HOLD R OUT

Y/R

R&FBOX 50 BASE: 0.50

W/R

0.5

FLOAT

TO (MAIN1) BASE: 0.50 L/R WATER PROOF 3

2.0

BASE:

BRIDGE(2)

TO (ENG1) BASE: 0.50

0.5

BASE:

TO (MAIN1) 0.5 f Y 9

BASE:

W/B

GND

BASE:

CAN-L

IND3

0.75 f

BASE:

2.0

IG 18 CAN SW 42

BASE:

Y/R

0.5

BASE:

B/W

BASE:

0.85

0.5 f BR/W

BASE:

0.75 f

BASE:

SCR TEMP SENSOR BASE: 0.5 f B/W

f B/W

BASE:

GND

0.5

BASE:

NULL

SENSOR(THERMO)

BASE:

0.75 f

0.5 f

SIG

0.5

BASE:

CAN1(+) 17 CAN1(-) 16

SCR TEMP SENSOR f P

BRIDGE(8)

BASE:

44 U-PRES 56 S5V 36 U 2 V 21 W 32 HT4 20 HT2 1 HT3 3 HT1 22

BASE: 0.5

DEF INJECTOR BASE: 0.5 f R

O/B

0.5

BASE:

HOLD L OUT

HOLD R

1.25 PUMP

CAN2(+) 28 CAN2(-) 27

RELAY(AUX2R F)

BASE:

AUX 2L OUT

Y/B

R&FBOX 52 BASE: 0.50

ECU(AC) 20 MiniFuses

L/R

BASE:

R&FBOX 25 BASE: 0.50

HOLD L

BASE: B

FUEL PUMP BASE: 0.50

0.5

MREL2

NULL

BASE:

SIGNAL

FUEL PUMP

0.5

BASE:

INJECTOR

DEF INJECTOR

NULL

LEVER R BASE: 0.5

AUX4 OUT

AUX L2

Control Elements 5 MiniFuses FuelPump 5 R&FBOX MiniFuses

R&FBOX

BASE:

MREL1

EGT2

BONDER(D) BASE:

BASE: 0.50

STARTER 5 MiniFuses CRS-ECU(AC) 5 MiniFuses

R&FBOX 3.0 R/L 31

0.5 f

5 6

TO (ENG2) 0.5 Y 1

OUT2

BASE: 0.85

R&FBOX R/L 35

BASE:

TO (ENGINE H5) BASE: 0.85 B

GND OUT1

SW(DPF INHIBIT) BASE: 0.50 W

3.0

f B 6

CCW

AUX

VCC

BACK-BUZZER 5 MiniFuses

BASE:

0.5 f

SGND

BASE: 0.5

TO (UNLOAD) BASE: 0.85 B 3

LEVER R BASE: 0.5 W/Y

Y/B BASE:

R&FBOX 3.0 R/L 51

BASE:

0.5

U-TEMP

BONDER(C)

GLIP(RH,MULTI)

BASE: 0.50

BASE:

TO (ENG1) BASE: 0.85

BASE:

HORN OUT

R&FBOX 3.00 B/W 26

0.85

0.5

TO (MAIN1) f W/B 4

BASE:

0.5

BASE:

EGT1

1.25

f R

BASE:

R/W

0.75

CAN-H

BASE:

0.5

50 10

f B 5

R&FBOX

START

OFF BASE: 3.0

0.85

BASE:

RELAY(AUX2L E)

STARTER-SW

B/W

BASE:

SENSOR(NOX,POST)

W/B

0.5

2nd

BASE: 3.00

0.5

BASE:

NULL

ADR-SW

B/Y

AUX 3L OUT

GND

O/B

0.5

BASE:

AUX 1R OUT

0.5

BASE:

AUX 1L OUT

AUX L3

GND GND GND GND GND GND

SENSOR

BASE:

STARTER-SW BASE: 3.0 R/L

0.5

GND

AUX R1

HEATER

0.85

HEATER

CCV HEATER2

AUX L1

BASE:

NOX

BAT

GND

GLIP(LH,MULTI) 1

BASE:

GND BASE:

0.85

R/L

BASE: 0.5

f G

RELAY(5) LEVER L 0.5 W

BASE:

CAN-L

POST NOX SENSOR BASE: 0.85 Y

CCV HEATER1 BASE: 1.25 L/W + 2

RELAY(5) 10 BASE: 1.25

R/L

2.0 f

CAN-H

G/B

2 BASE: 2.0

BASE: 0.85

2.0 f

BASE:

J/C(S GND2) 4

J/C(S GND2)

ACU BASE:

BASE: 0.5

CCV HEATER 20 FUSEBOX MiniFuses FUSEBOX

BASE: 0.85 B

TO J/C(CAN2 L) 1 BASE: 0.75

CCV HEATER RELAY

R 1

SENSOR(NOX,PRE)

GND

J/C(CAN2 L) J/C(CAN2 L)

BASE: 0.50 Y/R

BASE: 0.85

BASE:

INJ(+)

TH(-)

GND

f Y

J/C(CAN2 H)

AC: 3.0

ACU R/L

TULC

POWER

GND BASE: 0.5 Y/R

2.0 f

CAN-L

PRE NOX SENSOR BASE: 0.85 Y

BASE:

INJ(-)

TO J/C(S GND2) BASE: 0.85 B 4

BRIDGE(9)

ECU,ASSY(ACU,V38BB1) FUSEBOX

f B/Y

0.5

Y/R

f B/Y

BASE:

BASE: 2.0

BASE: 0.75

BASE: 2.0

2 TO (MAIN2)

ADV1

2 TO (ENG2)

J/C(CAN1 L)

A-VCC10

NULL

J/C(CAN1 L)

+12V

NULL

AIR FLOW SENSOR

AIR FLOW SENSOR BASE: 0.50 P/B

f R

CAN1H

B-77

J/C(CAN1 H)

CAN H

SOUT1

CAN2L

GND

CAN2H

B-76

CAN H

BASE: 0.75 f B

GND

VALVE,ASSY(EGR)

BASE: 0.75 f BR/W

f BR

BASE: 0.75

OUTV1

B-70

BASE: 0.50 f R ECU(CRS 91P)

A-6

f W

G SENSOR BASE: 0.50

6 BASE:

6Twist

O O

BASE: 0.50

OUT

0.50

5 Twist

f f

f W

VCC

BASE:

f BR

EGR VALVE BASE: 0.75 f BR

A-27

0.50

BASE:

G SENSOR

G SENSOR BASE: 0.50 f B

0.5

G-GND

BRIDGE(5)

BASE:

TO J/C(CAN1 H) 1 BASE: 0.75

BASE: 0.75 BASE: 0.75

f L

TO (MAIN2) BASE: 0.50

J/C(CAN1 H)

MicroComputer

J/C(CAN1 H)

ECU(CRS 105P) BASE: 0.50 f B

FORK(1)

GND

NE SENSOR BASE: 0.5

BASE:

BASE: 2.0

f Y

OUT

RELAY(1) BASE: 3.0 R/W 8

f Y

G-VCC

A-59

Null

0.50

NE SENSOR VCC

BASE: 0.5

EngineElements 5 MiniFuses

FUSEBOX B/R 11

3.0

FUSEBOX BASE: 0.75 8

BASE:

EGR 10 MiniFuses

FUSEBOX B/R 7

3.0

BASE: 0.5

BASE:

W/H00 W/H09 W/H13 W/H17 W/H20 W/H32 W/H33 W/H34

V0631-53364 V0631-53466 V0521-53351 V0621-53492 V0511-53394 V0631-53243 V0631-53251 V0631-53261

W/H(MAIN,C) W/H(ENGINE,C) W/H(ARM) W/H(UNLOAD VALVE) W/H(WIPER) CORD,BATTERY(+) CORD,BATTERY(-) CORD,BODY EARTH

BONDER(D)

KiSC issued 09, 2021 A

3) Closed cab specification (for Canada)

f L

BASE: 0.75

f L

ECU,SUB-ASSY(E40-V3) BONDER(A)

FUSEBOX BASE: 0.50 12

BASE: 0.5

f SB

ECU(CRS 91P) BASE: 0.75 f B/R

FUSEBOX

BASE: 2.0

B/R

BASE: 2.0

B/R

BASE: 2.0

B/R

NE-VCC

ECU(CRS 105P) BASE: 0.50 f G

NE SENSOR BASE: 0.50 f G

BATT

NE-GND

BASE:

BASE: 0.50

NE(MRE)

SWV23

BASE: 0.5 f L ECU(CRS 91P)

SWV11

SWV4

NULL

B-88 B-3 B-6 B-5

A-47 A-26 A-5

NULL

SWV10

CRS RELAY

f R/W 6

RELAY(1) 10 BASE: 3.00

4 5

B/R

BASE: 2.0

RELAY(1) 14 Twist

1 2

2 BASE:

0.75

f BR

3 BASE:

0.5

f BR

4 BASE:

0.5

f BR

0.5

BASE: 0.75

BASE:

CAN L

GND

BASE: 0.75 f L

NULL

OUTV1

NULL

B-87

B-59

NULL

POWER(12V)

SOUT2

0.75 f BR/W ECU(CRS 105P)

B-60

SOUT6 CAN1L SOUT5 NULL SOUT3 NULL SOUT7

NULL

TO J/C(CAN1 L) 1 BASE: 0.75

f BR/W

2 BASE:

0.75

f BR/W

3 BASE:

0.5

f BR/W

4 BASE:

0.5

f BR/W

3 4 5

6 BASE:

0.5

BASE: 0.50

G/W

BASE: 0.5

L/W

BASE: 0.50

Y/G

BASE: 0.50

SENSOR(+) VO

AIR FLOW SENSOR

GND

POWER(12V)

RESISTOR120OHM 1

120 Ohm

TO RESISTOR(120) 1 BASE: 0.5 f BR

2 BASE:

0.5

13 Twist

f BR/W

CAN L

GND

BASE:

0.50

BASE:

0.50

Y/R

BASE:

0.50

BR/W

BASE:

0.50

TO (ENG1) BASE: 0.50 BR/W 32

TO (ENG1) BASE: 0.50 B 13

TO (MAIN1) BASE: 31

TO (MAIN1) BASE: 0.5 32

TO (MAIN1) BASE: 0.50

0.5

Null

f BR

BASE: 0.75

f G

BASE: 0.75

f L

WATER SEPARATOR

f BR/W

WATER SEPARATOR BASE: 0.5 f SB

W/B

f B/R

ADV2

NULL

A-GND13

BASE:

0.5

L/W

BASE:

0.50

P/B

BASE:

0.50

G/W

BASE:

0.50

Y/G

BASE:

0.75

R/B

BASE:

0.75

B/R

BASE:

ECU(CRS 91P) 0.75 f G

BASE:

0.75

BASE:

0.75

ADE13

A-GND12

A-GND3

BASE:

0.75

f L/R

ADV5

A-VCC12

BASE:

0.75

f SB

A-80 A-96 A-75

A-78 A-99 A-58

A-GND-A

A-101

A-GND5

A-105

OUTE6

A-84 B-17 B-34

BASE:

WATER SEPARATOR BASE: 1.25 f B/W

BASE:

1.25

f R

BASE:

0.75

f B

BASE:

1.25

f B/W

BASE:

0.75

f W

BASE:

COOLANT TEMP SENSOR 0.75 f L

BASE:

0.75

BASE:

1.25

PRV f B/W

BASE:

1.25

f R

A-93

BASE:

0.75

f B

BASE:

0.75

f W

A-GND6

BASE:

0.75

f R

A-57 A-97

B-41

N.C.1 INJ1-COM

INJECTOR1

INJ2-COM INJ3-COM

INJECTOR2

INJ4-COM N.C.2 INJ1-DRV

INJECTOR3

INJ2-DRV INJ3-DRV

INJECTOR4

INJ4-DRV

1 2 3 4 5

BASE: 1.25 f

R 2

6 7 8 9

BASE: 1.25 f

BASE: 1.25

A-43 A-64 A-22 A-1

BASE:

0.5

f B4

f B6

COOLANT TEMP SENSOR BASE: 0.75 f L/R

BASE: 0.5

ADE3

f L/B

BASE: 0.75

L/B

BASE: 0.75

Y/R

BASE:

0.75

A-GND4

BASE:

0.75 f Y/R INTAKE AIR TEMP SENSOR

ADE4

BASE:

0.75

f G

BASE:

0.75

f L

A-79

A-73

A-GND1

A-32

INTAKE AIR TEMP SENSOR 1

ECU(CRS 91P)

4 5 6 7 8

J/C(SHIELD GND)

A-1

SIG

A-2

Pressure Sensor

GND

A-3

CN2

PRV-

B-1

Reducing Valve

PRV+

B-2

BOOST SENSOR

BOOST PRESSURE SENSOR

GND

INTAKE AIR TEMP SENSOR BASE: 0.75 f L

BASE: 0.5

SI BOOST SENSOR BASE: 0.75 f GR

A-61

SWV9

COM1 SWV12 COM2 SWV14

COM2 TWV1

A-2 A-23

A-65

BASE:

0.5

f GR

A-100

TWV4

SWV7

TWV2

SWV8

ADE7

NULL

BASE:

0.75

f Y

ADE8

BASE:

0.75

f B/R

NULL

A-GND3

BASE:

0.75

f GR

A-31 A-51 A-30

A-GND

ADE9

NULL

A-GND3

A-50 A-29

BASE:

0.75

f R/B

BASE:

0.75

f Y/R

NULL

GND

B-4

BASE: 2.0

f B

ECU(CRS 105P)

NULL

B-1 B-2

SWE1

NULL

SWV13

A-VCC4

NULL

OUTV2

NULL

BRIDGE(7)

GND

BASE:

NULL

CAN-SLD

NULL

f B

SENSOR DPF EX TEMP T2 BASE: 0.75 f R/B

GND GND

BASE: 0.75

B-20

NULL

f B

2.0

SENSOR DOC EX TEMP T1 BASE: 0.75 f B/R

SENSOR DPF EX TEMP T2

SENSOR DPF EX TEMP T2 BASE: 0.75 f Y/R

ECU(CRS 91P) BASE: 2.0

SENSOR DOC EX TEMP T0 BASE: 0.75 f W/B

SENSOR DOC EX TEMP T1

SWV5

NULL

ECU(CRS 105P) BASE: 0.75 f W/B

A-52

A-GND3

ECU(CRS 91P)

SENSOR DOC EX TEMP T0

SENSOR DOC EX TEMP T0 BASE: 0.75 f Y

TWV3

NULL

BRIDGE(4)

SENSOR,WATER TEMP.

0.75

OUTE1

RAIL PRESSURE SENSOR BASE: 0.75 f R

BASE:

COM1

A-44

BASE: 1.25

BRIDGE(6)

ECU(CRS 105P) BASE: 1.25 f G BASE: 1.25

PCV BASE: 1.25 f B/R

A-VCC2

SWV3

BASE: 1.25 f

PCV-

BRIDGE(1)

OUTV5

CRS INJECTOR

INJECTOR

PCV+

SWV1

SOUT4

BASE: 0.5

0.50

A-76

PUMP,ASSY(SUPPLY)

PCV

f L/R

A-VCC1

2 BASE:

A-72

SWV2

A-38

SERVICE TOOL(CAP)

A-67

A-GND2

SERVICE TOOL(CAP) 1

A-66

ADE1

f B3

RAIL,ASSY CN1

PRV+

ADE5

ECU(CRS 105P) BASE: 0.5 f Y/B ECU(CRS 91P) BASE: 0.75 f Y/R

4.7ohm

VOUT

f GR

ECU(CRS 91P)

GND

2 1

f B/R

A-86

OUTV3

f LG

1.25

PRV-

0.5

ASIC

1.25

A-VCC10

A-3

BASE: 0.75

GND

BASE:

A-GND3

BASE:

VDD

BASE:

A-85

SWV6

f L/R

PCV-HI

B-51

ECU(CRS 105P) 1.25 f B/W

BASE: 0.75

PCV-LO ADV3

DPF DIFF PRESS SENSOR

DPF DIFF PRESS SENSOR BASE: 0.75 f SB

ADE2

OUTE5

f B2

GND

ECU(CRS 105P) BASE: 0.75 f LG

0.50

0.75

J/C(SHIELD GND)

BASE:

ADE11

7 Twist

BASE: 0.50

ASSY

GND

TO (ENG1) BASE: 0.50 BR 31

6 Twist

SERVICE TOOL

TPS

H IC

RESISTOR SERVICE TOOL

BASE: 0.75

NULL

INTAKE THROTTLE VALVE BASE: 0.75 f R/B

A-VCC11

NULL

J/C(CAN1 L) INTAKE THROTTLE VALVE

NULL

f BR/W

RESISTOR(120)

BRIDGE(3)

A-GND12

NULL

SENSOR(-)

TO J/C(SHIELD GND) BASE: 0.5 f B1

NULL

BASE: 0.5

ADV6

POUT1

ADV7

NULL

OUTV4

NULL

INJ-SLD

NULL

A-98

BASE:

NULL

ADE6

BASE: 0.5

SWITCH, CCV PRESSURE

NULL

INJ-SLD

NULL

A-GND7

NULL

A-103

1.25

SW(PRESSURE)

BASE:

0.75

JH BASE:

0.75

Y/R

BASE:

1.25

1 2

J/C(S GND2) 1

NULL

BASE: 0.75 f

Y/R

BASE:

Y/R

GND

BONDER(ACU-HEATER)

R/L

RELAY(40A,ISO) ACU 20 MiniFuses

FUSEBOX BASE: 3.0 B/Y 5

FUSEBOX 6 BASE: 3.0

Null

RELAY(4)

R/B

3 BASE:

0.85 R/B 1

FUSEBOX

4 5

RELAY(4) 4

BASE: 3.0

BASE: 0.5 f G

BONDER(ACU COMP)

BASE: 0.5

f G

RELAY(4)

SWITCH(SENSOR) 10 MiniFuses FUSEBOX

FUSEBOX BASE: 1.25 f R 9

FUSEBOX 10 BASE: 0.75

f R

TANK SENSOR BASE: 0.85 Y Twist

BASE: 0.85

4 2 1

TANK,ASSY

CAN-H

Twist

J/C(CAN2 H)

J/C(CAN2 H) 1

Y/R f

2 3 4 5 6

f Y

2 BASE:

0.5

3 BASE:

0.85

4 BASE:

0.85

5 BASE:

0.85

6 BASE:

0.50

GND

SENSOR

GND

Twist

BASE: 0.85

BASE:

BASE: BASE: BASE:

J/C(CAN2 L) 1

1 2 3 4 5 6

BASE: 0.50 Y/R

TO J/C(CAN2 L) 1 BASE: 0.75

2 5

2 BASE:

0.5

3 BASE:

0.85

4 BASE:

0.85

5 BASE:

0.85

6 BASE:

0.50

0.85 0.75

G f R

0.85

GND

f G

R/L

2.0 f

R/L

BASE:

0.5

BASE:

0.5

BASE:

0.5

BASE:

0.5

BASE:

0.5 f

BASE:

0.5 f

BASE:

0.5

BASE:

0.5

10 11

CAN-L

NOX

BAT

GND GND GND GND GND GND

SENSOR

GND ADR-SW

0.5 f

BASE:

0.5 f BR/W

BASE:

0.5

Y/R

BASE:

0.5

18 CAN SW 42

BASE:

0.5

NULL

BASE:

0.5

GND

NULL

BASE:

0.5

GND

NULL

BASE:

0.5

GND

SW0

BASE:

0.5

GND

SW1

BASE:

0.5

CAN1(+) 17 CAN1(-) 16

10 7

BASE: 0.5

46 47 48

RELAY(5)

5 2

BASE: 0.5

CCV HEATER2 BASE: 1.25 f B

BAT

RC OUT

LEVER L BASE:

AUX 1L OUT

AUX R1

AUX 1R OUT

AUX L3

AUX R3

HORN

0.5

BASE:

0.5

BASE:

0.5

AUX 4

BAT

LEVER R BASE: 0.5

9 10 6 4

AUX R2

HOLD L

BASE:

0.5

W/B

BASE:

0.5

G/B

AUX 2R OUT

BASE:

0.5

BASE:

0.5

B/O

FLOAT SW

BASE:

0.5

L/G

GND

BASE:

0.5

BASE:

0.50

BASE:

0.50

Null Null

4 5

B 7

BASE:

R&FBOX 1.25 B/R 95

BASE:

0.5

0.50

BASE: BASE:

0.5

BASE:

R&FBOX 1.25 B/R 75

BASE:

0.5

3 1

5 2

4 5 2

3 2

0.50

Y/B

10 5

SUCTION HEATER BASE: 2.0 f R

0.75

BASE: 0.5

0.5

0.50

RESISTANCE(GND)

620

BASE:

0.50

SW2 IND1 IND2

ACU HEATER RELAY

4 5 2

0.50

R&FBOX 11 BASE:

R&FBOX 13 BASE:

R&FBOX 9 BASE:

1.25

0.85

0.50

R&FBOX 5 BASE:

0.85

1.25

R/L 1

RELAY(3) 4 BASE: 3.0

4 5

2 BASE:

0.5

GND

Twist

R&FBOX 97 BASE: 1.25

94 BASE:

B/L

0.5

BASE:

TO (ENG1) 1.25 L 29

1.25

TO (ARM H1)

TO (MAIN1) BASE: 1.25 29

99 BASE:

B/L

0.5

BASE:

1.25

BASE:

1.25

1 3

28 TO (MAIN1)

28 TO (ENG1)

TO (ENGINE ARM H1) BASE: 0.75 f B 2 BASE: 0.75 f L 1 BASE: 0.75 f R 3

hydro-proof

R&FBOX 102 BASE: 1.25

R&FBOX 72 BASE: 1.25

L/W

69 BASE:

0.5

B/L

R&FBOX 77 BASE: 1.25

R/G

74 BASE:

B/L

TO (MAIN2) BASE: 1.25

hydro-proof L/W

TO (ARM H2)

TO (MAIN2) BASE: 1.25

hydro-proof R/G

TO (ARM H2)

BASE:

TO (ENG2) 1.25 L/W 12

BASE:

TO (ENG2) 1.25 R/G 7

0.5

R&FBOX 1 BASE:

1.25

0.50

RELAY CASSETTE 5 BASE: 1.25 L/Y

4 5

2 BASE:

0.5

BASE:

TO (ENG2) TO (MAIN2) BASE: 1.25 L/Y 11 11

Null

G/L 6

BASE: BASE:

0.5

Y/R 88

Null

BASE:

R&FBOX 0.85 R 60

BASE:

0.5

BASE: 0.85

G 58

TO (ENGINE ARM H2) BASE: 0.75 f 1

BASE:

TO (ENG2) 1.25 R/L 10

BASE:

TO (ENG2) 1.25 BR 9

B/L

L/Y

TO (ARM H2) hydro-proof 4

TO (ENGINE ARM H2) BASE: 0.75 f L/Y 4

RELAY CASSETTE 10 BASE: 1.25 R/L

TO (MAIN2) BASE: 1.25

R/L

TO (ARM H2) hydro-proof 3

TO (ENGINE ARM H2) BASE: 0.75 f R/L 3

7 BASE:

0.5

B/L

R&FBOX 92 BASE: 1.25

4 5

TO (MAIN2) BASE: 1.25

TO (ARM H2) hydro-proof 5

BASE:

0.5

B/L

BASE:

Null

620

0.5

B/R

BASE: 0.50

OPC SW

Vcc(12V)

GND

SW PRESSURE1

SWITCH(METER,2)

BASE:

SW(0.74M) 2

BASE:

Vcc

BASE: 0.50

B/R

L/R

FUEL SENSOR

(+)

(-)

0.50

0.5

TO (MAIN1) BASE: 0.50 LG 23 TO (MAIN1) FUEL SENSOR BASE: 0.50 B 18 TO (MAIN1) BASE: 0.5 f W/Y 22

f O/L

7 ACCEL SENSOR F BASE: 0.5 f O/L

BASE:

0.5

CCW

GND Main Sub

W/R

SENSOR(ACCEL.)

DC5V

TO (ENG1) BASE: 0.50 LG 23 TO (ENG1) BASE: 0.50 B 18 BONDER(C) TO (ENG1) BASE: 0.50 W/Y 22

CCW

GND Main

Sub

W/R

5 2

59 BASE:

0.50

ACCEL SENSOR F BASE: 0.5 f P/L

4 2 1

BASE:

0.5 f LG/R

BASE:

0.5 f P/B

BASE:

0.5

P/L

BASE:

0.50

LG/R

BASE:

0.50

P/B

TO (MAIN1) BASE: 0.5 8

B-1

ACCEL SENSOR H BASE: 0.5 P/W

4 2 1

A-2

2 RESISTOR(OPC)

A-1

0.5

P/B

BASE:

0.5

LG/B

4 5

BASE: 0.5

BR/W

BASE: 0.85

Twist

BASE:

0.5

AUX HOLD SW(LEFT)

RxD

G/W

0.5

B/O

AUX HOLD SW(RIGHT)

CAN(H)

BASE:

0.50

G/W

AUX SW

CAN(H)

BASE:

0.50

PARKING SW

CAN(H)

CAN(L)

55 72

B/L

BASE: 0.50

B/W

BASE:

ECU(MAIN) BASE: 0.50

45 46 47 48

BASE: 0.5

BASE: 0.50

BR/W

BASE: 0.5

BASE: 0.50

BASE:

0.50

Y/R

HYDRAULIC UNLOCK SW

CAN(L)

BASE:

0.50

OPC SW

CAN(L)

BASE:

0.50

R/B

PRESSURE SW(BACK)

AUX SOLENOID(RIGHT)

BASE: 0.5

B/L

BASE:

0.50

FRONT WORK LIGHT SW

AUX SOLENOID(LEFT)

BASE: 0.50

R/G

BASE:

0.50

Y/B

DPF INHIBIT SW

AUX SOLENOID FEEDBACK

BASE: 0.50

BASE:

0.5

B/L

USER SETTING SW

BASE:

0.5

B/R

DISPLAY CHANGE SW

73 74

0.5

BASE: 0.50

O/L

STALL GUARD FEEDBACK

BASE: 0.50

O/B

HYDRAULIC HITCH SOLENOID

P/B

BASE:

0.5

G/B

0.50

L/R

PRESSURE SW(ARMS UP)

BASE:

0.50

PRESSURE SW(ARMS DOWN)

BASE:

0.50

G/W

SEAT BAR SW(RIGHT)

BASE: 0.50

G/W

TRAVEL SPEED SOLENOID

BASE: 0.50

G/R

3 1

Y/B

STARTER SW(START)

BASE:

0.5

L/G

FLOAT OPERATION SW

BASE: 0.5

B/L

AUX-RELAY1

BASE: 0.5

B/L

STARTER AUTO RELEASE RELAY

BASE: 0.85

W/B

GLOW RELAY

BASE: 0.50

W/B

BACK BUZZER

BASE: 0.50

WARNING BUZZER

BASE: 0.50

O/L

+5V OUTPUT(SENSOR USE)

W/Y

+5V OUTPUT(SENSOR USE)

78 80

BASE:

0.5

P/L

GND(SENSOR USE)

BASE:

0.5

O/B

GND(SENSOR USE)

BASE:

0.5

P/W

GND(SENSOR USE)

BASE:

0.50

FUEL SENSOR

BASE:

0.50

W/Y

OIL TEMP SENSOR

BASE:

0.5

W/R

AUX CONTROL1

BASE:

0.5

W/B

AUX CONTROL2

0.85

AUX-RELAY2

ENGINE OIL PRESSURE SW

0.5

BASE: 0.50

WAKEUP SIGNAL OUTPUT

BASE: 0.50

DPF INHIBIT LED

R/B L/R

25 6

LG/R

ACCELERATOR SENSOR F-1

BASE:

0.50

P/B

ACCELERATOR SENSOR F-2

0.50

Y/R 4

TO (MAIN2) BASE: 0.5

BASE:

TO (ENG2) 0.50 O/L 6

BASE:

0.50

TO (MAIN2) BASE: 0.5

O/B

Vcc

SW(WORK LIGHT) ON1

BASE:

0.5

LG/B

ACCELERATOR SENSOR H-1

BASE:

0.75

L/Y

BASE:

0.75

BASE:

0.75

L M N P

BASE:

1.25

HORNB

BASE:

1.25

HORN T1

A-1

B-1

J/C(CAN2 METER)

BASE:

0.50

BR/W 1

BASE:

0.50

BR/W 2

BASE:

0.5

BR/W 3

BASE:

0.50

BASE:

0.50

BASE:

0.5

1 2 3 4 5

6 J/C(CAN2 METER)

232C RxD

5Twist

TxD

BASE:

CAN TOOL 0.50 BR/W 1

CAP(CAN) 1

BASE:

0.50

CAN TOOL CAN(H)

CAN(L)

GND

CAN TOOL

VCC

SOLENOID(AUX-L)

SOLENOID(AUX-L) BASE: 0.5 f R/G

R/G

B/L

SOLENOID(AUX-R) BASE: 0.5 f B/L

O/L

SOLENOID(StallGuard) BASE: 0.5 f O/L

SW1

SW2

SOLENOID(AUX-L) BASE: 0.5 f O

SOLENOID(AUX-R)

SW1

SW2

SOLENOID(AUX-R) BASE: 0.5 f O

SOLENOID(StallGuard) 1

SW1

SW2

SOLENOID(StallGuard) BASE: 0.5 O/B

O/B

Null

SW(HITCH) Null

P/B

ON1

Null

WATER PROOF

Vcc

3 2

TO (ENG1)

0.50

R/B

TO (MAIN1)

17 H: 0.5 f O SOLENOID(Unlock)

(+)

SOLENOID(Unlock)

(-)

5 SOLENOID(Lock) H: 0.5 f R/B WATER PROOF

30 TO (MAIN1)

SOLENOID(Lock)

(+)

H: 0.5 f B SOLENOID(Unlock)

(-)

GND

SOLENOID(Lock) H: 0.5 f B

GND

HITCH Valve

BASE: 0.50

G/W

10 TO (ENG1)

0.5

0.50

BASE:

G/R

(+)

(-)

4 TO (UNLOAD)

4 TO (ENGINE H5)

TO (UNLOAD) 0.50 L/W 2

FLOAT SOL BASE: 0.5

f B

GND

0.5

B/R

VALVE UNLOAD1

BASE:

0.5

BASE:

VALVE UNLOAD2

SOLENOID(HydraulicLock)

BASE:

VALVE,ASSY

FLOAT SOL f G/W

2ND Hydlock Park Valve SOLENOID(HydraulicLock)

TO (ENGINE H5)

BASE:

10 TO (MAIN1)

SOLENOID(TravelSpeed)

G/R

VALVE UNLOAD1

SOLENOID(TravelSpeed)

BASE:

VALVE UNLOAD2

0.85

SOLENOID(HydraulicLock)

0.50

BONDER A

SOLENOID(TravelSpeed)

BASE:

TO (ENGINE H5)

BASE:

0.5

SOLENOID(Parking)

L/W

VALVE UNLOAD1

SOLENOID(Parking)

BASE:

VALVE UNLOAD2

0.50

SOLENOID(Parking)

BACK BUZZER

ACCELERATOR SENSOR H-2

BASE:

0.5

B/W

BASE:

0.5

1 2

BACK BUZZER

BASE:

1.25

STARTER SW(RUN)

BASE:

0.85

Y/R

+B(DIRECT)

BASE:

2.00

f B

GND(POWER)

TO (ENG1) BASE: 0.50 B/Y 27

TO (MAIN1)

OIL SW

OIL SW BASE: 0.75 f B/Y WATER PROOF

R&FBOX 87 BASE: 1.25 L/Y

4 5

BUZZER1 BUZZER2

METER

2 3 4 BASE: 0.50

BONDER(C)

METER

N.C(GND)

ACC

N.C(GND)

BATT

N.C(GND)

CAN L

N.C(GND)

CAN H

GND

N.C(GND)

METER BASE:

0.50

R/B

BASE:

0.50

Y/R

BASE:

0.50

BASE:

0.50

8 9

10 11

GND Twist 2

BASE:

TO (ENG1) 0.50 W/B 2

TO (MAIN1)

INTAKE HEATER RELAY

INTAKE HEATER RELAY A BASE: 0.5 f W/B

BASE:

15.0

A-1

B-1

INTAKE HEATER RELAY A BASE: 3.00 B

A-2

BASE:

C-1

15.0

GND

INTAKE HEATER RELAY C

BASE:

15.0

HEATER,INTAKE AIR

BASE:

BUZZER 0.50 BR

BASE:

0.50

BUZZER

0.50

B/W

Vcc

ON2

Null

R&FBOX BASE: 1.25 W/R 80

6 BASE: 0.50

AV0.5R(+)

AV0.5B(-)

BASE: 1.25

Vcc(R)

GND(W)

A-1

B-1

Vcc(R)

A-1

R&FBOX

R WORK LAMP L(B) BASE: 1.25 Y

Rear WorkLight L Vcc(R)

A-1

BONDER(A MAIN)

Rear WorkLight R Vcc(R)

0.50

ROOM LAMP ROOM LAMP LAMP(ROOM) LAMP(ROOM)1 LAMP(ROOM)2 BR BASE: 0.50 1 2

A-1

SW(ROOM LAMP)

TO (TAIL L H2)

TO (TAIL L H3)

SPEAKER

SPEAKER R RA: 0.5

Y/R

RA: 0.5

SPEAKER

SW(ROOM LAMP) BASE: 0.50 B

TO (TAIL L H3)

L/Y

R WORK LAMP R(A) BASE: 2 f B

GND(W)

B-1

BASE: 1.25

R WORK LAMP L(A) BASE: 0.85 B

GND(W)

B-1

REAR WORK L(RH)3

BASE: 1.25

TO (TAIL L H2)

F WORK LAMP R(A) BASE: 0.85 B

GND(W)

REAR WORK L(RH)3

BASE: 2.0 f B 1 REAR WORK L(RH)2

BONDER(A MAIN)

Front WorkLight R B-1

REAR WORK L(RH)2

F WORK LAMP L(A) BASE: 0.85 B

BONDER(A MAIN)

BONDER(B)

Front WorkLight L

79 BASE: 0.50 B

2 10

F-Light(+) 1

L/Y

F WORK LAMP R(B) BASE: 1.25 L/Y

R&FBOX 82 BASE: 1.25 Y

TailLamp

TO (TAIL L) BASE: 1.25 L/Y

84 BASE: 0.50 B

REAR WORK L RELAY

TO (ENG3) BASE: 5.00 R/W

SPEAKER L RA: 0.50

W/B

RA: 0.50

RA: 0.5 BR

CAP(RADIO CONVERT)

RADIO CONVERT RA: 0.5 Y/R 4

RA:

0.5

0.50 W/B 5

0.50

W 2

RA:

1.25

RA:

0.5

BR 6

RA:

1.25

RA: RA:

BASE: 104 BASE: 0.50

BONDER(B)

BASE: 5.00

ElectricalOutlet 15 MiniFuses

R&FBOX W/R 41

5.0

AC: 0.5

R&FBOX

SBF(2) AC:

BASE:

B 6

GND

ClosedCAB/SBF-50A 50 Bolt-on type

CCV HEATER/SBF-30A 30 Bolt-on type

Null

RELAY(2) 3.0 W/R 8

RELAY(2) 10 BASE: 3.0

4 5

7 BASE: 1.25

f W/B WATER PROOF

R&FBOX

R&FBOX AC: 3.0 R 55

3 1

5 2

R&FBOX 57 AC: 3.0

R/W

54 AC: 0.50

1 BASE: 1.25 B W/H00 1 TO (AIRRIDE-)

BONDER(A MAIN)

Attachments-2 20 MiniFuses

R&FBOX

TO_(E-OUT_ROOM) BASE: 3.00 G 2 W/H00

W/H22

SBF(2) BASE: 15.0 R

AC: 1.25 G/W

ASSY STARTER

CompressorClutch 10 MiniFuses

R&FBOX 21 AC: 1.25

BlowerMotor 20 MiniFuses

R&FBOX AC: 5.00 R 16

GND

LAMP(INDICATOR) BASE: 0.5 B/L

AIRRIDE+

AIR RIDE SEAT (+)

BASE:

2 AIRRIDE-

2.00

R/B

TO (MAIN1) AC: 0.5 5

R&FBOX 15 AC: 2.00 f R

Plug-in type

Null

RELAY(1) 3

SBF(3) AC: 3.0 B/Y 2 AC: 0.5 f B/L

SBF(3)

4 5 2

RELAY(1) 5 AC: 2.0 f

FAN MOTOR W

2 AC: 0.5 f Y/L

FAN1

FAN2

W/H23

B-1

LAMP(PTO,AUTO) 1

LAMP(INDICATOR)

TO_(IND_L-) BASE: 0.5 1 W/H23

B/L

TO_(MAIN_INDICATOR) BASE: 2.0 f B 4 W/H22

E-OUT(ROOF)B

TO_(E-OUT_ROOM) BASE: 0.50 BR 3

TO_(IND2+_L) hydro-proof BASE: 0.85 Y/R 1 W/H24

TO_(IND_MAIN-) W/H23

TO_(IND2-) BASE: 0.5 1 W/H22

TO_(E-OUT_ROOM) BASE: 3.00 B 4 W/H00

B/L

BONDER(B)

BASE:

ATTACHMENT 2 B 1

BASE:

2.0

TO_(MAIN_INDICATOR) BASE: 0.85 Br 3

W/H00

CAP(ATTACHMENT) CAP(ATTACHMENT) 1

G 2

CAP(STROBE)

STROBE BASE: 0.85 B 1

CAP(STROBE) 1

hydro-proof BASE: 0.85

Br 3

1 2 3

W/H22

Vcc ON

9 6

Vcc WS WS1

30mA

Null

WS2 Null Null

Null

3 2

SW(WIPER) AC: 1.25

G/W

AC:

1.25

L/W

AC:

0.50

AC:

0.50

WASHER MOTOR AC: 0.50 W

10 5

WASHER MOTOR (+)

(-)

WASHER MOTOR AC: 0.50 B

BONDER(A MAIN) TO (WIPER H) TO (WIPER H)

TO (MAIN H5) TO (MAIN H5)

TO (WIPER H) TO (MAIN H5) AC: 1.25 G/W @termi 1 AC: 1.25 L/W @termi 4 AC: 1.25 G @termi 3

WIPER MOTOR AC: 0.75 f G AC: 0.75

f W

AC: 0.75

f R

WIPER MOTOR 1 4 3

(+B) (S)

(+1)

WIPER MOTOR AC: 0.75 2

(-)

f B

TO (MAIN H5)

TO (WIPER H) AC: 0.85

2@termi

BONDER(A MAIN)

f R/B

COMPRESSOR RELAY Null

RELAY(2) AC: 0.5 f R/B 3 AC: 0.5

Y/L 1

4 5

RELAY(2) 5 AC: 1.25 f

2 AC: 0.5

B/L

TO DIODE(1) AC: 1.25 f L 1

DIODE(7321-9822)

DIODE(1) 1

CLUTCH,ASSY.MAGNET

COMPRESSOR AC: 1.25 f L AC: 0.5

RELAY(1)

Y/L AC:

0.5

Y/L

DIODE(1)

TO DIODE(1)

AC: 1.25

FAN MOTOR AC: 2.0 f B

GND

DIODE

RELAY(2)

FAN MOTOR 1

TO_(IND_L+)

FromRoom1 1 FromRoom2 2

CONDENSER RELAY Condensor Motor/SBF-

ACC

E-OUT(ROOF)

G/W

TO (ENG1) AC: 1.25 R/B 5

TO_(IND_MAIN+) BASE: 0.5 Y/R 1 W/H23

hydro-proof TO_(IND2-_L) BASE: 0.85 B/L 1 W/H24

(-)

R&FBOX

SBF(3) AC: 5.0 R 1

ASSY_INDICATOR SW(PRESSURE-)

SW(PRESSURE+) BASE: 0.85 Y/R A-1

R/B

R AC: 3.0

TO (ENG4) AC: 5.00 4

R&FBOX 19 AC: 1.25

15 MiniFuses

(+)

(-)

AC: 0.5

Wiper

R&FBOX AC: 3.0 R/W 20

(+)

E-OUT(ROOF)A BASE: 2.00 R/W

W/H00

TO_(IND2+) 0.5 Y/R 1 W/H22

hydro-proof

TO_(E-OUT_ROOM)

OFF

WS1 ON OFF WS2

SW(WIPER) AC: 1.25 G

A-1

TO_(MAIN_INDICATOR) BASE: 2.0 f G 2 W/H22

FUSE(INDICATOR) BASE: 2

SW(WIPER)

R&FBOX

STARTER A 3.0 W

TO (MAIN AIRRIDE+) W/H00 BASE: 1.25 V 1 BASE: 1.25 B 1 W/H00 TO (MAIN AIRRIDE-)

TO_(E-OUT_ROOM) W/H00 5

TO_(MAIN_INDICATOR)

BONDER(B)

SPEAKER R(+)

CIGGER SOCKET

CIGGER SOCKET BASE: 1.25 G

TO (AIRRIDE+) W/H00

R&FBOX 48 BASE: 1.25 V

TO_(MAIN_INDICATOR) W/H22 5 4

TO_(E-OUT_ROOM) TO_(MAIN_INDICATOR) BONDER(C) BASE: 3.00 B/Y BASE: 2.0 f B/Y 1 1 W/H00 W/H22

CAB RELAY Null

TO (MAIN4) BASE: 1.25 2

BASE: 1.25 B

AirRideSeat 20 MiniFuses

R&FBOX BASE: 5.00 W/R 47

RELAY(2)

AC: 0.5 B/W 53

NOTAC

R&FBOX 42 BASE: 1.25 G

Attachments-1 0 MiniFuses

STARTER RELAY

R&FBOX 40 BASE: 1.25 W

W/R

R&FBOX 106 BASE: 5.00

SPEAKER L(-)

BASE: 0.85

TO (ENG4)

G/W

ArmHarness 20 MiniFuses

BONDER(D)

FUSE(INDICATOR) 005 AutoFuses

FUSE(INDICATOR) BASE: 2.0 f B/Y 1

AC: 1.25

SPEAKER R(-)

CAP(RADIO CONVERT)

RA: 1.25

B/W 103

GND

0.50 BASE: 0.50

B/W

R&FBOX R/W 105

Null

SPEAKER L(+)

BONDER(A MAIN)

R AC: 3.0

BASE: 5.00

B/Y SBF(2) BASE: 5.0

ACU/SBF-40A 40 Plug-in type

R/L

TO J/C(CAN2 METER)

BASE: 0.5 5 TO (MAIN2)

5 TO (ENG2)

F WORK LAMP L(B) BASE: 1.25 L/Y

@termi 3

W/R SBF(2) BASE: 8.0

Main/SBF-60A 60 Bolt-on type SBF(2)

AC: 0.5 1 TO (ENG1)

GND

Y/L

f B/L

BLOWER RELAY

BASE:

AC:

0.5

f B/L

26 TO (MAIN1)

A-4

Null Null

GND

A-3

A-1

THERMOSTAT AC: 0.5 Y/L

DUAL PRESSURE SW AC: 0.5 B/L

64 AC:

BLOWER MOTOR BLOWER MOTOR BLOWER MOTOR(+) BLOWER MOTOR(-) AC: 2.00 f P/L M 1 2

BAT+ A BASE: 60.0

GND

BATTERY(31) -

BASE: 5.00

GND

BASE: 5.00 B

TO (MAIN4) 1

TO (ENG4) BASE: 5.00 1

GND

TO (ENG3) BASE: 5.00 @termi 1

TO (MAIN3)

BASE: 3.00

BONDER(D)

BONDER(B) BASE: 3.00

BASE: 5.0

GND

BONDER(D)

BONDER(C)

GND

BONDER(B)

GND BASE: 3.00

BONDER(A MAIN)

2 4 1 3

OFF Lo Me Hi SW(A/C) B/Y

AC: 1.25

B/Y

AC: 1.25

AC:

2.00

f L/Y

AC: 2.00

AC:

2.00

f G/R

AC: 2.00

L/Y G/R

AC: 0.85

BR/W

AC: 1.25

B/Y

GND(Blower)

7 3 8 4 5

SW(A/C) AC: 2.00 f B

BONDER(C)

Me Hi (+) SIGNAL

GND(A/C)

AC: 0.5

Y/L

Null

BASE: 3.00 B

GND

Y/L

ASSY SWITCH,A/C

BONDER(D)

GND B

BLOWER MOTOR AC: 2.00 f G/R

THERMOSTAT AC: 0.50 B/Y

Null

R B/Y

AC: 0.5

BLOWER RESISTER BLOWER RESISTER

BASE: 5.0

0.50

AC: 0.50 BR/W

f B/R

A-5

MGC

PIPE SUCTION2

R&FBOX 67 AC: 2.00 f

B/Y

THERMISTOR

B-2

A-2

R/B 63

B/Y

THERMOSTAT

A/C

0.5

R&FBOX

DUAL PRESSURE SW

PIPE SUCTION1

AC:

Null 30

AC: 0.50

B-1

B/L

R&FBOX 2.00 f P/L 65

AC: 0.50

TO (BAT+) TO (BAT H) BASE: 8.00 R @termi 2

THERMOSTAT

0.5

26 TO (ENG1)

DUAL PRESSURE SW AC: 0.50 BR/W

THERMISTOR

AC:

AC: 2.00 f G/R

SBF(1) R 8.00

Twist

TO (ENG1) 30

BATB/Y

0.75

0.50

P/B

BASE: BASE:

TO (UNLOAD)

BASE:

0.5

BASE: 0.5 3 TO (MAIN2) TO (MAIN2) BASE: 0.5 8

BR/W

0.5

B/L 2

O 3 TO (ENG2) TO (ENG2) 0.5 B/L 8

AC:

BASE:

0.50

ON2

AIR CONDITIONER RELAY

CHARGE INPUT

BASE:

0.50

H: 0.50

L/W

B/Y

BASE:

BASE: 0.50

W/R

BONDER(B)

BASE: 60.0

BASE:

SW(HITCH)

PARKING BRAKE SOLENOID

0.50

BASE:

TO (ENG2) 0.50 R/G 4

B/R

FLOAT SOLENOID

SEAT BAR SW(LEFT)

0.50

BASE: 0.50

HYDRAULIC LOCK SOLENOID

BASE:

0.50

Null

4TH FUNCTION

BASE:

Null

G 83

ELECTRICAL OUTLET RELAY

Alternator/SBF-120A 120 Bolt-on type

Heater/SBF-100A 100 Bolt-on type SBF(1) R 8.00

f R/G

SW(HITCH)

STALL GUARD SOLENOID

BASE:

0.75

FRONT WORK L RELAY

W/R

AC: 0.5

TO (BAT+) TO (BAT H) BASE: 8.00 R @termi 1

BASE:

ON1 N ON2

RIDE CONTROL SW

TO (ENG1)

R&FBOX BASE: 1.25 G 85

BASE:

SBF(1)

BAT+ B

f L/W

CAP(232C) 1

BASE:

0.50

50 3

O/B

BASE:

BONDER(A MAIN)

SBF(1) BASE: 15.0 R

SBF(1) BASE: 3.0 R/W

Engine/SBF-30A 30 Plug-in type

0.75

3 Twist

TO (MAIN1)

GND

BASE:

J/C(CAN2 METER)

232C B/W 1

+12V OUT

BASE: 0.50

TO (MAIN4) AC: 5.00 R 4

TO DIODE(HORN) 2 BASE: 0.50 B

232C

BASE:

GND(ENGINE) ENGINE B/Y 1

ALTERNATOR,ASSY

B-1 STARTER B

GND(FRAME) BASE: 60.0

0.75

HEATER INTAKE AIR

BASE: 60.0 f B/R

FRAME

BASE:

BONDER(B)

DIODE(HORN) 2

INTAKE HEATER RELAY B

BASE:

BASE: 0.5

BONDER(C)

120 Ohm

BATTERY

BONDER(C)

f B/W

TO (MAIN1)

SCR METER BASE: 0.5

BAT

BONDER(B)

TxD

BONDER(C)

BASE: 1.25 f

0.75

BONDER(B)

CAN-H

SENSOR OIL TEMP(TANK) BASE: 0.5 f P/L

O/L

ACCEL SENSOR F

DC5V

BASE: 0.75 f W 4 TO (ENGINE ARM H1)

CAN-L

R&FBOX 62 BASE: 1.25

+5V OUTPUT(SENSOR USE)

BONDER(C)

OIL TEMP. SENSOR

ECU(MAIN)

G/W

TRAVEL SPEED SW

BASE:

BONDER(C)

SEAT BAR R SW BASE: 0.50 2 BASE: 0.50 GND 1

Null

R WORK LAMP R(B) BASE: 1.25 Y

BASE:

TO (ENGINE ARM H2) BASE: 0.75 f BR

DIODE(HORN)

DIODE(HORN) 1

NULL

ECU(MAIN) 0.5 Y

BASE:

SEAT BAR L SW BASE: 0.50 G

Vout

R/G

DIODE

BASE:

BASE: 2

TO DIODE(HORN) BASE: 0.50 L 1

TO DIODE(AUX4 J) 1 BASE: 0.5 Y/R

SW(ARM DOWN) BASE: 0.50 L

SW PRESSURE2

0.5

SW(ARM UP) BASE: 0.50

SW PRESSURE1

DIODE(AUX4 J) 1 1

SW PRESSURE2

SW(SETTING/DISPLAY) BASE: 0.5 B/L

SW(0.74M,B) SW PRESSURE1

0.50

SW(BACK PRESSURE) BASE: 0.50 R/B

SW PRESSURE2

Vout

SENSOR OIL TEMP(TANK) BASE: 0.5 f W/Y

OPC SW BASE:

SW(0.55M)

Y/R

Vcc

FUEL SENSOR BASE: 0.50 LG

Y/R

Null

BASE: 0.50

RESISTANCE

Null

OPC SW 0.50 W

SEAT BAR L SW

1.25 W 4 TO (ARM H1)

RESISTOR

TO RESISTOR(OPC) BASE: 0.50 L 1

BASE:

SW(HYDRAULIC LOCK)

Null

RESISTANCE(GND)

0.50

SW(HYDRAULIC LOCK)

OFF

SBF(2)

0.75

BONDER(C)

OFF

DIODE(AUX4 J) A 2 2

R&FBOX

BASE: 0.50

DIODE(7321-9822)

HORN RELAY

SEAT BAR R SW

SEAT BAR R SW 0.50 W 3

BASE:

TO (ENGINE ARM H2) BASE: 0.75 f L/W 2

1.25

GND

BASE: 0.50 Y/R

R&FBOX 3 BASE:

Vcc(12V)

SW(ARM DOWN) BASE: 0.50 W

BASE: R&FBOX 7 BASE:

Null

DIODE(AUX4 J)

Null

OFF

TO (MAIN3)

Null

METER

hydro-proof

BONDER(E)

R/W

3.0

TANK HEATER VALVE

Null VALVE-

TO (ENG1) BASE: 0.50 B/W 8

SW(PARKING) BASE: 0.50

RESISTANCE

Null

SW(WORK LIGHT) BASE: 0.50 B/W

BASE:

B/R

R&FBOX 30 BASE:

R&FBOX 1.25 B/R 90

ON2ON1OFF 5.00

VALVE+

SW(WORK LIGHT) BASE:

SUCTION HEATER BASE: 2.0 f B/Y

VALVE,ASSY

COOLANT VALVE BASE: 0.5 R/G

G BASE:

GND

POWER SOCKET

Null

hydro-proof

SW(FLOW SET) BASE: 0.50 G/W

BASE: 0.50

ALTERNATOR A 0.75 f W/R

TUBE

H-DRV

GND

TO DIODE(AUX4 J) BASE: 0.5 G/B 2

SW(PARKING)

Null

ACCEL SENSOR H BASE: 0.5 O/L

BASE:

Null

L R/W BASE: 5.0

Null

RELAY CASSETTE BASE: 1.25 B/R 3

Y/B

BASE:

Null

BASE:

R/W

R&FBOX 1.25 B/R 100 0.5 W/B 98

R&FBOX 1.25 B/R 70

hydro-proof

RESISTANCE

GND

BASE: 3.0

B/Y 93

RELAY(AUX4 J)

620

Null

SEAT BAR L SW BASE: W 0.50

ALTERNATOR B 15.0 R

GND

RELAY CASSET

RESISTANCE(GND)

Null

SW(ARM UP) BASE: 0.50 W

BASE:

H-DRV

RETURN HEATER BASE: 2.0 f B/Y

GND

BASE:

L/R

OFF

TO (ENG1) BASE: 0.50 L/R

BASE:

BASE: 0.50 12 TO (ENG1)

TUBE

POWER SOCKET

Null

RELAY CASSETTE BASE: 1.25 B/R 8

0.50

Vcc(12V)

SW(SETTING/DISPLAY) BASE: 0.5 W

12 TO (MAIN1)

0.5

hydro-proof

BASE:

SW(BACK PRESSURE) BASE: 0.50 W

W/R

BASE:

BASE: RETURN HEATER BASE: 2.0 f G

RELAY(AUX3L H)

LED(AMBER GND)

ON 7

BASE:

B/R

BASE:

RELAY(AUX2L E)

680

OFF

SW(PARKING) BASE: 0.50 W

BONDER(C)

0.75

0.5

BASE:

DELIVERY HEATER BASE: 2.0 f B/Y

R&FBOX

LED(AMBER)

SWITCH(METER,1)

SW(FLOW SET) BASE: 0.50 W

BONDER(F)

BASE:

GND

RELAY(AUX1L C)

R&FBOX

R/G

TUBE

H-DRV

RELAY(3)

BONDER(C)

BASE:

Null

BONDER(C)

RoomLight&Strobe 5 MiniFuses

0.5

NULL

SW(DPF INHIBIT) OFF

SIGNAL

R&FBOX BASE: 5.00 R/W 2

BASE:

B/R

Vcc(12V)

BASE:

FrontWorkingLight 20 MiniFuses

DELIVERY HEATER BASE: 2.0 f Y

BASE: 0.50 19 TO (ENG1)

L/R

R&FBOX 32 BASE: 1.25

MiniFuses RearWorkingLight 15 MiniFuses

BASE:

HORN+

B/W

R&FBOX 34 BASE: 0.50

NULL

ON OFF

SIGNAL

R&FBOX 36 BASE: 0.50

Horn

2.0

R&FBOX SW(DPF,INHIBIT)

TO (MAIN1) BASE: 0.50 L/R WATER PROOF 3

R&FBOX BASE: 5.0 R/W 8

BASE:

ADR-SW

B/W

SW(HYDRAULIC LOCK) BASE: 0.50 W

R&FBOX R/W 12

GND

G/W

BASE:

ON OFF

BASE: 5.0

RELAY(AUX3R G)

HOLD R OUT

Y/R

R&FBOX 50 BASE: 0.50

W/R

0.5

HOLD L OUT

HOLD R

0.5

BASE:

FLOAT

AUX ElectricalPower 15 MiniFuses ECU-main(+B) 5 MiniFuses METER(+B) 5 MiniFuses

2.0

O/B

BASE:

AUX 2L OUT

GND

R&FBOX BASE: 1.25 P 29

BASE:

BASE: 0.5

BRIDGE(2)

BASE: 3.0

BASE:

Y/B

R&FBOX 52 BASE: 0.50

SWITCH(AC) 5 R&FBOX MiniFuses

BASE: 0.50 B/R TO (MAIN1) 19

R&FBOX 25 BASE: 0.50

ECU(AC) 20 MiniFuses

G/R

0.5

2.0

L/W

BASE:

BASE: 0.50 21 TO (ENG1)

B/W

BASE: 0.50 G/R TO (MAIN1) 21

GND

0.85

TO (ENG1) BASE: 0.50

PUMP

0.75 f

BASE:

RELAY(AUX2R F)

AUX4 OUT

AUX L2

L/R

BASE:

1.25 B

BASE:

BASE: 0.50

BASE:

FUEL PUMP

f B/W

TO (ENG2) 0.5 Y 1

OUT1

SIGNAL

FUEL PUMP BASE: 0.50

0.75 f

0.5

TO (ENGINE H5) BASE: 0.85 B

GND

OUT2

Control Elements 5 MiniFuses FuelPump 5 R&FBOX MiniFuses

R&FBOX

BASE:

NULL

BONDER(D) BASE:

BASE:

TO (UNLOAD) BASE: 0.85 B 3

START

STARTER 5 MiniFuses CRS-ECU(AC) 5 MiniFuses

R&FBOX 3.0 R/L 31

0.75 f

NULL

SG OUT

CCW

AUX

VCC

BASE: 0.85

R&FBOX R/L 35

W/B

GLIP(RH,MULTI)

LEVER R BASE: 0.5 W/Y

SW(DPF INHIBIT) BASE: 0.50 W

3.0

BASE:

R&FBOX

BACK-BUZZER 5 MiniFuses

BASE:

IND4

BONDER(C)

Y/B BASE:

R&FBOX 3.0 R/L 51

0.5

GND

BASE: 0.50

BASE:

R&FBOX 3.00 B/W 26

0.5

BASE:

OFF R/W

B/Y

HORN OUT

STARTER-SW

BASE: 3.0

SCR TEMP SENSOR BASE: 0.5 f B/W

BASE:

U-LEV

BASE:

0.5

G/L

NULL

GND

RELAY(3) BASE: 3.0 B/Y 3

BASE:

0.5

NULL

SENSOR(THERMO)

IND3

O/B

BASE:

2nd

AUX 3R OUT

B/W

BASE: 0.5

0.5

BASE:

AUX 3L OUT

0.85

BRIDGE(8)

BASE:

DEF INJECTOR BASE: 0.5 f R

f B/W

GLIP(LH,MULTI)

LEVER L 0.5 W

0.5

RELAY(AUX1R D)

AUX L1

BASE: 3.00

GND

BASE:

STARTER-SW BASE: 3.0 R/L

BASE: 0.5

CCV HEATER3 BASE: 1.25 f B

SIG

NULL

SENSOR

5 6

BASE:

TO (MAIN1) BASE: 0.50 L/W

SCR TEMP SENSOR f P

EGT2

0.5

CAN-L BAT

f B 6

NULL

NOX

BASE: 0.5

BASE:

BASE: 2.0 f W

BASE: 0.5

TO (ENG1) BASE: 0.50

Y/R 1

NULL

GND

BASE: 0.5

NULL

INJECTOR

DEF INJECTOR

TO (MAIN1) 0.5 f Y 9

BASE: 1.25 f B

HTREL

JOINT CONNECTOR BASE: 1.25 f B

BASE: 1.25 f B

HEATER

CCV HEATER3 RELAY(5)

BASE:

BASE: 2.0

CCV HEATER RELAY

Null

HEATER

CCV HEATER2

NULL

f B 5

W/B

BASE: 2.0

RELAY(5)

TO (ENG1) BASE: 0.85

TH(+)

TO (MAIN1) f W/B 4

FUSEBOX

Y/R 6

0.5

U-TEMP

BASE:

CAN-H

CCV HEATER1 BASE: 1.25 f B

MREL2

BASE: 0.5

1.25

BASE: 0.5

BASE: 2.0 f W

MREL1

44 U-PRES 56 S5V 36 U 2 V 21 W 32 HT4 20 HT2 1 HT3 3 HT1 22

BASE:

RELAY(5)

SGND

BASE:

SENSOR(NOX,POST)

G/B

2 BASE: 2.0

Null

RELAY(5) BASE: 2.0 R 8

CAN2(+) 28 CAN2(-) 27

BASE: 0.5

CCV HEATER AC: 3.0 R 1 30 FUSEBOX MiniFuses FUSEBOX

HEATER

CCV HEATER1 f W + 2

BASE: 2.0

EGT1

CCV HEATER RELAY

0.5

CAN-H

POST NOX SENSOR BASE: 0.85 Y Twist

J/C(CAN2 L) J/C(CAN2 L)

0.85

SENSOR(NOX,PRE) 4

2.0 f

BASE:

TH(-)

GND

J/C(CAN2 H)

TO (ENG1) BASE: 0.50 Y/R

TO (ENG1) BASE: 0.50 Y/B 24

BASE: 0.85

BASE: 0.85 B

TO (MAIN1) BASE: 0.5

TO (MAIN1) BASE: 0.75

Y/B f

TO J/C(CAN2 H) 1 BASE: 0.75

BASE:

INJ(+)

TULC

POWER

PRE NOX SENSOR BASE: 0.85 Y Twist

2.0 f

CAN-L

GND BASE: 0.5 Y/R

ACU R/L

BASE:

J/C(S GND2) 4

J/C(S GND2)

ACU BASE:

f B/Y

FORK(2)

4 BASE: 3.0

INJ(-)

f B/Y

ACU HEATER 30 MiniFuses

BASE: 3.0 B/Y 3

FUSEBOX

TO J/C(S GND2) BASE: 0.85 B 4

BRIDGE(9)

ECU,ASSY(ACU,V38BB1) FUSEBOX

BASE: 2.0

0.5

BASE: 2.0

2 TO (MAIN2)

ADV1

2 TO (ENG2)

J/C(CAN1 L)

A-VCC10

NULL

J/C(CAN1 L)

+12V

NULL

AIR FLOW SENSOR

AIR FLOW SENSOR BASE: 0.50 P/B

f R

CAN1H

B-77

J/C(CAN1 H)

CAN H

SOUT1

CAN2L

GND

CAN2H

B-76

CAN H

BASE: 0.75 f B

GND

VALVE,ASSY(EGR)

BASE: 0.75 f BR/W

f BR

BASE: 0.75

OUTV1

B-70

BASE: 0.50 f R ECU(CRS 91P)

A-6

f W

G SENSOR BASE: 0.50

6 BASE:

6Twist

O O

BASE: 0.50

OUT

0.50

5 Twist

f f

f W

VCC

BASE:

f BR

EGR VALVE BASE: 0.75 f BR

A-27

0.50

BASE:

G SENSOR

G SENSOR BASE: 0.50 f B

0.5

G-GND

BRIDGE(5)

BASE:

TO J/C(CAN1 H) 1 BASE: 0.75

BASE: 0.75 BASE: 0.75

f L

TO (MAIN2) BASE: 0.50

J/C(CAN1 H)

MicroComputer

J/C(CAN1 H)

ECU(CRS 105P) BASE: 0.50 f B

FORK(1)

GND

NE SENSOR BASE: 0.5

BASE:

BASE: 2.0

f Y

OUT

RELAY(1) BASE: 3.0 R/W 8

f Y

G-VCC

A-59

Null

0.50

NE SENSOR VCC

BASE: 0.5

EngineElements 5 MiniFuses

FUSEBOX B/R 11

3.0

FUSEBOX BASE: 0.75 8

BASE:

EGR 10 MiniFuses

FUSEBOX B/R 7

3.0

BASE: 0.5

BASE:

W/H00 W/H09 W/H13 W/H17 W/H20 W/H32 W/H33 W/H34

V0631-53364 V0631-53466 V0521-53351 V0621-53492 V0511-53394 V0631-53243 V0631-53251 V0631-53261

W/H(MAIN,C) W/H(ENGINE,C) W/H(ARM) W/H(UNLOAD VALVE) W/H(WIPER) CORD,BATTERY(+) CORD,BATTERY(-) CORD,BODY EARTH

BONDER(D)

*KCL : Kubota Canada Ltd. *KCL : Kubota Canada Ltd.

KiSC issued 09, 2021 A

7. JOINT CONNECTORS (1)

(1)

(3)

(4) (2)

(2)

(3)

(4)

(6) (5)

(6)

(5)

(1) Main Joint Connector 32P (2) Main Joint Connector 12P

(3) Main Joint Connector 4P (4) Main Joint Connector 3P

(5) Unload Valve Connector 4P (6) Wiper Motor Connector 4P

SVL97-2 KiSC issued 09, 2021 A

8. TESTER CODE AND ERROR CODE [1] SERVICE MODE

[2] TESTER MODE

Mode

Item

Explanation

No.

Item

No.

Item

No.

Item

No-01

Tester mode

Displays the machine information, and the status of the sensors and solenoids.

Engine speed

Travel speed shift solenoid

DPF inhibit switch

No-02

AUX knob-switch setting

Sets the L/R ends and neutral for the AUX knob switch. • When replaced the AUX knob switch

Battery voltage

Hydraulic lock release switch

DPF forced manual regeneration switch

No-03

AUX start-up point setting

Sets the original of the AUX. • When replaced an attachment or cylinder • When repaired hydraulic equipment

Engine oil

Hydraulic lock release SOL

AUX1 knob voltage (current value)

No-04

AUX current fine setting

Charge

AUX1 knob voltage (left setting value)

No-05

HST start-up point setting

Starter position

AUX relay

AUX1 knob voltage (setting value neutral)

No-06

Work lamp

AUX switch

AUX1 knob voltage (right setting value)

No-07

Accelerator dial/pedal setting

Coolant temperature

AUX current

Hydraulic oil temperature

Seat bar right switch

AUX left current start-up point setting value

No-08

Accelerator pedal main voltage

Seat bar left switch

AUX right current start-up point setting value

No-09

Read error history

Displays an error-code and hour meters that occurred in the past.

Accelerator pedal sub voltage

Parking brake switch

Hydraulic quick hitch SOL

No-10

Clear error history

Clear error history of No-09

Accelerator dial main voltage

Parking brake SOL

Anti-stall current

Read vall error history

Displays all error codes and hour meters that occurred in the past. • Cannot clear with No-10 (clear error history)

No-11

Accelerator dial sub voltage

Float switch

Cab relay output

AUX flow rate adjustment

Adjusts the AUX flow rate • When repaired related hydraulic equipment.

No-12

Accelerator pedal main voltage (MIN setting)

Float SOL

Buzzer

Accelerator pedal main voltage (MAX setting)

Boom up pressure switch

Model setup

Accelerator dial main voltage (MIN setting)

Boom down pressure switch

High flow setting

Accelerator dial main voltage (MAX setting)

Settings connector

DEF water level

Fuel voltage

Back buzzer switch

DEF concentration

Fuel resistance

Back buzzer output

DEF temperature

Water separator full of water switch

OPC switch

Time until engine output limit

Travel speed shift switch

DPF inhibit switch lamp

Time until idling output limit

Fine setting for the start-up point of the actuator (cylinder) attached to AUX. Sets the travel forward/reverse start-up point • When the HST pump, anti-stall Solenoid Valve, or travel pilot valve is replaced Adjusts the Accelerator dial/pedal • These settings are required when the ECU, accelerator dial / pedal, or accelerator sensor is replaced

SVL97-2 (1/2) KiSC issued 09, 2021 A

[3] ERROR LIST • Error warning list Display

Error

E:001

Meter CAN non-communication

E:004

Hydraulic oil temperature rising (advance warning)

E:005

Hydraulic oil temperature overheating

E:008

Fuel sensor error

E:009

Accelerator dial sensor error

E:010

Travel speed shift solenoid error

E:011

Parking brake solenoid error

E:012

Float solenoid error

E:013

Hydraulic unlock solenoid error

E:014

Low hydraulic oil temperature error

E:015

Hydraulic hitch solenoid error

E:016

AUX knob-switch error

E:018

AUX right solenoid error

E:019

AUX left solenoid error

E:020

Anti-stall solenoid error

E:021

5 V error

E:023

Battery over voltage

E:024

Hydraulic oil temperature sensor error

E:026

CRS CAN communication error

E:027

ACU CAN communication error

E:028

Accelerator pedal sensor error

E:9116

Engine overheating

E:9118

Engine oil pressure error

E:9119

Battery charging error

E:9120

Water separator error

• Engine error warning list • Use the engine diagnostic tool to check the details for engine error. Display

Error

Display

Error

Display

Error

E:9000

Level 2 Regeneration request

E:9123

PCV error

E:9503

Tank level: Empty

E:9001

Level 3 Regeneration request

E:9124

PRV error

E:9504

Tank leakage detected

E:9002

Level 3 Regenerating

E:9125

HP5 system error

E:9505

SCR temperature sensor error

E:9003

Level 4 Warning

E:9126

CCV pressure error

E:9506

CAN1 bus off communication error

E:9004

Level 5 Warning

E:9200

Air mass flow sensor system error

E:9507

CAN2 bus off communication error

E:9006

Level 2 Inhibit warning

E:9203

Intake throttle error

E:9508

NOx sensor CAN communication error

E:9007

Level 3 Inhibit warning

E:9204

Pressure differential sensor system error

E:9509

CAN receive data error

E:9010

Engine stop to protect DPF (Stopping the engine for DPF)

E:9205

Exhaust temperature sensor (DOC intake) error

E:9510

Urea injector error

E:9100

RPM sensor system error

E:9206

Exhaust temperature sensor (DOC outlet) error

E:9511

Suction line heater HT1 (S) error

E:9101

Fuel/rail pressure system error

E:9207

Exhaust temperature sensor (DPF outlet) error

E:9512

Delivery line heater HT3 (D) error

E:9102

SCV system error

E:9208

Simultaneous disconnection of all exhaust temperature sensors error

E:9513

Return line heater HT (R) error

E:9103

Intake temperature sensor system error

E:9211

DOC reaction error

E:9514

Supply unit heater HT2 (E) error

E:9104

Water temperature sensor system error

E:9212

DPF regeneration time up error

E:9515

Heater relay error

E:9105

Fuel temperature sensor system error

E:9213

Insufficient DPF regeneration/water temperature rise

E:9516

Tank heater coolant valve malfunction

E:9106

Injector system error

E:9214

Regeneration too frequent

E:9517

Diesel Exhaust Fluid piping pump error

E:9107

Intake pressure sensor system error

E:9300

P/L valve opening error

E:9518

SCR purification system

E:9108

Battery voltage error

E:9301

Rail pressure error high pressure

E:9519

Diesel Exhaust Fluid tank quality sensor error

E:9109

Sensor voltage system error

E:9302

Fuel leak (high-pressure fuel system)

E:9520

Diesel Exhaust Fluid quality error

E:9110

Main relay system error

E:9303

SCV sticking diagnosis

E:9521

Pre-NOx sensor

E:9112

Atmospheric pressure sensor system error

E:9304

Supply pump error (high-pressure)

E:9522

Post-NOx sensor

E:9113

EGR valve system error

E:9305

Insufficient intake error

E:9523

Urea injection pressure detection

E:9114

EGR starting to close warning

E:9306

Turbo boost insufficient increase error

E:9524

5 V analog power supply

E:9115

Emissions warning (overheat)

E:9307

Exhaust temperature increase error T0

E:9525

System power supply

E:9116

Engine overheating

E:9308

Exhaust temperature increase error T1

E:9526

ACU flash ROM

E:9117

Air heater system error

E:9309

Exhaust temperature increase error T2

E:9527

EGR system error

E:9118

Engine oil pressure error

E:9310

Starter drive inhibit error

E:9550

Other SCR system-related error

E:9119

Battery charging error

E:9400

Other engine ECU, DPF

E:9600

Horsepower limit for pump protection

E:9120

Water separator error

E:9500

Diesel Exhaust Fluid piping pressure sensor error

E:9601

Engine output limit

E:9121

Engine ECU error

E:9501

Diesel Exhaust Fluid tank temperature sensor error

E:9602

Engine idling limit

E:9122

Communication error

E:9502

Diesel Exhaust Fluid tank level sensor error

SVL97-2 (2/2) KiSC issued 09, 2021 A

INDEX A

abbreviation............................................................... xvii accelerator dial setting................................................................ 7-74 accelerator pedal..................................................... 4-25 part drawing....................................................... 4-25 removing............................................................ 4-25 removing/installing............................................. 4-25 setting................................................................ 7-74 adapter assembling.........................................................6-75 air cleaner................................................................ 5-27 cleaning..............................................................3-23 part drawing....................................................... 5-27 removing............................................................ 5-39 replacing............................................................ 3-25 air conditioner unit....................................................8-23 air conditioning equipment layout..................................................8-1 specifications....................................................... 8-7 air conditioning belt adjusting.............................................................3-67 checking.............................................................3-65 air conditioning control panel................................... 8-19 checking.............................................................8-19 air conditioning hose................................................ 8-29 checking.............................................................3-68 removing/installing............................................. 8-29 replacing............................................................ 3-69 air conditioning system.............................................. 8-1 general description...............................................8-3 troubleshooting.................................................. 8-15 air conditioning unit.................................................... 8-7 measuring and checking.................................... 8-23 parts drawing..................................................... 8-26 removing/installing............................................. 8-24 air filter cleaning..............................................................3-65 replacing............................................................ 3-67 air filter element replacing............................................................ 3-25 alternator checking.............................................................3-45 angular bearing press-fit jig (lower)..........................2-43 angular bearing press-fit jig (upper)......................... 2-43 armrest.......................................................................4-5 parts drawing....................................................... 4-5 AUX current fine setting........................................... 7-72 AUX flow rate adjustment........................................ 7-75 AUX flow rate setting......................................... 7-7,7-67 AUX knob set-up......................................................7-71 AUX solenoid valve system..............................................................6-187

battery handling............................................................... 2-5 removing..........................................4-31,5-37,6-149 battery condition checking.............................................................3-18 bearing press-in jig...................................................2-48 blower motor.............................................................. 8-8 measuring and checking.................................... 8-23 blower resistor............................................................8-9 measuring and checking.................................... 8-23 bolt and nut tightening............................................................. 2-1 breather filter replacing............................................................ 3-33 bucket cylinder.............................................6-160,6-184 components..................................................... 6-162 measuring the operating time............................ 6-53 removing.......................................................... 6-160 removing/installing........................................... 6-160 bus description..........................................................2-33 bushing.................................................................... 4-41 table................................................................... 4-41 bushing press-fit jig.................................................. 2-48 bushing punching jig................................................ 2-47 buzzer........................................................................ 7-5

SVL97-2

C cab tilting up..............................................................2-11 cabin.......................................................................... 4-2 removing................... 4-2,4-20,5-37,6-58,6-83,6-101 removing/installing............................................... 4-2 cabin lock.................................. 5-48,6-164,6-167,6-169 CCV heater checking.............................................................3-58 chain joint handling............................................................... 2-2 charging hose.......................................................... 2-51 circlip installing............................................................... 2-2 clear error history..................................................... 7-74 collecting refrigerant.................................................2-13 common rail system................................................. 5-11 general description.....................................5-11,5-12 composite terminal...................................................2-33 compressor........................................................ 8-4,8-20 adjusting the clearance...................................... 8-21 checking the magnetic clutch.............................8-20 function and structure.......................................... 8-5 measuring and checking.................................... 8-20 removing/installing............................................. 8-21

KiSC issued 09, 2021 A

specifications....................................................... 8-4 troubleshooting.................................................. 8-17 compressor oil functions and structures.......................................8-6 condenser.................................................................8-11 checking.............................................................3-66 function and structure.........................................8-11 measuring and checking.................................... 8-26 specifications......................................................8-11 condenser and receiver........................................... 8-26 removing/installing............................................. 8-27 condenser fan motor measuring and checking.................................... 8-26 connector diagram description............................................2-33 handling............................................................... 2-7 handling precaution............................................2-33 control "Main relief valve" functions and structures....... 6-12 "Overload relief valve" functions and structures 6-13 LS relief valve.................................................... 6-12 non-operation hydraulic description................... 6-14 control valve.......................................... 6-10,6-98,6-181 "Hydraulic quick hitch" hydraulic description......6-25 anti-Saturation hydraulic description..................6-23 assembling.......................................................6-108 AUX operation hydraulic description..................6-19 bucket leveling mechanism hydraulic description..... .....................................................................6-17 bucket operation hydraulic description...............6-18 disassembling.................................................. 6-102 float solenoid valve assembling.................................................6-114 removing.................................................... 6-107 functions and structures.....................................6-12 installing adapter layout................................... 6-119 lift arm down hydraulic description.....................6-15 lift arm float operation hydraulic description.......6-24 lift arm up hydraulic description......................... 6-16 load Sensing (flow control) hydraulic description...... .....................................................................6-20 measuring.......................................................... 6-98 relief valve assembling.................................................6-112 removing.................................................... 6-105 removing.......................................................... 6-102 removing/installing................................. 6-100,6-101 section assembling.......................................6-108,6-110 removing.................................................... 6-104 specifications..................................................... 6-10 coolant changing............................................................ 3-62 draining........................................................ 4-2,4-31 coolant level checking.............................................................3-13 coolant valve............................................................ 5-58 parts drawing..................................................... 5-58 II

parts drawing (closed cab model)...................... 5-58 parts drawing (open cab model)........................ 5-58 cylinder block disassembling.................................................... 6-63 cylinder block (engine side) assembling.........................................................6-69 cylinder block (pump side) assembling.........................................................6-73 cylinder head measuring the wear......................................... 6-158 cylinder rod disassembling.................................................. 6-150 measuring the bend......................................... 6-157 measuring the wear......................................... 6-158 cylinder spring measuring the length......................................... 6-98 cylinder tube...........................................................6-158

D DEF/AdBlue checking.............................................................3-10 draining.............................................................. 3-10 handling............................................................... 3-9 refilling................................................................3-10 DEF/AdBlue hose checking.............................................................3-44 routing................................................................ 5-56 DEF/AdBlue injector checking.............................................................3-49 DEF/AdBlue injector tip checking.............................................................3-43 DEF/AdBlue level checking.............................................................3-14 DEF/AdBlue pump parts drawing..................................................... 5-57 DEF/AdBlue pump filter replacing............................................................ 3-49 DEF/AdBlue tank removing............................................................ 5-54 description................................................................2-33 diagmaster connecting..........................................................2-14 dispose fluids correctly...............................................2-9 DPF..........................................................................5-14 general description.............................................5-14 output limit..........................................................5-15 PM deposit amount............................................ 5-15 warning lamp......................................................5-15 DPF differential pressure sensor rubber hose replacing............................................................ 3-63 DPF muffler checking.....................................................3-18,3-57 identification....................................................... 2-24 removing............................................................ 5-35 removing/installing............................................. 5-33 replacing............................................................ 3-48

SVL97-2 KiSC issued 09, 2021 A

dust valve checking.............................................................3-17 cleaning..............................................................3-24

E E:001 CAN communication error............................. 7-13 checking devices................................................7-13 checking on the meter panel..............................7-13 checking with circuit tester................................. 7-14 E:005 high hydraulic oil temperature....................... 7-14 checking devices................................................7-14 checking on the meter panel..............................7-14 E:008 fuel sensor error............................................ 7-15 checking circuit tester........................................ 7-16 checking devices................................................7-15 checking on the meter panel..............................7-15 E:009 accelerator dial sensor break/short......................................................... 7-17 E:009 accelerator sensor error checking devices................................................7-18 checking on the meter panel..............................7-17 E:009 Accelerator sensor error checking with circuit tester................................. 7-18 E:010 travel speed shift solenoid error break/short......................................................... 7-19 checking devices................................................7-20 checking on the meter panel..............................7-19 checking with circuit tester................................. 7-20 E:011 parking brake solenoid error break/short......................................................... 7-22 checking devices................................................7-22 checking on the meter panel..............................7-22 checking with circuit tester................................. 7-23 E:012 float solenoid error break/short......................................................... 7-24 checking on the meter panel..............................7-24 checking with circuit tester................................. 7-25 E:013 hydraulic lock release solenoid error break/short......................................................... 7-27 checking devices................................................7-27 checking on the meter panel..............................7-27 checking with circuit tester................................. 7-28 E:014 low hydraulic oil temperature checking on the meter panel..............................7-30 E:014 low hydraulic oil temperature error checking circuit tester........................................ 7-31 checking device................................................. 7-30 short................................................................... 7-30 E:015 hydraulic hitch solenoid error checking devices................................................7-32 checking on the meter panel..............................7-32 checking with circuit tester................................. 7-33 short................................................................... 7-32 E:016 AUX knob-switch error break/short......................................................... 7-35 checking devices................................................7-35 checking on the meter panel..............................7-35

SVL97-2

checking with the circuit tester........................... 7-35 E:018 AUX right solenoid error break.................................................................. 7-36 checking devices................................................7-37 checking on the meter panel..............................7-36 checking with circuit tester................................. 7-37 E:019 AUX left solenoid error break.................................................................. 7-38 checking devices................................................7-39 checking on the meter panel..............................7-38 checking with circuit tester................................. 7-39 E:020 Anti-stall solenoid error break.................................................................. 7-40 checking devices................................................7-41 checking on the meter panel..............................7-40 checking with circuit tester................................. 7-41 E:021 5 V error.........................................................7-42 checking devices................................................7-42 checking on the meter panel..............................7-42 E:021 external 5 V error checking with circuit tester................................. 7-44 E:023 overvoltage.................................................... 7-47 check devices.................................................... 7-47 checking on the meter panel..............................7-47 checking with circuit tester................................. 7-47 E:024 hydraulic oil temperature sensor error break/short......................................................... 7-48 checking devices................................................7-48 checking on the meter panel..............................7-48 checking with circuit tester................................. 7-48 E:026 CRS CAN communication error.....................7-50 checking devices................................................7-50 checking on the meter panel..............................7-50 checking with circuit tester................................. 7-52 E:027 ACU CAN communication error.....................7-52 check with circuit tester......................................7-55 checking devices................................................7-53 checking on the meter panel..............................7-52 E:028 foot accelerator sensor error break/short......................................................... 7-55 checking devices................................................7-56 checking on the meter panel..............................7-55 checking with circuit tester................................. 7-56 E:9116 engine overheating...................................... 7-58 checking devices................................................7-58 checking on the meter panel..............................7-58 E:9118 engine oil pressure error.............................. 7-58 check devices.................................................... 7-59 checking on the meter panel..............................7-58 checking with circuit tester................................. 7-60 E:9119 battery charging error...................................7-61 checking devices................................................7-61 checking on the meter panel..............................7-61 checking with circuit tester................................. 7-61 E:9120 water separator error................................... 7-62 checking devices................................................7-62 checking on the meter panel..............................7-62 checking with circuit tester................................. 7-63 III

KiSC issued 09, 2021 A

E:9126 CCV pressure error..................................... 7-63 checking circuit tester........................................ 7-64 checking devices................................................7-63 checking on the meter panel..............................7-63 E:9127 continuous CCV pressure error................... 7-66 checking on the meter panel..............................7-66 EGR checking.............................................................3-58 EGR cooler checking.............................................................3-43 EGR cooler hose replacing............................................................ 3-64 EGR piping checking.............................................................3-58 EGR system.............................................................5-12 EGR valve checking.............................................................3-47 elbow with male seat installing............................................................... 2-4 electrical circuit diagram description..........................................................2-31 unit symbol.........................................................2-31 electrical device......................................................... 7-1 layout................................................................... 7-1 electrical wiring checking.............................................................3-16 clamp................................................................. 2-32 color coding........................................................2-32 engine...................................................................... 5-37 checking.............................................................3-16 device layout........................................................ 5-1 dimension.............................................................5-6 parts drawing..................................................... 5-44 performance curve............................................... 5-7 removing............................................................ 5-41 removing/installing............................................. 5-37 specification......................................................... 5-5 engine control system................................................ 5-9 general description...............................................5-9 engine error warning list........................................... 7-11 engine mount parts drawing..................................................... 5-44 engine oil replacing............................................................ 3-29 engine oil filter replacing............................................................ 3-30 engine oil level checking.............................................................3-14 engine valve clearance adjusting.............................................................3-38 error troubleshooting.................................................... 7-9 error warning list........................................................ 7-9 evaporator..................................................................8-8 exhaust gas line checking.............................................................3-57 expansion valve......................................................... 8-9

F fan belt adjusting.............................................................3-27 checking.............................................................3-16 fin thermistor............................................................ 8-10 float solenoid error checking devices................................................7-25 floating seal replacing.............................................................. 2-4 floating seal insertion jig...........................................2-44 flow dividing valve adjusting...........................................................6-100 front idler.................................................................. 4-37 components....................................................... 4-38 part drawing....................................................... 4-37 front window...............................................................4-6 assembling...........................................................4-6 components....................................................... 4-14 front window frame assembling......................................................... 4-11 front window linkage assembling.........................................................4-10 front window roller cleaning..............................................................3-34 replacing............................................................ 3-37 fuel filter replacing............................................................ 3-31 fuel level checking.............................................................3-13 fuel line checking.............................................................3-26 replacing............................................................ 3-61 fuel pump parts drawing..................................................... 5-52 fuel tank................................................................... 5-51 draining.............................................................. 3-23 draining fuel............................................... 5-38,5-48 fuel hose route................................................... 5-53 parts drawing..................................................... 5-51 removing............................................................ 5-49 removing/installing............................................. 5-48 fuel tank cap cleaning..............................................................3-21 fuse.......................................................................... 8-17 handling............................................................... 2-7

G gear pump..................................................................6-9 specifications....................................................... 6-9 general working precaution........................................2-1 glass for rear window installing............................................................. 4-17 grease cylinder.........................................................4-37 component......................................................... 4-38 part drawing....................................................... 4-37

SVL97-2 KiSC issued 09, 2021 A

H handle...................................................................... 2-48 heater core.................................................................8-8 heater hose.............................................................. 8-30 checking.............................................................3-68 removing/installing............................................. 8-30 replacing............................................................ 3-69 hose clamp checking.............................................................3-25 hose route.............................................................. 6-177 hot water valve.........................................................8-10 HST filter................................................................ 6-179 replacing............................................................ 3-34 HST motor gear oil replacing............................................................ 3-32 HST pump............................................... 6-2,6-55,6-179 adjusting swash plate neutral.............................6-57 adjusting the travel straightness........................ 6-56 assembling.........................................................6-66 components....................................................... 6-76 disassembling.................................................... 6-61 functions and structures.......................................6-3 installing adapter layout..................................... 6-80 measuring.......................................................... 6-55 measuring the flow rate......................................6-55 measuring travel relief pressure.........................6-56 removing.................................................... 5-41,6-60 removing/installing............................................. 6-57 specifications....................................................... 6-2 working principles................................................ 6-3 hydraulic performance list................................................. 6-53 troubleshooting.................................................. 6-49 hydraulic cylinder..................................................... 6-44 bleeding air........................................................ 2-17 servicing standards.......................................... 6-157 specifications..................................................... 6-44 hydraulic equipment layout................................................................... 6-1 hydraulic hose........................................................6-176 connecting............................................................2-4 hydraulic hose fittings............................................ 6-176 hydraulic oil draining.................................................... 6-58,6-168 replacing............................................................ 3-39 hydraulic oil level checking.............................................................3-14 hydraulic oil tank.................................................... 6-168 components..................................................... 6-173 installing adapter layout................................... 6-175 removing.......................................................... 6-171 removing/installing........................................... 6-168 hydraulic pressure operating time.................................................... 6-53 hydraulic quick hitch parts drawing..................................................... 4-24 hydraulic quick hitch cylinder................................. 6-163

SVL97-2

components..................................................... 6-163 removing/installing........................................... 6-163 hydraulic tank vacuuming..........................................................2-11

I identification DPF muffler model............................................. 2-25 engine................................................................ 2-23 injector code.......................................................2-27 information safety labels......................................................... 1-5 injector checking.............................................................3-41 inner race extraction jig............................................2-45 inoperable machine towing.................................................................2-36 intake air line checking.....................................................3-26,3-57 replacing............................................................ 3-62 intercooler................................................................ 5-23 installing.................................... 5-23,5-28,5-33,5-39 parts drawing..................................................... 5-25 removing....................................5-23,5-28,5-33,5-39

L lift arm...................................................................... 4-20 locking................................................................2-13 removing.................................................. 4-20,6-149 removing/installing............................................. 4-20 lift arm cylinder.............................................6-149,6-150 assembling.......................................................6-153 assembling the cylinder head.......................... 6-153 assembling the cylinder rod............................. 6-154 components..................................................... 6-159 cylinder head disassembling............................................ 6-152 disassembling.................................................. 6-150 disassembling/installing................................... 6-149 measuring the operating time............................ 6-53 removing.......................................................... 6-149 linkage......................................................................4-20 removing/installing............................................. 4-20 linkage 1 removing............................................................ 4-22 liquid gasket handling............................................................... 2-3 LS pump removing.................................................. 6-60,6-171 LS relief valve measuring.......................................................... 6-99 lubricant quantity........................................................3-5 lubrication point greasing............................................................. 3-15

KiSC issued 09, 2021 A

machine loading............................................................... 2-35 unloading........................................................... 2-35 machine dimension.................................................. 2-29 machine identification.............................................. 2-23 machine layout...........................................................4-1 magnetic clutch functions and structures.......................................8-5 main frame cleaning..............................................................3-27 maintenance interval table..................................................................... 3-1 manifold gauge........................................................ 2-50 mechanical quick hitch parts drawing..................................................... 4-23 meter panel................................................................ 7-4 display..................................................................7-4 function................................................................ 7-6 lamp..................................................................... 7-5 normal mode........................................................ 7-6 service mode........................................................7-8 user settings mode...............................................7-7 meter panel setting.................................................. 7-66 meter panel switches operation............................................................ 7-66 muffler bracket parts drawing..................................................... 5-47

pilot valve.....................................................6-141,6-189 assembling.............................................6-145,6-146 components..................................................... 6-148 disassembling.................................................. 6-142 measuring........................................................ 6-141 pilot valve (front operation)...................................... 6-29 specification....................................................... 6-29 pilot valve (lift arm, bucket) measuring pressure......................................... 6-142 pilot valve (travel).....................................................6-26 (Shuttle valve) functions.....................................6-29 functions and structures.....................................6-28 measuring pressure......................................... 6-141 specification....................................................... 6-26 working principles.............................................. 6-28 pilot valve (working equipment operation) functions and structures.....................................6-32 working principles.............................................. 6-32 pin............................................................................ 4-41 table................................................................... 4-41 piston clearance measuring.......................................................... 6-97 piston pump............................................. 6-5,6-82,6-177 assembling.........................................................6-89 bleeding air........................................................ 6-82 components............................................. 6-94,6-116 disassembling.................................................... 6-85 functions and structures.......................................6-6 gear pump assembling...................................................6-93 removing...................................................... 6-86 installing adapter layout..................................... 6-96 internal parts assembling...................................................6-89 removing...................................................... 6-87 measuring.......................................................... 6-82 measuring the flow rate......................................6-82 pump casing removing...................................................... 6-86 regulator...............................................................6-6 assembling...................................................6-89 disassembling.............................................. 6-88 removing............................................................ 6-85 removing/installing............................................. 6-83 servicing standards............................................ 6-97 specification......................................................... 6-5 valve cover assembling...................................................6-92 working principles................................................ 6-6 piston pump dimension measuring jig......................2-49 piston ring correction jig........................................... 2-50 piston wear ring measuring the wear......................................... 6-158 positive crankcase ventilation valve checking.............................................................3-42

N needle bearing insertion jig...................................... 2-41 normal mode display..................................................................7-6

O O-ring replacing.............................................................. 2-3 oil amount in the compressor...................................8-22 oil cooler checking.............................................................3-15 oil seal replacing.............................................................. 2-3 oil seal press-fit jig................................................... 2-44 oil separator parts drawing..................................................... 5-46 oil separator element replacing............................................................ 3-41 oil separator hose replacing............................................................ 3-63 outer element cleaning..............................................................3-23 overload relief valve measuring.......................................................... 6-99

SVL97-2 KiSC issued 09, 2021 A

pre-cleaner checking.............................................................3-17 pressure switch........................................................ 8-12 function and structure........................................ 8-13 specifications..................................................... 8-12 pump coupling part drawing....................................................... 6-81

Q quality of DEF/AdBlue checking.............................................................3-55 quick hitch................................................................ 4-23 parts drawing..................................................... 4-23 quick hitch cylinder removing.......................................................... 6-163 quick hitch model specifications................................................... 6-191 quick hose coupling connecting............................................................2-5 disconnecting....................................................... 2-5

R radiator.....................................................................4-31 checking.............................................................3-15 parts drawing..................................................... 4-33 removing.................................................... 4-32,5-38 removing/installing............................................. 4-31 tilting...................................................................2-12 radiator hose checking.............................................................3-25 radiator hose and clamp replacing............................................................ 3-61 read all error history................................................. 7-75 read error history......................................................7-74 rear bonnet...............................................................4-25 opening.............................................................. 2-11 parts drawing..................................................... 4-28 removing............................................................ 4-25 removing/installing............................................. 4-25 rear bonnet lock....................................................... 4-20 rear cover.................................................................4-25 closed cab model............................................... 4-30 parts drawing............................................. 4-29,4-30 removing............................................................ 4-26 removing/installing............................................. 4-25 rear cover (open cab model) parts drawing..................................................... 4-29 rear idler...................................................................4-40 components....................................................... 4-40 part drawing....................................................... 4-40 rear window..............................................................4-17 removing/installing............................................. 4-17 receiver.....................................................................8-11 function and structure........................................ 8-12 specifications......................................................8-11 recommended lubricant............................................. 3-7

SVL97-2

reducing valve assembling.......................................................6-145 disassembling.................................................. 6-144 removing.......................................................... 6-143 refrigerant charging............................................................. 2-17 checking.....................................................3-53,3-69 refrigerant gas collecting......................................................4-2,4-26 refrigerant gas canister............................................ 2-51 refrigerant gas leak tester........................................ 2-51 refrigerant gas vacuum machine..............................2-51 relay............................................................... 6-189,8-18 checking.............................................................8-18 relief cut..................................................................... 6-8 relief valve assembling.........................................................6-68 disassembling.................................................... 6-64 return filter replacing............................................................ 3-32 revision history...............................................................ii ring gear disassembly jig......................................... 2-45 ring nut tightening jig................................................2-43 roller bearing press-fit jig..........................................2-44 rubber crawler.......................................................... 4-36 parts drawing..................................................... 4-37 removing............................................................ 4-36 removing/installing................................... 4-36,6-121

S safety label maintenance.......................................................1-11 placement............................................................ 1-5 safety valve functions and structures.......................................8-6 SCR DEF/AdBlue concentration and quality.............. 5-18 DEF/AdBlue defrost control............................... 5-19 DEF/AdBlue level...............................................5-17 DEF/AdBlue pump............................................. 5-20 deratig................................................................ 5-22 output limit..........................................................5-17 parts numbers.................................................... 2-26 serial numbers................................................... 2-26 system errors............................................. 5-21,5-22 tampering...................................................5-20,5-21 warning lamp......................................................5-17 SCR muffler..............................................................5-28 installing............................................................. 5-30 parts drawing..................................................... 5-33 removing............................................5-29,5-35,5-41 removing/installing............................................. 5-28 SCR system general description.............................................5-16 seal ring insertion inner jig....................................... 2-45 seal ring insertion jig................................................ 2-46 seat............................................................................ 4-6

VII

KiSC issued 09, 2021 A

parts drawing....................................................... 4-6 seat belt..................................................................... 4-6 assembly drawing................................................ 4-6 section....................................................................6-102 service mode operations.......................................................... 7-67 settings list........................................................... 7-8 servo cylinder assembling.........................................................6-66 servo piston disassembling.................................................... 6-64 set the AUX start-up point........................................7-71 set the hst start-up point.......................................... 7-73 shaft (engine side) assembling.........................................................6-71 shaft (pump side) assembling.........................................................6-73 shaft assembly disassembling.................................................... 6-61 shaft seal press-fit jig............................................... 2-41 shim table................................................................... 4-41 shoe measuring thickness.......................................... 6-97 shoe crimping section measuring the play.............................................6-97 side window............................................................. 4-18 parts drawing..................................................... 4-19 removing............................................................ 4-18 removing/installing............................................. 4-18 slow-blow fuse checking.............................................................8-17 solenoid valve anti-stall................................................... 6-47,6-167 disassembly / assembly.............................6-167 removing.................................................... 6-167 AUX......................................................... 6-47,6-167 removing.................................................... 6-167 removing/installing..................................... 6-167 hydraulic quick hitch...........................................6-48 solenoid valve (Anti-stall, AUX) installing adapter layout................................... 6-168 solenoid valve (Anti-stall, AUX) specification specifications..................................................... 6-47 solenoid valve (hydraulic quick hitch).................... 6-168 installing adapter layout................................... 6-168 specifications..................................................... 6-48 special jig and tool engine compression pressure measuring kit..... 2-39 specification............................................................. 2-28 spherical bushing measuring the sinkage.......................................6-98 split pin handling............................................................... 2-2 spring pin installing............................................................... 2-2 starter motor checking.............................................................3-45 VIII

step removing..................................5-48,6-58,6-83,6-169 suction filter replacing............................................................ 3-37 supercharger system............................................... 5-13 general description.............................................5-13

T temperature sensor functions and structures.......................................8-6 tension spring part drawing....................................................... 4-37 tension spring components...................................... 4-37 components....................................................... 4-38 tester mode.............................................................. 7-68 this machine measuring.......................................................... 6-53 thread seal tape wrapping.............................................................. 2-4 thread-locking fluid applying................................................................2-1 tightening torque adapter (taper thread)........................................ 2-21 bolt and nut........................................................ 2-19 hose clamp.........................................................2-21 hydraulic hose (taper thread)............................. 2-20 hydraulic hose fitting.......................................... 2-20 locknut of adapter with o-ring (straight thread).. 2-20 stud bolt............................................................. 2-19 total length of hydraulic hose................................. 6-176 track roller................................................................ 4-39 components....................................................... 4-39 part drawing....................................................... 4-39 track tension checking.............................................................3-23 travel motor....................................................6-33,6-121 "Parking brake" working principles.....................6-36 "Reduction gear" working principles.................. 6-34 "Travel speed shift" working principles...............6-36 (Flushing) hydraulic description......................... 6-35 assembling.......................................................6-128 assembling the gear case................................ 6-128 assembly of motor............................................6-133 components..................................................... 6-139 disassembling.................................................. 6-122 functions and structures.....................................6-34 gear case disassembling............................................ 6-122 hydraulic motor disassembling............................................ 6-125 installing adapter layout................................... 6-141 measuring the block performance......................6-54 measuring the operating time............................ 6-54 measuring the travel straightness...................... 6-55 removing.......................................................... 6-121 removing/installing........................................... 6-121 specifications..................................................... 6-33

SVL97-2 KiSC issued 09, 2021 A

working principles.............................................. 6-34 travel system............................................................6-37 "charge circuit" hydraulic description................. 6-42 "Forward" hydraulic description......................... 6-37 "Left swivel" hydraulic description......................6-39 "Pivot turn (forward left)" hydraulic description.. 6-41 "Reverse" hydraulic description......................... 6-38 "Right swivel" hydraulic description................... 6-40 anti-stall function................................................ 6-43 traveling troubleshooting hydraulic................................... 6-51 trim installing............................................................. 4-17 troubleshooting........................................................ 8-15 troubleshooting electrical engine start.......................................................... 7-9 troubleshooting electrical issues................................ 7-9 turbocharger checking.............................................................3-48

water separator draining.............................................................. 3-16 water separator element replacing............................................................ 3-31 window parts assembling...........................................................4-6 wiper ring press-fit jig............................................... 2-47 wire harness handling............................................................... 2-5 wiring color..................................................................... 2-8 working equipment measuring the drift............................................. 6-54 troubleshooting hydraulic................................... 6-49

U U-joint tightening jig................................................. 2-42 U-ring insertion inner jig........................................... 2-46 U-ring insertion jig.................................................... 2-47 unload LS valve measuring.......................................................... 6-98 unload valve.................................................6-164,6-185 installing adapter layout................................... 6-166 parking brake..................................................... 6-45 functions and structures...............................6-46 removing.......................................................... 6-164 removing/installing........................................... 6-164 travel speed shift................................................6-45 functions and structures...............................6-46 work equipment..................................................6-45 functions and structures...............................6-46 unload valve (travel speed shift, parking brake, work equipment) specifications..................................................... 6-45 working principles.............................................. 6-46 upper window...........................................................4-16 installing............................................................. 4-16 removing............................................................ 4-16 removing/installing............................................. 4-16 urea SCR system.....................................................5-16

V vacuum pump installing....4-20,4-32,6-85,6-101,6-121,6-164,6-167

W washer liquid level checking.............................................................3-18 washing washing with a high pressure washer.................. 2-8

SVL97-2

KiSC issued 09, 2021 A

Editor : Kubota Corporation Construction Machinery Service Technical Support Dept. Address : 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 2021. 09, H, EI, EI, engusa Code No. RY911-29121 2020. 12, H, EI, EI, engusa