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90Z6

93213-00761 August 2016

SHOP MANUAL

General Information Function & Structure

WHEEL LOADER

90Z6 General Information Function & Structure

Printed in Japan (K) （輸出一般用）

93213-00761

SECTION AND GROUP SECTION 1 GENERAL Group 1 Specifications CONTENTS

93213-00761

Group 2 Component Layout Group 3 Component Specifications

SECTION 2 SYSTEM SHOP MANUAL (Function & Structure)

Group 1 Controller Group 2 Control System Group 3 ECM System Group 4 Hydraulic System Group 5 Electrical System

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Control Valve Group 3 Cooling Fan System Group 4 Steering Pilot Valve (Orbitrol) Group 5 Steering Valve Group 6 Pilot Valve Group 7 Charging Block Group 8 Drive Unit Group 9 Axle Group 10 Brake Valve All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

Group 11 Ride Control Device Group 12 Others

ATTACHMENT Hydraulic Circuit Diagram & Brake Circuit Diagram Electrical Connection Diagram Electrical Wiring Diagram - Front Chassis Electrical Wiring Diagram - Rear Chassis Electrical Wiring Diagram - Floor (Front Console) Electrical Wiring Diagram - Floor (Rear & Side Console) Electrical Wiring Diagram - CAB

90Z6

MEMO

90Z6

INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.  Be sure to thoroughly read this manual for correct product information and service procedures.

Additional References Please refer to the other materials (operation and maintenance manual, parts catalog, engine technical material, Kawasaki shop materials, etc.) in addition to this manual.

Manual Composition Our shop manuals consist of the Technical Manual, the Workshop Manual and the Engine Manual.

 Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assembly / disassembly procedures.

 Information included in the Technical Manual: Technical information needed for machine pre-delivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

 Information included in the Engine Manual: Technical information needed for machine pre-delivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assembly / disassembly procedures.

Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T Technical Manual 1 Section Number 3 Group Number 5 Consecutive Page Number for Each Group

 Workshop Manual: W 1-3-2-5 W Workshop Manual (Disassembly & Reassembly) 1 Section Number 3 Group Number 2 Sub Group Number 5 Consecutive Page Number for Each Group

IN-01

INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

d This is the safety alert symbol. When you see this

symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

dCAUTION: Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death. IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

fNOTE: Indicates supplementary technical information.

Units Used SI Units (International System of Units) are used in this manual. MKSA (Meter, Kilogram, Second, Ampere) system units and English units are also indicated in parentheses just behind SI units. Quantity Length Volume Weight Force Torque Pressure Power Temperature Velocity Flow rate

To Convert From mm mm L L m3 kg N N N·m MPa MPa kW kW °C km/h min-1 L/min mL/rev

Example: 24.5 MPa (250 kgf/cm2, 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes. Into in ft US gal US qt yd3 lb kgf lbf kgf·m kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

fNOTE: The numerical value in this manual might be different from the above-mentioned table.

IN-02

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 0.10197 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

Symbol and Abbreviation Symbol and Abbreviation Symbol / Abbreviation S/M T/C T/M MC

Name

Explanation

Shop Manual Torque Converter Transmission Main Controller

ECM

Engine Control Module

ICF CAN

Information Controller Controller Area Network

A/C HVAC OP, OPT MPDr.

Air Conditioner Heating, Ventilation, and Air Conditioning Option Maintenance Pro Dr.

Shop Manual Torque Converter Transmission Main controller. MC controls the engine, pump, and valve according to the machine operating condition. Engine controller. ECM controls fuel injection amount according to the machine operating condition. Stores the operating information and alarms. CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization). Air conditioner.

ATT

Attachment

Optional component. MPDr. is software that troubleshooting, monitoring, and adjustment. Front attachment, such as bucket

SY-1

Symbol and Abbreviation (Blank)

SY-2

SECTION 1

GENERAL CONTENTS Group 1 Specifications

Specifications........................................................................ T1-1-1 Weight of Main Components.......................................... T1-1-2

Group 2 Component Layout

Main Component (Overview).......................................... T1-2-1 Main Component (Travel System)................................. T1-2-3 Electric Component Layout (Overview)...................... T1-2-4 Electrical System (Cab)....................................................... T1-2-5 Controller and Relays.................................................... T1-2-6 Right Console................................................................... T1-2-7 Monitor and Switches................................................... T1-2-8 Monitor Panel.................................................................. T1-2-9 Electrical System (Relays)................................................T1-2-10 Engine/Fan Pump..............................................................T1-2-11 Transmission and Torque Converter Assembly.......T1-2-12 Hydraulic Pump Device...................................................T1-2-13 Multiple Control Valve......................................................T1-2-14 Charging Block....................................................................T1-2-15 Front Axle..............................................................................T1-2-15 Steering Valve......................................................................T1-2-16 Brake Valve...........................................................................T1-2-16 Fan Motor.............................................................................T1-2-16 Pilot Valve.............................................................................T1-2-16 Ride Control Group (Option).........................................T1-2-17 Secondary Steering Group.............................................T1-2-18 Secondary Steering Pump........................................T1-2-18

Group 3 Component Specifications

Engine...................................................................................... T1-3-1 Engine Accessories.............................................................. T1-3-4 Hydraulic Component........................................................ T1-3-5 Electrical Component......................................................... T1-3-9

90Z6 F&S

(Blank)

90Z6 F&S

SECTION 1 GENERAL Group 1 Specifications Specifications (S/N 0101~)

37°

45°

37°

90Z6-FK-GSC

Bucket Capacity: heaped Operating Weight Tipping Load (Full Turn) Engine A: Overall Length B: Overall Width (Bucket) C: Overall Height D: Wheel Base E: Tread F: Ground Clearance G: Bucket Hinge Height H: Dumping Clearance (45 °) I: Dumping Reach (45 °) R1: Minimum Rotation Radius R2: Bucket Carry Position Travel Speed Forward/Reverse Transmission Speeds (F/R) Articulation Angle (Left/Right) deg Tire Size

GSC 4.0 23100 15900 CUMMINS QSM11 8790 3100 3470 3450 2230 505 4410 3095 1215 6270 7330 34.7/34.7 4/4 37 26.5-25-20PR (L-3)

m kg kg

mm mm mm mm mm mm mm mm mm mm mm km/h (°) -

fNOTE: These specifications are subject to change without notice. Values with bolt-on cutting edges.

T1-1-1

LSC 4.5 23230 15770 CUMMINS QSM11 8910 3100 3470 3450 2230 505 4410 3010 1300 6270 7360 34.7/34.7 4/4 37 26.5-25-20PR (L-3)

SECTION 1 GENERAL Group 1 Specifications Specifications (S/N 9001~)

37°

45°

37°

90Z6-FK-GSC

GSC 4.0 23230 16050 CUMMINS QSM11 8790 3100 3470 3450 2230 505 4410 3095 1215 6270 7280 34.7/34.7 4/4 37 26.5-25-20PR (L-3)

m kg kg

mm mm mm mm mm mm mm mm mm mm mm km/h (°) -

fNOTE: These specifications are subject to change without notice. Values with bolt-on cutting edges.

T1-1-2

LSC 4.5 23360 15920 CUMMINS QSM11 8910 3100 3470 3450 2230 505 4410 3010 1300 6270 7315 34.7/34.7 4/4 37 26.5-25-20PR (L-3)

SECTION 1 GENERAL Group 1 Specifications Weight of Main Components Unit Name

Chassis

Item Part Name Front chassis Rear chassis Rear chassis belly guard Fender (front) (RH, LH) Center pin group Floor board Radiator guard Side cover (main) (RH, LH) Roof mount Rear grill mount Deck (RH, LH) Fender (rear) Step (main) (RH, LH) Hydraulic tank Fuel tank Lift Arm (Boom) Z-Lever (Bell Crank) Bucket Link Counter weight Battery box Battery Cab ROPS Cab Bucket (GSN) Tire

Approx. Weight Remarks (kg) 1950 1655 95 Option (S/N 0101~), Standard (S/N 9001~) 25 x 2 55 250 With rubber cushions 15 x 2 30 x 2 65 40 30 x 2 With handrails 75 40 (RH), 35 (LH) 40 x 2 Step to CAB 225 320 1585 405 80 2540 30 x 2 36 x 2 430 (S/N 0101~) 700 (S/N 9001~) 1790 The weight differs depending on the bucket type. 670 x 4 26.5-25-20PR (L-3) with wheel disc

fNOTE: The weights are for reference and not the exact values. IMPORTANT: When handling each component, be careful and prepare tools of enough capacity considering additional weight.

T1-1-3

SECTION 1 GENERAL Group 1 Specifications

Unit Name

Power line

Item Part Name Engine (dry) Transmission assy Second propeller shaft Third propeller shaft Radiator mount Cooling unit mount Fan mount Air cleaner Exhaust group Axle assy (TPD) Axle assy (LSD) (Option)

Hydraulic system

Main pump assy Multiple control valve Combination valve assy Loading pilot valve Steering valve OrbitrolTM Unloader valve Brake valve assy Brake accumulator assy Lift arm cylinder Bucket cylinder Steering cylinder

Approx. Remarks Weight (kg)

Front Rear Front Rear

940 865 70 22 160 50 50 20 55 1310 1510 1320 1520 110 65 25 7 22 6 15 12 20 185 x 2 195 27 x 2

Cummins QSM11 Drive unit

Radiator (30) + T/C oil cooler (13) + Shroud assy (110) Hydraulic oil cooler (7) + Air cooler (23) Fan (5) + Fan motor (12) + Bracket (18) Muffler (25) Excluding tires and oil Excluding tires and oil, Including axle supports Excluding tires and oil Excluding tires and oil, Including axle supports Including pilot pump

Steering pilot valve, Eaton Brake charge valve Accumulator (6) x 2 Excluding oil Excluding oil Excluding oil

fNOTE: The weights are for reference and not the exact values. IMPORTANT: When handling each component, be careful and prepare tools of enough capacity considering additional weight.

T1-1-4

SECTION 1 GENERAL Group 2 Component Layout Main Component (Overview)

5 2

1 6

11 10

12345-

Bucket Lever (Bell Crank) Bucket Cylinder Headlight Front Working Light

67-

CAB Rear Working Light (Option) Rear Working Light

T1-2-1

Rear Combination Light (Turn Signal Light, Hazard Light, Clearance Light, Brake Light, Backup Light) Turn Signal Light, Hazard Light, Clearance Light

90Z6T1-2-01

10- Lift Arm (Boom) Cylinder 11- Lift Arm (Boom) 12- Bucket Link

SECTION 1 GENERAL Group 2 Component Layout Main Component

18 17 16 15 14 13

3 4

12 11

10 9

90Z6T1-2-02

6 13 11

123456789101112131415-

Multiple Control Valve (Loading) Pilot Valve Stop Valve Torque Converter Oil Filter Charging Block (Unloader and Accumulators) Engine Fuel Filter Fuel Tank Engine Oil Filter Hydraulic Oil Cooler Inter Charge Air Cooler Fan Motor Torque Converter Oil Cooler Radiator Coolant Level and Surge Tank

161718192021222324-

Air Cleaner Muffler Hydraulic Tank Safety Device (Pilot Shut-off Valve) Front Attachment (Implement) Pressure Sensor (at Pilot Valve) Brake Valve Orbitrol (Steering Pilot Valve) Steering Valve Fuel Cooler

24 90Z6T1-2-02

T1-2-2

SECTION 1 GENERAL Group 2 Component Layout Main Component (Travel System)

9 90Z6T1-2-03

8 123-

Front Axle Brake Pressure Sensor Steering Cylinder

456-

Hydraulic Pump Transmission Axle Support (Rear)

789-

T1-2-3

Rear Axle Axle Support (Front) Third (Rear) Propeller Shaft

6 10- Steering Accumulator 11- Second (Front) Propeller Shaft

SECTION 1 GENERAL Group 2 Component Layout Electric Component Layout (Overview)

5 4

2 3 90Z6T1-2-23

1 7 8 7 3

9 10

90Z6T1-2-04

12345-

Bucket Leveler Proximity Switch Lift Arm Kickout Proximity Switch Lift Arm Angle Sensor (Option) Hydraulic Oil Temperature Sensor (at Hydraulic Tank Bottom) Air Cleaner Restriction Switch

678910-

Backup Alarm Battery Fuel Level Sensor (at Fuel Tank) Secondary Steering Pump (Option) Outside Temperature Sensor

11- Components Related with Cab (Refer to T1-2-5)

90Z6T1-2-23

T1-2-4

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Cab) 1

11 3

6 4

9 5 7

90Z6T1-2-05

12345-

Radio Upper Switch Panel (Option) Speaker Rear Wiper Motor Brake Lamp Switch

678-

Front Wiper Motor Outside Temperature Sensor (for A/C) Components in Right Side Console (Refer to T1-2-7)

T1-2-5

90Z7-01-02-01

Components Related with Controllers and Relays (Refer to T1-2-6) 10- Components Related with Monitor and Switches (Refer to T1-2-8) 11- Air Conditioner Control Unit

SECTION 1 GENERAL Group 2 Component Layout Controller and Relays

5 12 11 10 9

17 16 15 14 13 2

22 21 20 19 18

27 26 25 24 23 32 31 30 29 28 7

Arrow View A

1234567891011121314-

Flasher Relay GSM (Option) ICF (Monitor Controller) MCZ (Main Controller) MPDr. Connector Fuse Box A Fuse Box B ECM Relay 1 Head Light Relay High-Beam Relay Bucket Leveler Relay Lift Arm Height Kickout Relay Working Lamp Relay (Front) Working Lamp Relay (Rear)

90Z6T1-2-06

1516171819202122232425262728-

Turn Signal Light Relay (Right) Horn Relay Load Dump Relay 2 Parking Brake Relay 1 Parking Brake Relay 2 Engine Alternate Droop Relay Brake Lamp Relay Load Dump Relay 1 Neutral Relay Turn Signal Light Relay (Left) Front Washer Relay Rear Wiper Relay Rear Washer Relay ECM Relay 2

fNOTE: Refer to “Fuses and Relays” and “Floor Cable Layout” in the Diagrams for the other parts.

T1-2-6

293031323334-

Backup Lamp Relay CAB Working Light Relay (Front) (Option) CAB Working Light Relay (Rear) (Option) Secondary Steering Relay (Option) Pilot Shut-Off Relay (Option) Voltage Relay

SECTION 1 GENERAL Group 2 Component Layout Right Console 20

Fingertip Control Type 4 3 (2)

8 9 10 11 12

2 (1) 1 (3)

18 6

7 17

15 14

90Z6T1-2-07a

MNEC-01-042

fNOTE: The control lever positions can be changed. Multi-Function Joystick Type (Option) 22

1 6 7

19 13

12345678910-

Auxiliary Control Lever (Option) Bucket Control Lever Lift Arm Control Lever Forward/Reverse Switch (Option) Auxiliary Auxiliary Power Mode Switch Forward/Reverse Selector Switch (Option) Fan Reverse Rotation Switch (Option)

15 14

MNEC-01-044

90Z6T1-2-07b

11- Auxiliary 12- Hydraulic Quick Coupler Switch (Option) 13- Secondary Steering Operation Check Switch (Option) 14- Lift Arm Auto Leveler Kickout Switch (Height) (Option) 15- Lift Arm Auto Leveler Kickout Switch (Lower) (Option) 16- Auxiliary 17- Ride Control Switch (Option)

T1-2-7

1819202122232425-

Hold Switch Control Lever Lock Handle (Safety Device) DSS (Down Shift Switch) Horn Switch Quick Power Switch Multi-Function Joystick Lever Hold Switch (Under the Lever) Horn Switch (Under the Lever)

SECTION 1 GENERAL Group 2 Component Layout Monitor and Switches

9 10

3 2 11 1

90Z6T1-2-08

1234-

Front/Rear Wiper Switch Hazard Switch Working Light Switch Parking Brake Switch

5678-

Forward/Reverse Lever, Shift Switch Monitor Panel (Refer to T1-2-9) Travel Mode Selector Switch Key Switch

T1-2-8

9- Declutch Position Sensor 10- Shift Change Delay Mode Switch (Option) 11- Turn Signal Lever, Light Switch, High-Low Beam Switch

SECTION 1 GENERAL Group 2 Component Layout Monitor Panel

39 38

37 12 36 35

14 15

33 32

Left Turn Signal Light Indicator 2- High Beam Indicator 3- Working Light Indicator 4- Right Turn Signal Light Indicator 5- (Not used) 6- (Not used) 7- Service Indicator 8- Maintenance Indicator 9- Parking Brake Indicator 10- Clearance Light Indicator 11- Control Lever Lock Indicator 12- Axle Oil Temperature Indicator

16 31 30

29 28 27 26

MNDB-01-034

25 24 23 22 21 20 19 18 17

13- Brake Oil Low Pressure Indicator 14- (Not used) 15- Secondary Steering Indicator (Option) 16- Low Steering Oil Pressure Indicator (Option) 17- Seat Belt Indicator 18- Discharge Warning Indicator 19- Fuel Gauge 20- Power Mode Indicator 21- Monitor Display Selection Switch 22- (Not used)

23- Monitor Display Selection Switch (Up) 24- Preheat Indicator 25- Monitor Display Selection Switch (Down) 26- Forward/Reverse Selector Switch Indicator (Option) 27- Monitor Display 28- Fan Reverse Rotation Indicator (Option) 29- Engine Warning Indicator 30- Overheat Indicator 31- Coolant Temperature Gauge 32- Engine Oil Low Pressure Indicator

T1-2-9

3334353637-

Air Filter Restriction Indicator (Not used) (Not used) (Not used) Hydraulic Oil Temperature Indicator 38- Transmission Warning Indicator 39- Transmission Oil Temperature Indicator 40- Transmission Oil Temperature Gauge

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Relays)

90Z6T1-2-19

3 90Z6-05-01-01

12-

Battery Relay Fusible Link (100 A) (3 used)

34-

Fusible Link (70 A) Intake Air Heater Relay

T1-2-10

SECTION 1 GENERAL Group 2 Component Layout Engine/Fan Pump 6 7 5

3 16

2 8

9 10

12 14

123456-

Engine Oil Filter Filter Outlet Pressure Coolant Inlet Pressure Coolant Temperature Sensor Alternator Intake Manifold Pressure Sensor

7891011-

After Charge Air Cooler (Intake Manifold) ECM ECM Cooling Plate Engine Position Sensor Engine Oil Pressure and Temperature Sensor

T1-2-11

90Z6T1-2-09

1213141516-

Fuel Filter Fan Pump Fuel Pump Starter DCA4 Coolant Filter

SECTION 1 GENERAL Group 2 Component Layout Transmission and Torque Converter Assembly 2

9 10 11 12 13 14

15 4

90Z6T1-2-10

123456789-

Torque Converter Torque Converter Charging Pump Machine Speed Sensor Transmission Output Speed Sensor Transmission Middle Shaft Sensor Parking Brake Transmission Control Valve Regulator Valve Proportional Solenoid Valve (For Forward Clutch)

10- Proportional Solenoid Valve (For Reverse Clutch) 11- Proportional Solenoid Valve (For 1st Speed Clutch) 12- Proportional Solenoid Valve (For 2nd Speed Clutch) 13- Proportional Solenoid Valve (For 3rd Speed Clutch) 14- Proportional Solenoid Valve (For 4th Speed Clutch)

fNOTE: Parking Brake pressure sensor is installed to the charging block.

T1-2-12

15- Parking Brake Pressure Port 16- Flange (for 2nd Propeller Shaft) 17- Torque Converter Oil Temperature Sensor 18- Hydraulic Pump Device (Refer to T1-2-13)

SECTION 1 GENERAL Group 2 Component Layout Hydraulic Pump Device 1

2 3

12-

Main Pump Regulator

34-

Priority Valve Pump Delivery Pressure Sensor

T1-2-13

T4GB-01-02-009

56-

Pilot Pump Steering Relief Valve

SECTION 1 GENERAL Group 2 Component Layout Multiple Control Valve 9 7

7 6

4 5

90Z6T1-2-11

12-

Overload Relief Valve (Lift Arm: Bottom Side) Overload Relief Valve (Bucket: Bottom Side)

3456-

Overload Relief Valve (Bucket: Rod Side) Make-up Valve (Lift Arm: Rod Side) Main Relief Valve Check Valve (with 1.0 Orifice)

T1-2-14

789-

Check Valve (with 1.2 Orifice) Lift Arm Spool Bucket Spool

SECTION 1 GENERAL Group 2 Component Layout Charging Block 3

4 5 6

1 7 10 8 9

90Z6T1-2-13

1234-

Charging Block Pilot Accumulator Pressure Sensor (Parking) Parking Brake Solenoid Valve

5678-

Pump Torque Control Solenoid Valve Relief Valve (for Cut-in/Cut-out Pressure) Pilot Relief Valve Service Brake Accumulator (Rear)

9- Service Brake Accumulator (Front) 10- Pressure Sensor (Service Brake Primary Pressure)

Front Axle

1 90Z7-05-04-01 1-

Axle Oil Temperature Sensor

T1-2-15

SECTION 1 GENERAL Group 2 Component Layout Steering Valve

Fan Motor

1 2 90Z6T1-2-15 12-

Overload Relief Valve Overload Relief Valve

90Z6T1-2-14 1-

Brake Valve

Fan Speed Control Solenoid Valve (Relief Valve)

Pilot Valve

1 2 90Z6T1-2-17 1-

Pressure Switch (For Stop Lamp)

Pressure Sensor (Service Brake Secondary Pressure for Declutch)

90Z6T1-2-22 12-

T1-2-16

Pilot Valve Pressure Sensor (Pilot Primary Pressure)

SECTION 1 GENERAL Group 2 Component Layout Ride Control Group (Option) 1 4 3

90Z6T1-2-21 12-

Ride Control Valve (Option) Overload Relief Valve

34-

Ride Control Solenoid Valve Ride Control Accumulator (Option)

6 90Z6T1-2-20 56-

Pressure Sensor (Lift Arm Raise) (Option) Multiple Control Valve

T1-2-17

SECTION 1 GENERAL Group 2 Component Layout Secondary Steering Group

Hydraulic Tank

3 2

1 90Z6T1-2-18

Main Pump

Secondary Steering Pump (Option)

Pressure Switch (Secondary Steering) (Option)

Secondary Steering Block (Check Valve Assy) (Option)

Secondary Steering Pump 1 2

90Z6T1-2-16

123-

Electric Motor Relief Valve Gear Pump

45-

Pressure Sensor (Secondary Steering Pump) Check Valve

fNOTE: Secondary steering is an optional equipment for EXP Spec. machine (S/N 0101~).

T1-2-18

SECTION 1 GENERAL Group 3 Component Specifications Engine Manufacturer

Cummins Inc.

Model

QSM11

Type

Diesel, 4-cycle, water-cooled, direct injection type with turbo charged, and air-cooled Intercooler

Dry Weight

940 kg

Dimensions (L x W x H)

1312 x 989 x 1181 mm (excluding fan)

No. of Cylinders - Bore × Stroke

6 - 125 × 147 mm

Piston Displacement

10.8 L

Rated Output / Rated RPM (Net)

216 kW/2100 min-1

Compression Ratio

16.3

Firing Order

1-5-3-6-2-4

Rotation Direction

Clockwise (Viewed from crank pulley side)

T1-3-1

SECTION 1 GENERAL Group 3 Component Specifications Engine Cooling Fan

Dia. 850 mm (33.5 in), 5 blades (resin-blade, steel center) Draw-in type

Thermostat

Cracking temperature at atmospheric pressure : 82 ºC Full open : 93 ºC

Fan Pump

Fixed displacement type gear pump Theoretical displacement: 44.5 cm3/rev

Lubrication Pump Type

Gear pump

Oil Filter

Combination full flow paper and bypass filters

Oil Cooler

Water cooled type

Motor

Electromagnetic pinion shift reduction type

Voltage/Output

24 VDC/8.25 kW

Preheat System

Preheating Method

Grid air heater (24 V, 100 A)

Engine Stop System

Stop Method

Fuel shut-off (electronic control)

Type

AC type (built-in regulator)

Voltage/Output

24 V/75 A, brushless

Type

Exhaust-turbocharger type

Type

Unit injector type

Governor

Electronic all speed control

Injection Nozzle

Electrical multi-hole injector

Cooling System

Lubrication System

Starting System

Alternator Intake Air Charging System Fuel System

fNOTE: Filter part numbers

Engine Oil Filter: YE4331005 Fuel Filter: YE3329289 Coolant Filter: YE4058964 with DCA 8 unit

T1-3-2

SECTION 1 GENERAL Group 3 Component Specifications Engine IMPORTANT : This list shows design specifications, which are not servicing standards.

Performance

Fuel Consumption Ratio

229 g/kW·h

Maximum Output Torque (Net)

1478 N·m at 1400 min-1

Valve Clearance (Intake/Exhaust) 0.36 / 0.69 mm (when cool) No Load Speed

Low: 800±20 RPM (min-1) High: 2130±30 RPM (min-1)

T1-3-3

SECTION 1 GENERAL Group 3 Component Specifications Engine Accessories Weight

Radiator Mount

Radiator sub-assy

30 kg

Torque Converter Cooler

13 kg

Capacity (water)

Fuel Cooler

Battery

Total: 40 L

Radiator sub-assy (water)

17.6 L

Water tank (water)

9.2 L

Torque Converter Cooler (oil)

9.2 L

Weight Cooling Unit

Mount weight: 160 kg

Mount weight: 50 kg

Charge Air Cooler

23 kg

Hydraulic Oil Cooler

7 kg

Capacity (oil)

2.6 L

Weight

3 kg

Capacity (oil)

1.5 L

Type

160F51

Voltage

12 V

Capacity

108 Ah

Cold Cranking Amps

765 CCA

Weight

35.5 kg × 2

T1-3-4

SECTION 1 GENERAL Group 3 Component Specifications Hydraulic Component Type

Swash plate type variable displacement axial plunger pump

Theoretical Displacement

340 L/min

PTO Gear Ratio

1.0

Regulator

Type

Hydraulic pressure operated type

Priority Valve

Relief Set-Pressure

29.4 MPa (300 kgf/cm2) at 90 L/min

Type

Pilot pressure operated type (2-spools)

Main Relief Set-Pressure

29.4 MPa (300 kgf/cm2) at 290 L/min

Overload Relief Set-Pressure

36.8 MPa (375 kgf/cm2) at 50 L/min (Lift arm) 32.5 MPa (330 kgf/cm2) at 50 L/min (Bucket)

Hydraulic Main Pump

Multiple Control Valve

fNOTE: See T1-3-2 for fan pump.

T1-3-5

SECTION 1 GENERAL Group 3 Component Specifications Hydraulic Component Fan Control Solenoid Valve

Fan motor reverse control (Option) Fan motor speed control

Function

Cut In Pressure : 11.8 MPa (120 kgf/cm2)

Charging Pressure

Cut Out Pressure : 14.7 MPa (150 kgf/cm2)

Charging Block

Service Brake Accumulator Steering Valve Steering Pilot Valve Steering Accumulator Brake Valve Ride Control Valve (Option) Ride Control Accumulator (Option)

Function

Parking brake ON/OFF control Main pump torque control

Capacity

1.4 L x 2

Charging Pressure

6.8 MPa (70 kgf/cm2) at 20 °C

Type

Flow amp type

Over Load Relief Set-Pressure

34.4 MPa (350 kgf/cm2) at 50 L/min

Type

Orbitrol ® type

Gerotor Capacity

80 cm3/rev

Capacity

0.2 L

Charging Pressure

8 MPa (81.6 kgf/cm2) at 20 °C

Brake Pressure

4.6 MPa (47 kgf/cm2)

Type

Pilot pressure operated type

Charge Cut Pressure

11.3 MPa (115 kgf/cm2)

Capacity

5.0 L

Charging Pressure

3.0 MPa (30.6 kgf/cm2) at 20 °C

T1-3-6

SECTION 1 GENERAL Group 3 Component Specifications Hydraulic Component Model

Transmission

Axle (Front/Rear)

Propeller Shaft

Gear Ratio

TM310 Forward 1st

3.507

Forward 2nd

2.067

Forward 3rd

1.071

Forward 4th

0.631

Reverse 1st

3.507

Reverse 2nd

2.067

Reverse 3rd

1.071

Reverse 4th

0.631

Parking Brake Release Pressure

2.7 MPa (28 kgf/cm2)

Model

Two stage transmission (inboard planetary gear reduction)

Brake Type

Wet multi-plate inboard disk brake

Brake Pressure

4.8 MPa (49 kgf/cm2)

Reduction Gear Ratio

27.484

Type

Cruciform joint type

Dimension between Universal Joint Centers

Second (Front)

1641.4 mm

Third (Rear)

261 mm

T1-3-7

SECTION 1 GENERAL Group 3 Component Specifications Hydraulic Component

Hydraulic Cylinder

Hydraulic Filter

Lift Arm (Boom)

Bucket

Steering

Rod Diameter

95 mm

110 mm

45 mm

Cylinder Bore

145 mm

185 mm

70 mm

Stroke

930 mm

510 mm

542 mm

Fully Retracted Length 1481 mm

1240 mm

900 mm

Full-Flow Filter (Filtration)

β10≥2.0 (filters 50% or more particles 10 μm in diameter)

Suction Filter (Filtration)

177 μm (80 mesh)

Pilot/Steering Filter (Filtration)

150 mesh

Transmission Oil Filter (Filtration) β10≥3 (filters 66% or more particles 10 μm in diameter)

T1-3-8

SECTION 1 GENERAL Group 3 Component Specifications Electrical Component Engine Oil Pressure Sensor

Operating Pressure

110.4 kPa or less

Coolant Temperature Sensor

Operating Temperature

105 °C or higher

Air Filter Restriction Switch

Operating Pressure

6.3±0.6 kPa

Fuel Level Sensor

Resistance Value

Empty : 90+10/-0 Ω Full : 10+0/-4 Ω

Hydraulic Oil Temperature Sensor

Operating Temperature

-30 to 120 °C

Battery Relay

Voltage/Current

24 V/109 A

Heater Relay

Voltage

24 V

Voltage/Current

24 V/3.0±0.5 A

Sound Pressure

113±5 dB (A) at 2 m

Horn

T1-3-9

SECTION 1 GENERAL Group 3 Component Specifications Electrical Component

Illumination

Air Conditioner

Secondary Steering Pump Unit (Option)

Working Light

Halogen 24 V, 55/70 W

Cab Dome Light

24 V, 10 W

Head Light

Halogen 24 V, 75/70 W

Turn Signal Light

24 V, 25 W

Clearance Light

24 V, 5 W

Backup Light

24 V, 12 W

Tail Light

24 V, 10 W

Brake Light

24 V, 12 W

Refrigerant

134 a

Cooling Ability

4.65 kW or More

Cool Air Volume

550 m3/h or more

Heating Ability

5.81 kW or more

Warm Air Volume

400 m3/h or more

Temperature Adjusting System

Electronic type

Refrigerant Quantity

1000±50 g

Compressor Oil Quantity

160 cm3 (9.8 in3)

Type

Electric motor operated type

Theoretical Displacement

10.0 cm3/rev

Maximum Flow

20.8 L/min at 8.1 MPa

Electric Motor Voltage

24 V, 2.4 kW

T1-3-10

SECTION 2

SYSTEM CONTENTS Group 1 Controller

Outline..................................................................................... T2-1-1 CAN Circuit............................................................................. T2-1-2

Group 2 Control System

Outline..................................................................................... T2-2-1 Engine Control...................................................................... T2-2-4 Accelerator Pedal Control............................................ T2-2-6 Auto-Warm Up Control................................................ T2-2-8 Engine Load Idle Speed Control.............................T2-2-10 Forward/Reverse Operation Engine Speed Limiter.........................................................................T2-2-12 Engine Speed Regulator For Digging...................T2-2-14 Speed Limit Control with Power Mode OFF.......T2-2-16 Machine Overheat Engine Speed Limiter............T2-2-18 Reversing Fan Idle Speed Control..........................T2-2-20 Pump Control......................................................................T2-2-23 Base Torque Control....................................................T2-2-24 Torque Decrease Control While Dumping Bucket............................................................................T2-2-26 Transmission Control........................................................T2-2-28 Neutral Control..............................................................T2-2-30 Forward/Reverse Lever Priority Control (Option).........................................................................T2-2-32 Manual Speed Shift Control.....................................T2-2-34 Automatic Speed Shift Control................................T2-2-36 Downshift Control........................................................T2-2-38 Speed Shift Delay Control.........................................T2-2-40 Declutch Control..........................................................T2-2-42 Shift Holding Control..................................................T2-2-44 Fan Control, Valve Control..............................................T2-2-47 Fan Speed Control........................................................T2-2-48 Fan Reverse Rotation Control (Option).................T2-2-50 Ride Control (Option)..................................................T2-2-52 Other Controls....................................................................T2-2-55 Transmission Alarm Control.....................................T2-2-56 Low Brake Oil Pressure Indicator Control............T2-2-58 Low Steering Oil Pressure Indicator Control (Option).......................................................................T2-2-60 Overrun Alarm Control...............................................T2-2-62

Lift Arm Auto Leveler Height Kickout Control (Option).......................................................................T2-2-64 Lift Arm Auto Leveler Lower Kickout Control (Option).......................................................................T2-2-66 Quick Power Mode Control.......................................T2-2-68 Secondary Steering Control.....................................T2-2-70 Combined Electric and Hydraulic Control Circuit..T2-2-73 Bucket Auto Leveler Control.....................................T2-2-74 Lift Arm Float Control.................................................T2-2-76 Lift Arm Kickout Control............................................T2-2-78

Group 3 ECM System

Outline..................................................................................... T2-3-1 Fuel Injection Control......................................................... T2-3-2 Operation of Fuel Injection.............................................. T2-3-4 Fuel Flow Diagram......................................................... T2-3-4

Group 4 Hydraulic System

Outline..................................................................................... T2-4-1 Main Circuit............................................................................ T2-4-2 Outline................................................................................ T2-4-2 Priority Valve Circuit...................................................... T2-4-4 Neutral Circuit.................................................................. T2-4-6 Single Operation Circuit............................................... T2-4-6 Combined Operation Circuit...................................... T2-4-8 Pilot Circuit...........................................................................T2-4-12 Outline..............................................................................T2-4-12 Charging Circuit (Brake Priority Circuit)...............T2-4-14 Lift Arm/Bucket Operation Control Circuit..........T2-4-16 Pump Control Circuit...................................................T2-4-18 Service Brake Circuit....................................................T2-4-20 Parking Brake Circuit...................................................T2-4-22 Ride Control Circuit (Option)....................................T2-4-24 Steering Circuit..............................................................T2-4-26 Steering Shock Dampening Function...................T2-4-28 Steering Stop Circuit...................................................T2-4-30 Secondary Steering Circuit.............................................T2-4-32 Fan Speed Control Circuit...............................................T2-4-34 Reversing Fan Circuit (Option)......................................T2-4-36

90Z6 F&S

Group 5 Electrical System

Outline..................................................................................... T2-5-1 Main Circuit............................................................................ T2-5-2 CAN Circuit........................................................................ T2-5-3 Electric Power Circuit (Key Switch: OFF)................. T2-5-4 Accessory Circuit (Key Switch: ACC)........................ T2-5-6 Starting Circuit (Key Switch: START)........................ T2-5-8 Neutral Engine Start Circuit...................................T2-5-10 Charging Circuit (Key Switch: ON)..........................T2-5-12 Surge Voltage Prevention Circuit............................T2-5-14 Engine Stop Circuit......................................................T2-5-16 Accessory Circuit................................................................T2-5-19 Head Light Circuit........................................................T2-5-20 Clearance Light, License Light, Tail Light Circuit........................................................T2-5-20 Head Light Circuit.....................................................T2-5-22 High-Beam Circuit.....................................................T2-5-24 Hazard Light Circuit (Key Switch: OFF).................T2-5-26 Turn Signal Light Circuit.............................................T2-5-28 Horn Circuit (Key Switch: OFF).................................T2-5-30 Reverse Light / Buzzer Circuit..................................T2-5-32 Brake Light Circuit........................................................T2-5-34 Parking Brake Circuit...................................................T2-5-36 Parking Brake: Applied............................................T2-5-36 Parking Brake: Released.........................................T2-5-38 Work Light Circuit.........................................................T2-5-40 Wiper Circuit...................................................................T2-5-42 Front Wiper Circuit....................................................T2-5-42 Rear Wiper Circuit......................................................T2-5-44 Washer Circuit.............................................................T2-5-46 Cab Dome Light Circuit..............................................T2-5-48 Cab Light Switch........................................................T2-5-48 Rear Cab Light Switch..............................................T2-5-48

90Z6 F&S

SECTION 2 SYSTEM Group 1 Controller Outline The following controllers are provided in this machine in order to control functions. Each controller excluding the communication controller communicates by using the CAN circuit and sends or receives the required signal. Controller

Control

MC (Main Controller) ECM (Engine Control Module) ICF (Information Controller) Column Monitor Controller

Controls the engine speed, transmission, pumps, and valves. Controls the engine. Stores the operating information and alarms. Controls the wiper and buzzer, etc. Displays the gauge and alarm lights. Controls the air conditioner. Sends the e-mails and operating information.

Air Conditioner Controller Communication Controller (Option)

fNOTE: Refer to the corresponding group for details of each controller control.

T2-1-1

Comment on Control T2-2 T2-3 T5-2 T2-5 T2-5, T5-7 T5-3

SECTION 2 SYSTEM Group 1 Controller CAN Circuit CAN (Controller Area Network) is ISO Standards of the serial communication protocol. CAN is used for the engine control and for the accessories. CAN consists of two harnesses, CAN-H (High) (1) and CAN-L (Low) (2). Each controller judges the CAN level due to potential difference between CAN-H (High) (1) and CAN-L (Low) (2). Each controller arranges the CAN level and sends the signal and data to other controllers. In addition, termination resistors (120 Ω) (3) are installed to both ends of CAN.

1 Monitor

MPDr. ICF

GSM

A/C

INSITE

Rear View Monitor

Opt CAN

ECM

3 2 90Z6-02-05-02

fNOTE: CAN communication is indicated by bold line. fNOTE: ICF: Information Controller MC: Main Controller A/C: Air Conditioner Controller INSITE: Engine Diagnostic Tool (Option) ECM: Engine Control Module

T2-1-2

SECTION 2 SYSTEM Group 2 Control System Outline Main Controller (MC) is used in order to control the machine operations. The signals from the accelerator pedal sensor, various sensors, and switches are sent to MC and processed in the logic circuit. MC uses the Controller Area Network (CAN) to communicate required signals to the Engine Control Module (ECM) which controls engine outputs, such as revolutions and power curve. (Refer to SYSTEM / ECM System.) MC receives signals from the shift switch, forward/reverse lever, and transmission for machine movement and process them in the logic circuit. The MC also operates the forward/reverse clutch solenoid valves and speed range solenoid valves, and controls the transmission.

T2-2-1

SECTION 2 SYSTEM Group 2 Control System Engine Control, Pump Control, Transmission Control < Input Signal > Accelerator Pedal Sensor Driving Mode Switch Power Mode Switch Pump Delivery Pressure Sensor Pressure Sensor (Brake Secondary Pressure) Pressure Sensor (Parking Brake) Hydraulic Oil Temperature Sensor Declutch Position Switch Lift Arm Angle Sensor Pressure Sensor (Lift Arm Raise) (Option) Key Switch Forward/Reverse Lever Forward/Reverse Switch (Option) Forward/Reverse Selector Switch (Option) Shift Switch Downshift Switch (DSS) Hold Switch Torque Converter Input Speed Sensor Torque Converter Output Speed Sensor Transmission Intermediate Shaft Speed Sensor (Machine Speed Sensor (Backup)) Machine Speed Sensor Torque Converter Oil Temperature Sensor Shift Change Delay Switch Axle Oil Temperature Sensor

    

Main Controller (MC)

              

< Output Signal > Engine Control  Accelerator Pedal Failure Control  Auto-Warm Up Control  Engine Load Idle Speed Control  Forward/Reverse Operation Engine Speed Limiter  Engine Speed Regulator For Digging  Speed Limit Control with Power Mode OFF  Machine Overheat Engine Speed Limiter  Reversing Fan Idle Speed Control

Pump Control  Torque Control  Torque Decrease Control While Dumping Bucket (Hydraulic Load Reduction)

Transmission Control  Neutral Control  Forward/Reverse Lever Priority Control  Manual Speed Shift Control  Automatic Speed Shift Control  Downshift Control  Shift Holding Control

   

Coolant Temperature Sensor Engine Revolution Sensor Boost Temperature Sensor

  

Engine Control Module (ECM)

Maintenance Pro Dr. (MPDr.) Monitor

 

Information Controller (ICF)

 Speed Shift Delay Control  Declutch Control

 Controller Area Network (CAN) Column Monitor Controller

T2-2-2

SECTION 2 SYSTEM Group 2 Control System Fan Control, Valve Control, Other Controls < Input Signal > Accelerator Pedal Sensor Driving Mode Switch Power Mode Switch Quick Power Switch Fan Reversing Switch Pump Delivery Pressure Sensor Pressure Sensor (Parking Brake) Pressure Sensor (Primary Pilot Pressure) Pressure Sensor (Brake Primary Pressure) Pressure Sensor (Brake Secondary Pressure) Fan Pump Delivery Pressure Sensor Secondary Steering Pump Delivery Pressure Sensor (Option) Steering Pressure Switch (Option) Hydraulic Oil Temperature Sensor Declutch Position Switch Lift Arm Angle Sensor Pressure Sensor (Lift Arm Raise) (Option) Pressure Sensor (Refrigerant Pressure) Secondary Steering Check Switch (Option) Forward/Reverse Lever Forward/Reverse Switch (Option) Forward/Reverse Selector Switch (Option) Shift Switch Torque Converter Input Speed Sensor Torque Converter Output Speed Sensor Transmission Intermediate Shaft Speed Sensor (Machine Speed Sensor (Backup))

 

Main Controller (MC)

 

< Output Signal > Fan Control, Valve Control  Fan Speed Control  Fan Reverse Rotation Control  Ride Control (Option)

  



Other Controls  Transmission Alarm Control  Parking Brake Operation Indicator Control  Brake Oil Low Pressure Indicator Control  Low Steering Oil Pressure Indicator Control (Option)  Overrun Alarm Control  Lift Arm Auto Leveler Lower Kickout Control (Option)



Lift Arm Auto Leveler Height Kickout Control (Option)



Quick Power Mode Control Secondary Steering Control (Option)

      



   

Combined Electric and Hydraulic Control Circuit



Torque Converter Oil Temperature Sensor Machine Speed Sensor



Coolant Temperature Sensor Engine Revolution Sensor Boost Temperature Sensor



Maintenance Pro Dr. (MPDr.) Monitor



Bucket Auto Leveler Control Lift Arm Float Control  Lift Arm Lift Kickout Control



Engine Control Module (ECM)



Information Controller (ICF) 

Column Monitor Controller

T2-2-3

Controller Area Network (CAN)

SECTION 2 SYSTEM Group 2 Control System Engine Control The engine control consists of the followings.  Accelerator Pedal Failure Control  Auto-Warm Up Control  Engine Load Idle Speed Control  Forward/Reverse Operation Engine Speed Limiter  Engine Speed Regulator For Digging  Speed Limit Control with Power Mode OFF  Machine Overheat Engine Speed Limiter  Reversing Fan Idle Speed Control

T2-2-4

SECTION 2 SYSTEM Group 2 Control System Engine Control System Layout 43

SW1 SW2 1

Column Monitor Controller

41 42 45

2 3

8 Monitor

23 24 25 26

5 9

R F

10 ECM (mounted on the Engine)

Main Controller (MC)

37 36 35

17 11 Engine

A1 M

Regulator

16 T/M

a b

14 15

Information Controller (ICF)

6 A/C Controller

27 24

MPDr.

OFF

c 34

90Z6-02-02-01 a-

Brake Pedal Position: Lightly applied

12345-

Accelerator Pedal Accelerator Pedal Sensor Main Controller (MC) Column Display Controller Controller Area Network (CAN) Air Conditioner Controller Maintenance Pro (MP) Dr. Monitor Information Controller (ICF) Engine Control Module (ECM) Engine Hydraulic Main Pump Boost Temperature Sensor Engine Revolution Sensor

15- Coolant Temperature Sensor 16- Transmission 17- Machine Speed Sensor (Backup) 18- Torque Converter Oil Temperature Sensor 19- Torque Converter Input Speed Sensor 20- Torque Converter Output Speed Sensor 21- Machine Speed Sensor 22- Shift Switch 23- Forward/Reverse Lever 24- Forward Position 25- Neutral Position

67891011121314-

OFF

Brake Pedal Position: Fully applied

26- Reverse Position 27- Forward/Reverse Switch (Option) 28- Forward/Reverse Selector Switch (Option) 29- Pump Delivery Pressure Sensor 30- Torque Control Solenoid Valve 31- Parking Brake Solenoid Valve 32- Pressure Sensor (Parking Brake) 33- Parking Brake Switch 34- Declutch Position Switch 35- Power Mode Switch

T2-2-5

36373839404142434445-

Travel Mode Selector Switch AUTO 2 Mode Manual Mode AUTO 1 Mode Key Switch Hydraulic Oil Temperature Sensor Pressure Sensor (Lift Arm Raise)(Option) Brake Pedal (Left) Pressure Sensor (Brake Secondary Pressure) Axle Oil Temperature Sensor

SECTION 2 SYSTEM Group 2 Control System Accelerator Pedal Failure Control Purpose: The accelerator pedal control controls the engine speed according to the accelerator pedal angle (1).

A E

Operation: 1. Main Controller (MC) (3) receives the signals from the accelerator pedal and responds by sending a signal to Engine Control Module (ECM) (10) via Controller Area Network (CAN) communication (5) based on the accelerator pedal angle.

F G C

B TNED-02-02-002

2. ECM (10) controls the engine speed by responding to CAN signal (5) from MC (3).

A - Engine Speed B - Accelerator Pedal Position C - Accelerator Pedal Position: Not applied D - Accelerator Pedal Position: Fully applied

- In case of abnormal sensor signal detection 3. When the signal from accelerator pedal sensor (2) is out of acceptable range, MC (3) sends a backup signals to ECM (10). 4. ECM (10) limits the engine speed to specified value 1000 min-1 (RPM) (F). 5. When accelerator pedal sensor (2) fails and has to be replaced, the engine RPM control will be returned to the accelerator pedal by doing the following. 1) Turn the key switch (40) OFF. 2) Be sure the key switch (40) is OFF for at least 10 seconds. 3) Turn the key switch (40) ON. The RPM's should now be controlled by the accelerator pedal sensor. 6. After the above procedure 5 has been done, ECM (10) will recognize the signal coming from the MC (3) as provided from accelerator pedal sensor (2), according to the angle of the pedal, and the engine RPM's will be controlled by accelerator pedal (1).

f NOTE: If a signal from accelerator pedal sensor (2)

cannot be sent to MC (3) due to the sensor circuit problem, an auxiliary connector is available to connect the accelerator pedal sensor to send the signal directly from the pedal to ECM (10). This enables the engine to run in proportion to the accelerator pedal angle.

T2-2-6

E-

High Idle Speed (2130 min-1 (RPM)) F - Limited RPM's (1000 min-1 (RPM)) G - Low Idle Speed (800 min-1 (RPM))

SECTION 2 SYSTEM Group 2 Control System

SW1 SW2 1

Column Monitor Controller

41 42 45

2 3

8 Monitor

23 24 25 26

5 9

R F

10 ECM (mounted on the Engine)

37 36 35

14 15

3 Main Controller (MC)

Information Controller (ICF)

6 A/C Controller

27 24

MPDr.

17 11 Engine

A1 M

Regulator

16 T/M

OFF

33 90Z6-02-02-02

1234567891011121314-

T2-2-7

36373839404142434445-

SECTION 2 SYSTEM Group 2 Control System Auto-Warm Up Control A

Purpose: The auto-warm up control warms up the engine as shown below.

Operation: 1. MC (3) receives the hydraulic oil temperature signal from hydraulic oil temperature sensor (41).

D E

2. When key switch (40) is in the ON or START position and hydraulic oil temperature is below 0 °C (32 °F), MC (3) sends the target engine RPM signal to ECM (10) by using CAN communication (5). 3. ECM (10) increases the engine speed from 800 min-1 (RPM's) (E) to 1000 min-1 (RPM's) (D). This action permits quicker warm-up of the engine.

B TNED-02-02-004

A - Engine Speed B - Target Engine Speed C - High Idle Speed (2130 min-1 (RPM))

4. When all of the items under the topic below of "Deactivation Conditions" exist, MC (3) deactivates the auto-warm up control. 5. At this point, ECM (10) returns the engine speed (min-1 or RPM) control back to the accelerator pedal (1) position. Deactivation Conditions:  After key switch (40) has been in the ON or START position for 10 minutes or more, the auto warm-up feature is deactivated.  Hydraulic Oil Temperature: 30 °C (85 °F) or more  Coolant Temperature: 40 °C (105 °F) or more  Parking Brake: Released

fNOTE: The engine low idle speed can be adjusted by

Maintenance Pro (MP) Dr. (7) or machine monitor panel (8).

IMPORTANT: When adjusting the auto-idle speed, deactivate the auto-warm up control by using monitor panel (8). Make this adjustment only after waiting for 10 minutes to permit the systems to warm up.

T2-2-8

D - Auto- Warm Up Speed (1000 min-1 (RPM)) E - Low Idle Speed (800 min-1 (RPM))

SECTION 2 SYSTEM Group 2 Control System

SW1 SW2 1

Column Monitor Controller

41 42 45

2 3

8 Monitor

23 24 25 26

5 9

R F

10 ECM (mounted on the Engine)

37 36 35

14 15

3 Main Controller (MC)

Information Controller (ICF)

6 A/C Controller

27 24

MPDr.

17 11 Engine

A1 M

Regulator

16 T/M

OFF

33 90Z6-02-02-03

1234567891011121314-

T2-2-9

36373839404142434445-

SECTION 2 SYSTEM Group 2 Control System Engine Load Idle Speed Control A

Purpose: When the machine is climbing up an incline and the engine speed is slow, the engine load idle control engages and raises the engine RPM's from 800 RPM's (G) to 1100 RPM's (F) to prevent engine stall due to overload from application of hydraulics.

Operation:

1. ECM (10) communicates the engine torque data to MC (3) via CAN communication (5).

B TNED-02-02-006

2. When all of the items under the topic below of "Conditions" exist, MC (3) sends the target engine RPM's to ECM (10) via CAN communication (5). 3. ECM (10) increases responds by adjusting the engine RPM's up to 1100 min-1 (RPM's) (F) if the engine revolutions are less than that RPM level. This helps to prevent a load related stall.

A - Engine Speed B - Accelerator Pedal Position C - Accelerator Pedal Position: Not applied D - Accelerator Pedal Position: Fully applied

Conditions:  Forward/Reverse Lever (23): In operation  Machine Speed: 20 km/h (12.5 mph) or less  Accelerator Pedal (1) Position: Lightly applied (Engine Speed: 1000 min-1 (RPM) or less)  Engine Torque: Beyond specified value (Reference: 20 % or more)

fNOTE: Engine torque idle speed-up control is activated by the signal of forward/reverse switch (option) (27) when it is in use on the machine.

T2-2-10

E-

High Idle Speed (2130 min-1 (RPM)) F - Engine Load Idle Speed Speed Increase (1100 min-1 (RPM)) G - Low Idle Speed (800 min-1 (RPM))

SECTION 2 SYSTEM Group 2 Control System

SW1 SW2 1

Column Monitor Controller

41 42 45

2 3

8 Monitor

23 24 25 26

5 9

R F

10 ECM (mounted on the Engine)

37 36 35

14 15

3 Main Controller (MC)

Information Controller (ICF)

6 A/C Controller

27 24

MPDr.

17 11 Engine

A1 M

Regulator

16 T/M

OFF

33 90Z6-02-02-04

1234567891011121314-

T2-2-11

36373839404142434445-

SECTION 2 SYSTEM Group 2 Control System Forward/Reverse Operation Engine Speed Limiter Purpose: The forward/reverse operation engine speed limiter limits the engine RPM's (min-1) while moving the machine at a fast speed. The normal engine deceleration and resulting speed reduction of the engine has an effect of slowing the machine down through the transmission and drive train. This helps to lower shock loads and material loss from the bucket.

A E

Operation:

1. Main Controller MC (3) receives a signal from machine speed sensor (21) and transmission (16) and forward/reverse lever (23) or forward/reverse switch (27).

B TNED-02-02-009

2. When all of the items under the topic below of "Conditions" exist, MC (3) sends a target RPM (min-1) signal to Engine Control Module (ECM) (10) via CAN communication (5) when forward/reverse lever (23) or switch (27) has been applied. ECM (10) reduces and limits the engine RPM's as shown by "Specified Value (1300 min-1) (RPM)" (F).

A - Engine Speed B - Accelerator Pedal Position C - Accelerator Pedal Position: Not applied D - Accelerator Pedal Position: Fully applied

Conditions:  Machine Speed: Specified speed or more  Speed Shift: Third or Fourth

E-

High Idle Speed (2130 min-1 (RPM)) F - Specified Value (1300 min-1 (RPM)) G - Low Idle Speed (800 min-1 (RPM)

A E H

3. When forward/reverse lever (23) or switch (27) has been applied except when the above "Conditions", ECM (10) first limits the engine RPM's to 1750 min-1 (H), and then gradually reduces to 1650 min-1 (J).

4. When any of the item listed under "Deactivation Conditions" exist, ECM (10) returns the engine speed (min-1 or RPM) control back to the accelerator pedal (1) position. Deactivation Conditions:  Machine Speed: Specified speed or less  Forward/Reverse Lever (23) or Switch (27): Neutral Position (25)  2nd range modulation is completed while operating in manual shift change mode at specified speed or less

B TNED-02-02-011

A - Engine Speed B - Accelerator Pedal Position C - Accelerator Pedal Position: Not applied D - Accelerator Pedal Position: Fully applied E - High Idle Speed (2130 min-1 (RPM))

fNOTE: Forward/reverse selection speed limit control

while traveling is deactivated by the signal of forward/ reverse switch (option) (27) when it is in use on the machine.

T2-2-12

G - Low Idle Speed (800 min-1 (RPM)) H - Specified Value (1750 min-1 (RPM)) J- Specified Value (1650 min-1 (RPM))

SECTION 2 SYSTEM Group 2 Control System

SW1 SW2 1

Column Monitor Controller

41 42 45

2 3

8 Monitor

23 24 25 26

5 9

R F

10 ECM (mounted on the Engine)

37 36 35

14 15

3 Main Controller (MC)

Information Controller (ICF)

6 A/C Controller

27 24

MPDr.

17 11 Engine

A1 M

Regulator

16 T/M

OFF

33 90Z6-02-02-05

1234567891011121314-

T2-2-13

36373839404142434445-

SECTION 2 SYSTEM Group 2 Control System Engine Speed Regulator for Digging Purpose: The engine speed regulator for digging limits high idle speed and improves balance between tractive force and digging force.

A G H

Operation:

1. Main Controller (MC)(3) receives signals from machine speed sensor (21). B

2. Engine Control Module (ECM) (10) sends the actual engine speed signals from engine (11) to MC (3) via CAN communication (5).

4. When all of the items under the topic below of "Conditions" exist, MC (3) sends a target engine speed RPM (min-1) signal to ECM (10) via CAN communication (5).

Conditions:  Forward/Reverse Lever (23): Forward (F) Position (24)  Pump Delivery Pressure: High Pressure (Reference: 14 MPa (143 kgf/cm2, 2030 psi) or more)  Torque Converter Rotation Speed Ratio: Below specified value (Reference: 15 % or less)

Power Mode Selector Switch (35) High Idle Speed (G) Specified RPM at Roll Back (H) Specified RPM When Fully Rolled Back (I)

G - High Idle Speed (2130 min-1 (RPM)) H - Specified RPM While Digging I - Specified While Rolling Back Fully

OFF

(Reference) (Unit: min-1 (RPM)) ON

2100 1760

2130 2130

1650

2130

fNOTE: Specified RPM's (H, I) of the engine speed are

fNOTE: Torque converter rotation speed ratio is calculated from the following equation.

A=B/C C-

Engine Speed Operating Hours (second) Roll Back Start While Rolling Back While Rolling Bucket Back Roll Back Finish

Engine Speed according to Work Mode

5. ECM (10) reduces and limits the engine RPM's (min-1) to the values (G), (H), (I) relative to the curved graph. The speed will adjust only if the RPM's are above the values shown. CAN communication (5) transfers this data as required.

A - Torque Converter Rotation Speed Ratio B - Torque Converter Output Speed

TNED-02-02-013

ABCDEF-

3. MC (3) receives the signal from pump delivery pressure sensor (29) and the signal from power mode switch (35).

Actual Engine Speed

fNOTE: Engine Speed Regulator For Digging is activated by the signal of forward/reverse switch (option) (27) when it is in use on the machine.

T2-2-14

different according to the power mode application (ON or OFF).

SECTION 2 SYSTEM Group 2 Control System

SW1 SW2 1

Column Monitor Controller

41 42 45

2 3

8 Monitor

23 24 25 26

5 9

R F

10 ECM (mounted on the Engine)

37 36 35

14 15

3 Main Controller (MC)

Information Controller (ICF)

6 A/C Controller

27 24

MPDr.

17 11 Engine

A1 M

Regulator

16 T/M

OFF

33 90Z6-02-02-06

1234567891011121314-

T2-2-15

36373839404142434445-

SECTION 2 SYSTEM Group 2 Control System Speed Limit Control with Power Mode OFF Purpose: This speed limiter limits the high idle speed according to propulsion load when the power mode is deactivated (OFF). Therefore, fuel consumption is reduced.

Speed Shift: Second or less

Operation: 1. Main Controller (MC) (3) receives a signal about machine speed from machine speed sensor (21). A

2. Torque converter input speed sensor (19) sends the actual engine speed data to MC (3). 3. When all of the items under the topic below of "Conditions" exist, MC (3) sends a target RPM (min-1) a signal to ECM (10) via CAN communication (5). 4. ECM (10) reduces and limits the engine speed to the specified value from the high idle speed according to CAN communication (5) when the engine speed is above the limited engine speed engaged by the speed limiter. When the selected range is second or first, the engine speed is limited to a given value as indicated in the chart. The engine speed value is relative to the propulsion load.

B TNED-02-02-058KC

A - Engine Speed B - Propulsion Load

fNOTE: The power mode can be set to ON or OFF by using MPDr. (7) with key switch (40) ON or OFF.

Conditions:  Power Mode Selector Switch (35): OFF  Forward/Reverse Lever (23): Forward Position (24) or Reverse Position (26)

In addition, the power mode ON/OFF status can be held or released with key switch (40) OFF until key switch (40) is turned ON. MC (3) detects driving load by using torque converter speed ratio. Torque converter speed ratio is calculated from the following equation.

fNOTE: When 3rd or 4th range is selected, the speed limit control with power mode OFF is deactivated.

fNOTE: Speed limit control with power mode OFF is activated by the signal from forward/reverse switch (option) (27) when it is in use on the machine.

A=B/C A - Torque Converter Speed Ratio

BC-

T2-2-16

Torque Converter Output Speed Actual Engine Speed

SECTION 2 SYSTEM Group 2 Control System

SW1 SW2 1

Column Monitor Controller

41 42 45

2 3

8 Monitor

23 24 25 26

5 9

R F

10 ECM (mounted on the Engine)

37 36 35

14 15

3 Main Controller (MC)

Information Controller (ICF)

6 A/C Controller

27 24

MPDr.

17 11 Engine

A1 M

Regulator

16 T/M

OFF

33 90Z6-02-02-07

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T2-2-17

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SECTION 2 SYSTEM Group 2 Control System Machine Overheat Engine Speed Limiter Purpose: The machine overheat engine speed limiter limits the high idle speed and resists overheating when the axle oil temperatures reach their upper limit. A

Operation: D E

1. Main Controller (MC) (3) receives a signal from axle oil temperature sensor (45). 2. When the axle oil temperature is at 97 °C (206.6 °F) or higher, MC (3) sends a target RPM (min-1) signal to ECM (10) via CAN communication (5).

3. ECM (10) reduces and limits the engine speed to 1970 min-1 (RPM) (H) from high idle speed (F) relative to the oil temperature when the RPM's (min-1) are above the limited speed of the machine overheat engine speed limiter.

B 90Z6-02-02-10

A - Engine Speed B - Axle Oil Temperature C- 97 °C (206.6 °F)

4. Therefore, the overheating is prevented.

T2-2-18

D - High Idle Speed (2130 min-1 (RPM)) E - Specified Value (1970 min-1)

SECTION 2 SYSTEM Group 2 Control System

SW1 SW2 1

Column Monitor Controller

41 42 45

2 3

8 Monitor

23 24 25 26

5 9

R F

10 ECM (mounted on the Engine)

37 36 35

14 15

3 Main Controller (MC)

Information Controller (ICF)

6 A/C Controller

27 24

MPDr.

17 11 Engine

A1 M

Regulator

16 T/M

OFF

33 90Z6-02-02-08

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T2-2-19

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SECTION 2 SYSTEM Group 2 Control System Reversing Fan Idle Speed Control A

Purpose: The idle speed-up control increases the engine revolutions (min-1 (RPM's)) when the accelerator pedal is released while the cooling fan is turned manually in reverse rotation. This is done to prevent the fan from stopping operation. (Refer to page T2-2-xx "Fan Reverse Rotation Control".)

Operation:

G B

1. Engine Control Module (ECM) (10) receives signals from fan reverse rotation switch (46).

D TNED-02-02-004

2 When all of the items under the topic below of "Conditions" exist, MC (3) sends a target engine speed RPM (min-1) signal to ECM (10) via CAN communication (5).

A - Engine Speed B - Accelerator Pedal Position C - Accelerator Pedal Position: Not applied D - Accelerator Pedal Position: Fully applied

Condition:  Forward/Reverse Lever (23): Neutral Position (25)  Fan Reverse Rotation Switch (46): ON 3. When the reversing fan idle speed control is applied, ECM (10) responds to this signal by increasing the idle speed from low idle speed (G) to 850 min-1 (RPM) (F). 4. When any of the item listed under "Deactivation Conditions" exists, MC (3) deactivates the reversing fan idle up control. ECM (10) returns the engine speed (Min-1 or RPM's) control back to the accelerator pedal (1) position. Deactivation Condition:  Forward/Reverse Lever (23): Forward Position (24) or Reverse Position (26)  Fan Reverse Rotation Switch (46): OFF

f NOTE: When fan auto-reverse rotation (option) mode

is selected, idle speed-up control (fan reverse rotation) is disabled.

fNOTE: Reversing fan idle speed control is activated

by the signal from forward/reverse switch (option) (27) when it is in use on the machine.

T2-2-20

E-

High Idle Speed (2130 min-1 (RPM)) F - Reversing Fan Idle Speed Control (850 min-1 (RPM)) G - Low Idle Speed (800 min-1 (RPM))

SECTION 2 SYSTEM Group 2 Control System

SW1 SW2 1

2 3

Column Monitor Controller

41 42 45

8 Monitor

23 24 25 26

5 9

R F

10 ECM (mounted on the Engine)

37 36 35

14 15

3 Main Controller (MC)

Information Controller (ICF)

6 A/C Controller

27 24

MPDr.

17 11 Engine

A1 M

Regulator

16 T/M

OFF

90Z6-02-02-09

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T2-2-21

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SECTION 2 SYSTEM Group 2 Control System (Blank)

T2-2-22

SECTION 2 SYSTEM Group 2 Control System Pump Control The pump control consists of the following items.  Base Torque Control  Torque Decrease Control While Dumping Bucket

T2-2-23

SECTION 2 SYSTEM Group 2 Control System Base Torque Control Purpose: The base, or standard, torque control controls the hydraulic pump delivery flow rate in response to the engine speed changes due to variations in load so that the engine output power can be used more efficiently.

Operation: 1. Engine Control Module (ECM) (10) sends the actual speed of engine (11) to Main Controller (MC) (3) via the Controller Area Network (CAN) communication (5). 2. MC (3) sends a signal to hydraulic pump load torque control solenoid valve (30) relative to the actual engine speed as communicated by CAN communication (5) from ECM (10). 3. Torque control solenoid valve (30) delivers pilot pressure oil to the regulator depending on the signal received to control the pump delivery flow rate.

P TNED-02-02-024 P-

fNOTE: The calculated values of MC (3) are different at low temperature and at high temperature.

fNOTE: Refer to Torque Decrease Control While Dumping Bucket while dumping the bucket.

T2-2-24

Pressure

Q - Flow Rate

SECTION 2 SYSTEM Group 2 Control System

SW1 SW2 1

Column Monitor Controller

41 42 45

2 3

8 Monitor

23 24 25 26

5 9

R F

10 ECM (mounted on the Engine)

37 36 35

14 15

3 Main Controller (MC)

Information Controller (ICF)

6 A/C Controller

27 24

MPDr.

17 11 Engine

A1 M

Regulator

16 T/M

OFF

33 90Z6-02-02-11

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Accelerator Pedal Accelerator Pedal Sensor Main Controller (MC) Column Monitor Controller Controller Area Network (CAN) Air Conditioner Controller Maintenance Pro (MP) Dr. Monitor Information Controller (ICF) Engine Control Module (ECM) Engine Hydraulic Main Pump Boost Temperature Sensor Engine Revolution Sensor

T2-2-25

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SECTION 2 SYSTEM Group 2 Control System Torque Decrease Control While Dumping Bucket Purpose: The torque decrease control while dumping bucket (hydraulic load reduction) feature reduces pump oil flow and load so that the power from the engine can be applied to forward movement of the machine. Operation: 1. When all of the items under the topic below of "Conditions" exist, Main Controller (MC) (3) judges that machine is digging and sets the target torque 315 N·m (32 kgf·m)(232 lbf·ft). Conditions:  Torque Converter Rotation Speed Ratio: Below specified value (Reference: 15 % or less)  Forward/Reverse Lever (23): Forward Position (24)  Pump Delivery Pressure: High Pressure (Reference: 20 MPa (204 kgf/cm2, 2900 psi) or more) 2. MC (3) sends a signal to torque control solenoid valve (30) depending on the target torque. 3. Torque control solenoid valve (30) adjusts the hydraulic oil flow delivery rate at the regulator relative to the electrical signal it receives from the MC (3). 4. When any of the following "Deactivation Conditions" exists, the Torque Decrease Control While Dumping Bucket is deactivated. Deactivation Conditions:  Torque Converter Rotation Speed Ratio: Above specified value (Reference: 40 % or more)  Forward/Reverse Lever (23): Neutral Position (25) or Reverse Position (26)  Pump Delivery Pressure: Low Pressure (Reference: 9.8 MPa (100 kgf/cm2, 1421 psi) or less)

fNOTE: Torque Decrease Control While Dumping Bucket is activated by the signal from forward/reverse switch (option) (27) when it is in use on the machine.

fNOTE: When the power mode selector switch (35) is ON, the engine speed is controlled according to the lift arm angle, and there is a case where the Torque Decrease Control While Dumping Bucket is deactivated.

T2-2-26

SECTION 2 SYSTEM Group 2 Control System

SW1 SW2 1

Column Monitor Controller

41 42 45

2 3

8 Monitor

23 24 25 26

5 9

Controller

R F

10 ECM (mounted on the Engine)

37 36 35

14 15

3 Main Controller (MC)

Information Controller (ICF)

6 A/C

27 24

MPDr.

17 11 Engine

A1 M

Regulator

16 T/M

OFF

33 90Z6-02-02-12

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T2-2-27

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SECTION 2 SYSTEM Group 2 Control System Transmission Control The transmission control consists of the following.  Neutral Control  Forward/Reverse Lever Priority Control  Manual Speed Shift Control  Automatic Speed Shift Control  Downshift Control  Speed Shift Delay Control  Declutch Control  Shift Holding Control

T2-2-28

SECTION 2 SYSTEM Group 2 Control System Transmission Control System Layout 40

23 4

SW1 SW2 1

Column Monitor Controller

7 Monitor

3 4

6 A/C

MPDr.

Controller

24 25 26 27

Information Controller (ICF)

F N

28 25

ECM (mounted on the Engine)

3 Main Controller (MC)

10 Engine 19

Regulator

38 37 36 35 34

A1 M

18 OFF

13 T/M

33 32

90Z6-02-02-13

Brake Pedal Position: Lightly applied

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Accelerator Pedal Accelerator Pedal Sensor Main Controller (MC) Column Monitor Controller Controller Area Network (CAN) Air Conditioner Controller Monitor Information Controller (ICF) Engine Control Module (ECM) Engine Downshift Switch (DSS) Hold Switch Transmission

14- Torque Converter Oil Temperature Sensor 15- Torque Converter Input Speed Sensor 16- Torque Converter Output Speed Sensor 17- Machine Speed Sensor (Backup) 18- Machine Speed Sensor 19- Forward Clutch Solenoid Valve 20- Reverse Clutch Solenoid Valve 21- Speed Shift Solenoid Valve

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a b

OFF

Brake Pedal Position: Fully applied

22232425262728-

Hydraulic Main Pump Shift Switch Forward/Reverse Lever Forward Position Neutral Position Reverse Position Forward/Reverse Switch (Option) Forward/Reverse Selector Switch (Option) Parking Brake Solenoid Valve Pressure Sensor (Parking Brake) Parking Brake Switch

29303132-

T2-2-29

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Declutch Position Switch Power Mode Switch Travel Mode Selector Switch AUTO 2 Mode Manual Mode AUTO 1 Mode Key Switch Brake Pedal (Left) Pressure Sensor (Brake Secondary Pressure) 42- Lift Arm Angle Sensor 43- Pressure Sensor (Lift Arm Raise)(Option)

SECTION 2 SYSTEM Group 2 Control System Neutral Control Purpose: The neutral control deactivates the forward/reverse lever (24) operation and does not connect the transmission forward/reverse clutches when the parking brake is applied. Therefore, the parking brake is prevented from dragging.

6. Therefore, the forward/reverse clutch of transmission (13) is not engaged when the parking brake is applied, thus the parking brake is prevented from dragging. 7. When the parking brake is released, parking brake switch (32) is turned to "OFF", parking brake solenoid valve (30) sends pilot pressure oil to the parking brake unit to release it. It releases by compressing the parking brake spring with the piston.

1. Main Controller (MC) (3) receives a signal from parking brake pressure sensor (31). 2. MC (3) receives the signal from forward/reverse lever (24). (Refer to Forward/Reverse Lever Priority Control.)

8. MC (3) sends the input signal from forward/ reverse lever (24) to engage forward/reverse clutch solenoid valves (19, 20) of transmission (13) when the parking brake is released. (Pressure sensor (parking brake) (31) sends a signal that the parking brake release circuit has been pressurized, and it is ok to operate the transmission.)

3. MC (3) reads the parking brake pressure sensor (31) input signal when operating forward/reverse lever (24). 4. Parking brake solenoid valve (30) opens the circuit between the parking brake actuator and the hydraulic oil tank and engages the parking brake. This is done via use of parking brake switch (32). The parking brake is applied with spring force, and releases with oil pressure.

9. Therefore, the forward/reverse clutch of transmission (13) is engaged.

fNOTE: The operation of forward/reverse switch (option)

5. When the parking brake is applied, MC (3) does not respond to the signal from forward/reverse lever (24). Thus forward/reverse clutch solenoid valves (19, 20) of transmission (13) will not be energized when the parking brake is applied and the parking brake does not receive pressure to be released (pressure sensor at parking brake (31) is below the specified pressure).

T2-2-30

(28) becomes invalid when the parking brake is applied. When the park brake is applied, it is not possible to engage transmission (13) and drive through the parking brake.

SECTION 2 SYSTEM Group 2 Control System

44 4

SW1 SW2 1

Column Monitor Controller

7 Monitor

3 4

6 A/C

MPDr.

Controller

24 25 26 27

Information Controller (ICF)

F N

28 25

ECM (mounted on the Engine)

3 Main Controller (MC)

10 Engine 19

Regulator

38 37 36 35 34

A1 M

A2 PW

18 33

OFF

13 T/M

33 11

12 90Z6-02-02-14

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15- Torque Converter Input Speed Sensor 16- Torque Converter Output Speed Sensor 17- Machine Speed Sensor (Backup) 18- Machine Speed Sensor 19- Forward Clutch Solenoid Valve 20- Reverse Clutch Solenoid Valve 21- Speed Shift Solenoid Valve 22- Hydraulic Main Pump 23- Shift Switch 24- Forward/Reverse Lever 25- Forward Position

26- Neutral Position 27- Reverse Position 28- Forward/Reverse Switch (Option) 29- Forward/Reverse Selector Switch (Option) 30- Parking Brake Solenoid Valve 31- Pressure Sensor (Parking Brake) 32- Parking Brake Switch 33- Declutch Position Switch 34- Power Mode Switch 35- Travel Mode Selector Switch 36- AUTO 2 Mode 37- Manual Mode 38- AUTO 1 Mode

T2-2-31

39- Key Switch 40- Brake Pedal (Left) 41- Pressure Sensor (Brake Secondary Pressure) 42- Lift Arm Angle Sensor 43- Pressure Sensor (Lift Arm Raise)(Option) 44- Parking Brake Indicator

SECTION 2 SYSTEM Group 2 Control System Forward/Reverse Lever Priority Control (Option) Purpose: The forward/reverse lever is given priority over the optional forward/reverse switch (28) when the machine forward/reverse movement is controlled by forward/ reverse switch (28). Operation: 1. Forward/reverse lever (24), forward/reverse switch (option) (28), and forward/reverse selector switch (option) (29), machine speed sensor (18), and parking brake pressure sensor (31) all send a signal to the Main Controller (MC) (3). When MC (3) receives these signals, it then responds with an output signal to the forward/reverse clutch solenoid valves (19, 20) of transmission (13). 2. When forward/reverse selector switch (29) is OFF, MC (3) responds to forward/reverse lever (24) only. 3. When forward/reverse selector switch (29) has been turned ON while machine stops (machine speed: 0 km/h (0 mph), forward/reverse switch (28) and forward/reverse lever (24): neutral position (26)), MC (3) turns ON forward/reverse selector switch indicator on monitor (6), and will act on the next input from forward/reverse switch (28) or forward/ reverse lever (24). 4. When forward/reverse lever (24) is used or when starter key (39) is placed to ON position, it is given priority by MC (3) over forward/reverse switch (28). MC (3) turns OFF forward/reverse selector switch indicator on monitor (6). 5. To use forward/reverse switch (28) again, turn the switch (28) OFF, and go back to step 3.

fNOTE: In case forward/reverse lever (24) fails, MC (3)

sets transmission (13) in neutral then directional input control is given to forward/reverse switch (28). In case forward/reverse switch (28) fails, directional input control is given to forward/reverse lever (24). In case both forward/reverse lever (24) and forward/ reverse switch (28) fail, the transmission is fixed in neutral and the machine cannot move.

T2-2-32

SECTION 2 SYSTEM Group 2 Control System

44 4

SW1 SW2 1

Column Monitor Controller

7 Monitor

3 4

6 A/C

MPDr.

Controller

24 25 26 27

Information Controller (ICF)

F N

28 25

ECM (mounted on the Engine)

3 Main Controller (MC)

10 Engine 19

Regulator

38 37 36 35 34

A1 M

A2 PW

18 33

OFF

13 T/M

33 11

12 90Z6-02-02-15

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T2-2-33

39- Key Switch 40- Brake Pedal (Left) 41- Pressure Sensor (Brake Secondary Pressure) 42- Lift Arm Angle Sensor 43- Pressure Sensor (Lift Arm Raise)(Option) 44- Forward/Reverse Indicator

SECTION 2 SYSTEM Group 2 Control System Manual Speed Shift Control Purpose: The manual speed shift control changes the selected transmission range manually.

4. MC (3) also limits the range selection when this would be damaging to the transmission. 5. MC (3) changes the downshifting ranges a step at a time so as not to damage transmission (13); i.e. from fourth to third, from third to second, etc. These step by step shifts are done according to the machine speed.

Operation: 1. Main Controller (MC) (3) receives a signal to manually control the transmission from operating mode switch (35). (Refer to Automatic Speed Shift Control.) 2. MC (3) receives a signal from machine speed sensor (18) and shift switch (23). Shift switch (23) is divided into two sections. Notice the two sides, "A" and "B" in the table below. When first range is selected, "Side A" would be "ON" and "Side B" would be "OFF". When second range is selected, both "Side A" and "Side B" would remain in the "OFF" position, as the table shows. This signal is sent to MC (3) and it provides an appropriate output to control transmission (13). Speed Shift Side A Side B

First ON

Second Third ON

Fourth ON ON

3. The speed range signal from shift switch (23) is sent to MC (3) which responds with an output signal to speed range solenoid valve (21) of transmission (13) when operation mode switch (35) is on manual mode (37). This changes the selected range of transmission (13) manually.

T2-2-34

6. This protects the transmission by reducing downshift shock loads. 7. When selected range is changed, MC (3) sends a signal to column monitor controller (4) via CAN communication (5) to indicate on the monitor panel which transmission range is currently applied. 8. Column monitor controller (4) displays the applied range on monitor panel (7).

SECTION 2 SYSTEM Group 2 Control System

23 4

SW1 SW2 1

Column Monitor Controller

7 Monitor

3 4

6 A/C

MPDr.

Controller

24 25 26 27

Information Controller (ICF)

F N

28 25

ECM (mounted on the Engine)

3 Main Controller (MC)

10 Engine 19

Regulator

38 37 36 35 34

A1 M

A2 PW

18 33

OFF

13 T/M

33 11

12 90Z6-02-02-16

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T2-2-35

39- Key Switch 40- Brake Pedal (Left) 41- Pressure Sensor (Brake Secondary Pressure) 42- Lift Arm Angle Sensor 43- Pressure Sensor (Lift Arm Raise)(Option)

SECTION 2 SYSTEM Group 2 Control System Automatic Speed Shift Control Purpose: The automatic speed shift control changes the speed shift of transmission automatically. The shift change mode can be selected according to the work mode or work condition requirements. In addition, the timing of automatic speed shift is changed according to the power mode application to help with reducing fuel consumption and maintain the performance.

4. MC (3) limits shift switch (23) downshift signal so as to avoid engine over speed. 5. MC (3) adapts transmission (13) downshift selection to the operation parameters and permits transmission (13) downshift to occur in a step by step manner when the parameters will permit MC (3) to safely do so; for example, when downshifting transmission (13) from fourth to third, the machine speed must be in an acceptable range before MC (3) will permit the shift to occur, etc. If the selection is attempted to be made in such a way that the downshift could make operation unsafe or damage the machine, MC (3) will not permit the downshift to occur.

Operation: 1. Main Controller (MC) (3) receives an input signal from travel mode selector switch (35) and power mode selector switch (34). 2. MC (3) receives signals from machine speed sensor (18) and shift switch (23), and judges the currently selected speed range.

6. Therefore, downshift shock loads are reduced, the shift is made smoothly and the transmission is protected.

3. MC (3) sends the speed shift signal to speed shift solenoid valve (21) of transmission (13) in response to the input signal. Transmission (13) will automatically shift as required by the operating conditions.

7. MC (3) sends a speed range signal to column monitor controller (4) via CAN communication (5) at the shift selection changes are taking place. 8. Column monitor controller (4) displays the current speed range on monitor panel (7).

Travel (Shift Change) Mode  AUTO 1 Mode (38): The machine starts out in second range. When operating load is high, it will automatically downshift from second to first range.  AUTO 2 Mode (36): The machine starts out in second range. When operating load is high, it will not automatically downshift to first speed range.  Manual (37): The speed range is selected manually. (Refer to Manual Speed Shift Control.) Power Mode:  OFF: The transmission shifts up to the next range more quickly than usual. This improves the rate of fuel consumption while operating the machine in low load conditions.  ON: The transmission shifts up to the next range less quickly than usual. This improves the operation of the machine while under high load conditions.

fNOTE: The shift switch (23) provides the highest speed range.

fNOTE: When shift switch (23) is set to first range in

AUTO 1 or AUTO 2 mode, transmission (13) remains in the first range.

fNOTE: When travel mode switch (35) becomes

malfunctions, MC (3) sets the driving shift change mode to manual mode.

fNOTE: When machine speed sensor (18) and machine

T2-2-36

speed sensor (backup) (17) becomes malfunctions, MC (3) sets the driving shift change mode to manual mode via backup control.

SECTION 2 SYSTEM Group 2 Control System

23 4

SW1 SW2 1

Column Monitor Controller

7 Monitor

3 4

6 A/C

MPDr.

Controller

24 25 26 27

Information Controller (ICF)

F N

28 25

ECM (mounted on the Engine)

3 Main Controller (MC)

10 Engine 19

Regulator

38 37 36 35 34

A1 M

A2 PW

18 33

OFF

13 T/M

33 11

12 90Z6-02-02-17

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T2-2-37

39- Key Switch 40- Brake Pedal (Left) 41- Pressure Sensor (Brake Secondary Pressure) 42- Lift Arm Angle Sensor 43- Pressure Sensor (Lift Arm Raise)(Option)

SECTION 2 SYSTEM Group 2 Control System Downshift Control Purpose: The downshift control permits transmission (13) to downshift to the next lower range when it is applied.

7. When any of the following conditions exists under the topic "Deactivation Conditions", the downshift control is deactivated.

Operation: 1. Main Controller (MC) (3) receives the signals from machine speed sensor (18), shift switch (23), driving mode selector switch (35), downshift switch (DSS) (11) and the currently applied range within transmission (13). 2. When downshift switch (11) is applied, MC (3) downshifts by one range when the machine speed reaches the target speed for downshift (as from 4 to 3, from 3 to 2, etc.). MC (3) sends the shift signal to solenoid valve (21) of transmission (13) to downshift the speed range to the next one.

Deactivation Conditions:  Forward/Reverse Lever (24) or Switch (Option) (28): In use  Driving Mode Switch (35): In use  Hold Switch (12): Operated with the shift change mode set to AUTO 1 mode (38) or AUTO 2 mode (36)  Shift Switch (23): Operated, with Manual mode (37)

fNOTE: Downshift switch (11) is located on a front attachment control lever.

fNOTE: When machine speed sensor (18) malfunctions,

3. With AUTO1 (38) or AUTO2 (36) shift change mode selected, when driving machine while holding downshift switch (11) depressed, MC (3) downshifts the speed range from fourth to third, then from third to second by one range automatically when the machine speed reaches the target speed, and holds the speed range in second until releasing the downshift switch (11). 4. By applying downshift switch (DSS) (11) within 2 seconds after releasing it, MC (3) changes downshifts the speed range from second to first when the machine speed reaches the target speed for downshift. 5. The downshift control is deactivated and is returned to automatic speed shift control in 2 seconds after the speed shift is lowered. (Refer to Automatic Speed Shift Control.) 6. With the Manual (37) shift change mode selected, MC (3) downshifts the speed range by applying downshift switch (DSS) (11) by one range when the machine speed reaches the target speed for downshift. The selected shift range is held after lowering to the next one down. Apply downshift switch (11) again to downshift to the next one down. (Refer to Manual Speed Shift Control.)

T2-2-38

MC (3) sets the driving shift change mode to manual mode via back up control.

SECTION 2 SYSTEM Group 2 Control System

23 4

SW1 SW2 1

Column Monitor Controller

7 Monitor

3 4

6 A/C

MPDr.

Controller

24 25 26 27

Information Controller (ICF)

F N

28 25

ECM (mounted on the Engine)

3 Main Controller (MC)

10 Engine 19

Regulator

38 37 36 35 34

A1 M

A2 PW

18 33

OFF

13 T/M

33 11

12 90Z6-02-02-18

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T2-2-39

39- Key Switch 40- Brake Pedal (Left) 41- Pressure Sensor (Brake Secondary Pressure) 42- Lift Arm Angle Sensor 43- Pressure Sensor (Lift Arm Raise)(Option)

SECTION 2 SYSTEM Group 2 Control System Speed Shift Delay Control Purpose: The transmission shift delay control holds back the upshift timing at automatic speed shift control. Therefore, this control maintains machine performance during bucket and lift arm movement while loading. Operation: 1. When the following items listed below under "Requirements" exist, the timing of shift up (2~3) is delayed at automatic speed shift control. Requirements:  Forward/Reverse Lever (24) or Forward/Reverse Switch (28): Forward Position (25) or Reverse Position (27)  Shift Change Mode Switch (35): AUTO 1 mode (38), AUTO 2 mode (36)  Machine Speed: Beyond specified value (Reference: Power Mode OFF: 8.6 km/h (5.3 mph) or more, Power Mode ON: 10.1 km/h (6.3 mph) or more)  Speed Shift: Second or first  Parking Brake: Unlock  Shift Change Delay Mode Setting: ON 2. Main Controller (3) delays the current speed shift signal for 8 seconds while in forward and 8 seconds while in reverse with the machine in motion. 3. Therefore, the upshift timing of speed-shift up (second to third) is delayed.

fNOTE: Speed shift delay control is activated by the

signal of forward/reverse switch (option) (28) when it is in use on the machine.

fNOTE: Speed shift delay control is deactivated when

power mode switch (34) or shift change mode switch (35) is operated, or when parking brake switch (32) is ON.

T2-2-40

SECTION 2 SYSTEM Group 2 Control System

23 4

SW1 SW2 1

Column Monitor Controller

7 Monitor

3 4

6 A/C

MPDr.

Controller

24 25 26 27

Information Controller (ICF)

F N

28 25

ECM (mounted on the Engine)

3 Main Controller (MC)

10 Engine 19

Regulator

38 37 36 35 34

A1 M

A2 PW

18 33

OFF

13 T/M

33 11

12 90Z6-02-02-19

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T2-2-41

39- Key Switch 40- Brake Pedal (Left) 41- Pressure Sensor (Brake Secondary Pressure) 42- Lift Arm Angle Sensor 43- Pressure Sensor (Lift Arm Raise)(Option)

SECTION 2 SYSTEM Group 2 Control System Declutch Control Purpose: The declutch control disengages the forward or reverse clutches (whichever engaged at the time) by applying the brake pedal. With the drivetrain not drawing torque from the engine, the power can be concentrated on the loading circuit functions.

4. When all the items listed under "Deactivation Conditions" exist, MC (3) sends a signal to energize forward or reverse clutch solenoid valves (19, 20) of transmission (13). In this state, a forward or reverse clutch is engaged. 5. Monitor (6) displays the forward/reverse position with declutch cutoff control when the forward/ reverse clutches of transmission (13) are disengaged.

Operation: 1. Main Controller (MC) (3) receives a signal from declutch position switch (33). 2. When all the items listed under "Conditions" exist, MC (3) stops energizing forward/reverse clutch solenoid valves (19, 20) of transmission (13). In this state, neither forward/reverse clutches are engaged. 3. Consequently, the engine output power can be concentrated on the loading circuit functions.

Deactivation Conditions:  Declutch Position Switch (33): OFF Position  Speed Range: Third speed or more  Pressure Sensor (Brake Second Pressure) (41): Below specified pressure

fNOTE: When declutch position switch (33) and pressure

Conditions:  Declutch Position Switch (33): (a) or (c) Position  Speed Range: Second or less  Machine speed: 20 km/h (12.5 mph) or less  Declutch pedal (left): Applied  Pressure Sensor (Brake Second Pressure) (41): Above specified pressure Declutch Position

Brake pedal (42) lightly applied (a)

sensor (brake secondary pressure line) (41) malfunctions, the declutch control is deactivated.

Brake pedal (42) fully applied (b)

Throttle Pedal Position Not applied

Fully applied

Not applied

Fully applied

Speed Range: First

1.25 MPa (181 psi)

1.5 MPa (218 psi)

2.5 MPa (363 psi)

3.0 MPa (435 psi)

Speed Range: Second

0.6 MPa (87 psi)

0.8 MPa (116 psi)

1.5 MPa (218 psi)

2.5 MPa (363 psi)

T2-2-42

SECTION 2 SYSTEM Group 2 Control System

23 4

SW1 SW2 1

Column Monitor Controller

7 Monitor

3 4

6 A/C

MPDr.

Controller

24 25 26 27

Information Controller (ICF)

F N

28 25

ECM (mounted on the Engine)

3 Main Controller (MC)

10 Engine 19

Regulator

38 37 36 35 34

A1 M

18 OFF

13 T/M

33 32

90Z6-02-02-20

Brake Pedal Position: Lightly applied

12345-

678910111213-

a b

OFF

Brake Pedal Position: Fully applied

22232425262728-

29303132-

T2-2-43

333435363738394041-

SECTION 2 SYSTEM Group 2 Control System Shift Holding Control Purpose: The shift holding control holds the current speed shift of transmission by operating the hold switch if necessary at automatic speed shift control. Operation: 1. Main Controller (MC) (3) receives a signal from shift hold switch (12). 2. MC (3) keeps transmission (13) engaged in the current speed range after shift hold switch (12) has been applied once. 3. With the shift hold control applied, the engaged transmission (13) speed range is held in that range, despite accelerator pedal (1) and brake pedal (40, 42) position changes.

fNOTE: The shift holding control is activated with

AUTO 1 mode (38) or AUTO 2 mode (36) selected by shift change mode switch (35).

4. When all of the items in the following under "Deactivation Conditions" exist, MC (3) deactivates the shift hold control feature. Deactivation Conditions:  Key Switch (39): OFF  Shift Hold Switch (12): Operated once more  Downshift Switch (11): Operated  Forward/Reverse Lever (24) or Forward/Reverse Switch (28): Operated  Forward/Reverse Selector Switch (29): ON  Shift Switch (23): Operated  Shift Change Mode Switch (35): Operated  Parking Brake: Applied  Power Mode Selector Switch (34): Operated

T2-2-44

SECTION 2 SYSTEM Group 2 Control System

23 4

SW1 SW2 1

Column Monitor Controller

7 Monitor

3 4

6 A/C

MPDr.

Controller

24 25 26 27

Information Controller (ICF)

F N

28 25

ECM (mounted on the Engine)

3 Main Controller (MC)

10 Engine 19

Regulator

38 37 36 35 34

A1 M

A2 PW

18 33

OFF

13 T/M

33 11

12 90Z6-02-02-21

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T2-2-45

39- Key Switch 40- Brake Pedal (Left) 41- Pressure Sensor (Brake Secondary Pressure) 42- Lift Arm Angle Sensor 43- Pressure Sensor (Lift Arm Raise)(Option)

SECTION 2 SYSTEM Group 2 Control System (Blank)

T2-2-46

SECTION 2 SYSTEM Group 2 Control System Fan Control, Valve Control The fan control and valve control consist of the followings.  Fan Speed Control  Fan Reverse Rotation Control (Option)  Ride Control (Option)

T2-2-47

SECTION 2 SYSTEM Group 2 Control System Fan Speed Control Purpose: The fan speed control optimizes the fan speed depending on engine speed, engine coolant temperature, power mode setting, oil temperatures, etc. Operation: 1. The following items provide inputs to Main Controller (MC) (1) via Controller Area Network (CAN) communication (3).  Engine speed signal, from torque converter input speed sensor (16)  Coolant temperature sensor (14) signal, from ECM (9)  Intake air temperature sensor (13), from ECM (9) 2. The following items provide a sensor signal inputs to MC (1).  Torque converter temperature sensor (17) signal  Hydraulic oil temperature sensor (37) signal  HVAC refrigerant pressure sensor (38)  Power mode selector switch (35) signal 3. MC (1) optimizes the signal sent to fan speed control solenoid valve (31) as adjusted by the input signals shown in the above listed items.

T2-2-48

SECTION 2 SYSTEM Group 2 Control System

MPDr.

Column Monitor Controller

7 Monitor 8

Information Controller (ICF)

Main Controller (MC)

19 35

21 3 4

A/C Controller

ECM (mounted on the Engine)

11 12 13 14

Regulator

10 Engine

28 31

15 T/M

29 41

25 90Z6-02-02-22

123456789101112131415-

Main Controller (MC) Column Monitor Controller Controller Area Network (CAN) Air Conditioner Controller Outside Temperature Sensor Maintenance Pro (MP) Dr. Monitor Information Controller (ICF) Engine Control Module (ECM) Engine Exhaust Temperature Sensor Engine Revolution Sensor Intake Air Temperature Sensor Coolant Temperature Sensor Transmission

16- Torque Converter Input Speed Sensor 17- Torque Converter Oil Temperature Sensor 18- Forward/Reverse Lever 19- Forward Position 20- Neutral Position 21- Reverse Position 22- Forward/Reverse Switch (Option) 23- Forward/Reverse Selector Switch (Option) 24- Parking Brake Solenoid Valve 25- Parking Brake Switch 26- Pressure Sensor (Parking Brake) 27- Fan Pump

28- Fan Motor 29- Fan Reversing Spool(Option) 30- Fan Reverse Rotation Control Solenoid Valve(Option) 31- Fan Speed Control Solenoid Valve(Option) 32- Hydraulic Fan Circuit Pressure Sensor 33- Fan Valve 34- Fan Reversing Switch(Option) 35- Power Mode Switch 36- Key Switch 37- Hydraulic Oil Temperature Sensor 38- Pressure Sensor (Refrigerant Pressure) 39- Accelerator Pedal

T2-2-49

40- Accelerator Pedal Sensor 41- Unloader Valve (Brake Charge Valve)

SECTION 2 SYSTEM Group 2 Control System Fan Reverse Rotation Control (Option) Purpose: The fan reverse rotation control reverses the rotation of the cooling fan from the normal rotation direction by operating the fan reversing switch (34).

Operation (MANUAL): 1. Main Controller (MC) (1) receives a signal from fan reversing switch (34). 2. MC (1) activates fan reverse rotation control solenoid valve (30) and shifts fan reversing spool (29) when fan reversing switch (34) is set to manualreverse rotation position.

fNOTE: As the cooling fan direction is reversed, dust that has lodged in the radiator and oil cooler is discharged, helping to clear the cooling elements of blockage.

3. MC (1) receives the ON/OFF signals from pressure sensor (parking brake) (26) via column display controller (2) via Controller Area Network (CAN) communication (3).

Operation (AUTO): 1. Main Controller (MC) (1) receives a signal from fan reversing switch (34).

4. MC (1) holds the fan in reverse rotation until the key switch is turned OFF when fan manual reversing switch (34) is set to OFF with the parking brake applied.

2. MC (1) activates fan reverse rotation control solenoid valve (30) and shifts fan reversing spool (29) when fan reversing switch (34) is set to autoreverse rotation position.

5. MC (1) rotates the fan motor in the normal direction after the fan has rotated in reverse rotation for one minute with the parking brake released.

3. Therefore, fan motor (28) rotates in reverse. 4. MC (1) activates fan speed control solenoid valve (31) at the same time and fixes the fan rotation speed at 1300 min-1 (specified value). 5. After setting fan reversing switch (34) to autoreverse position, the fan rotates in normal direction for 10 minutes, then in reverse direction for 1 minute. After that, repeats Normal rotation (30 minutes)  Reverse rotation (1 minute)  Normal rotation (30 minutes). The fan reverse rotation interval is 90 seconds when outside temperature is low. 6. The fan speed control now optimizes the fan rotation speed depending on engine speed, engine coolant temperature, etc. (Refer to Fan Speed Control.)

6. MC (1) sends fan reversing signal to column display controller (2) via Controller Area Network (CAN) communication (3). Column display controller (2) lights fan reverse rotation indicator (41) on the monitor.

fNOTE: The fan automatic reverse rotation can be set with MPDr. (6) (option).

fNOTE: When the cooling fan rotation is changed, it

7. When the fan reverse rotation control is deactivated by setting fan reversing switch (34) to OFF position, etc. the fan rotates only in normal direction until the fan reverse rotation control is activated again.

T2-2-50

reverses the direction of air flow; what was the outlet side is now the inlet side, and what was the inlet side is now the outlet side.

SECTION 2 SYSTEM Group 2 Control System

MPDr.

Column Monitor Controller

7 Monitor 8

Information Controller (ICF)

Main Controller (MC)

19 35

21 3 4

A/C Controller

ECM (mounted on the Engine)

11 12 13 14

Regulator

10 Engine

28 31

15 T/M

29 41

25 90Z6-02-02-23

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T2-2-51

40- Accelerator Pedal Sensor 41- Unloader Valve (Brake Charge Valve)

SECTION 2 SYSTEM Group 2 Control System Ride Control (Option) 7. When all of the items shown below under the topic of "Temporary Deactivation Conditions" exist, MC (1) deactivates the ride control system to temporarily cease to operate.

Purpose: The ride control reduces the fore and aft pitching that normally occurs while moving a wheel loader over uneven terrain by organizing a damper circuit in the lift arm (boom) cylinder. This is helpful to reduce operator discomfort and material spillage from the bucket.

Temporary Deactivation Conditions:  Lift Arm Raise Operation (Pressure Sensor (Lift Arm Raise) (Option) (12)): Beyond specified pressure (Reference: 0.41 MPa, 4.1 kgf/cm2, 60 psi or more)  Pump Delivery Pressure Sensor (21): Beyond specified pressure (Reference: 30 MPa, 306 kgf/cm2, 4350 psi or more)

Operation: 1. Main Controller MC (1) receives a machine speed signal from machine speed sensor (9). MC (1) receives a signal from ride control switch (option) (10). 2. MC (1) monitors the machine speed when ride control is in AUTO mode or is ON.

8. MC (1) sends the ride control operation status to column monitor controller (2) via Controller Area Network (CAN) communication (3).

3. MC (1) energizes ride control solenoid valve (18) when the machine reaches the speed to turn on ride control, and permits pilot oil to shift ride control spool (19).

9. Monitor controller (2) displays the ride control state on monitor (4).

4. When this occurs, a damper circuit is organized between the rod side and bottom side of lift arm cylinder (16) by directing oil to designated circuits. 5. The damper circuit absorbs and dissipates the fore and aft pitching energy caused from the up and down movement of the lift arms while running over uneven terrain. The rod end of lift arm cylinder (16) will open to the tank circuit so that there is minimal latent vacuum at the rod side of the circuit. The base end of lift arm cylinder (16) opens to work against accumulator (20) to absorbs the fore and aft pitching shock cycles.

fNOTE: The speed at which ride control engages and

disengages can be adjusted with monitor (4) and MPDr. (22). The setting range can be adjusted between 3 km/h (1.9 mph) and 10 km/h (6.2 mph).

fNOTE: When the following parts become defective, the

6. MC (1) deactivates the ride control when machine speed falls below the point of ride control engagement.

T2-2-52

ride control is deactivated.  Machine Speed Sensor (9)  Lift Arm Angle Sensor (Option) (11)  Pressure Sensor (Lift Arm Raise) (Option) (12)  Pump Delivery Pressure Sensor (21)

SECTION 2 SYSTEM Group 2 Control System MPDr.

Column Monitor Controller

4 Monitor 5

Information Controller (ICF)

Main Controller (MC)

21 6

ECM (mounted on the Engine)

14 Regulator

7 Engine

8 T/M

Tank

20 Pump

90Z6-02-02-24

1234567-

Main Controller (MC) Column Monitor Controller Controller Area Network (CAN) Monitor Information Controller (ICF) Engine Control Module (ECM) Engine

891011-

Transmission Machine Speed Sensor Ride Control Switch (Option) Lift Arm Angle Sensor (Option) 12- Pressure Sensor (Lift Arm Raise) (Option) 13- Ride Control Indicator

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T2-2-53

Lift Arm Spool Multiple Control Valve Lift Arm Cylinder Ride Control Valve (Option) Ride Control Solenoid Valve Ride Control Spool Ride Control Accumulator (Option)

21- Pressure Sensor (Pump Delivery Pressure) 22- Maintenance Pro (MP) Dr. (Option)

SECTION 2 SYSTEM Group 2 Control System (Blank)

T2-2-54

SECTION 2 SYSTEM Group 2 Control System Other Controls The other controls consist of the followings.  Transmission Alarm Control  Low Brake Oil Pressure Indicator Control  Low Steering Oil Pressure Indicator Control (Option)  Overrun Alarm Control  Lift Arm Auto Leveler Height Kickout Control (Option)  Lift Arm Auto Leveler Lower Kickout Control (Option)  Quick Power Mode Control  Secondary Steering Control (Option)

T2-2-55

SECTION 2 SYSTEM Group 2 Control System Transmission Alarm Control Purpose: The transmission alarm control illuminates transmission warning indicator (27) on the monitor control panel when there is a transmission fault. Operation: 1. When there is a transmission fault, Main Controller (MC) (3) sends a signal to column monitor controller (4). 2. Transmission warning indicator (27) on the monitor panel illuminates in response to the signal from column monitor controller (4).

T2-2-56

SECTION 2 SYSTEM Group 2 Control System

26 4

27 28 29 30

Column Monitor Controller

7 Monitor

5 8

Information Controller (ICF)

6 A/C Controller

N R 18

9 ECM (mounted on the Engine)

F R

3 Main Controller (MC)

12 10 Engine

14 Regulator

11 T/M 15

16 24 25

90Z6-02-02-25

1234567891011-

12131415161718192021-

Torque Converter Oil Temperature Sensor Torque Converter Input Speed Sensor Torque Converter Output Speed Sensor Machine Speed Sensor Machine Speed Sensor (Backup) Forward/Reverse Lever Forward/Reverse Switch (Option) Pressure Sensor (Brake Primary Pressure) Steering Pressure Switch Brake Pedal (Left)

T2-2-57

22- Pressure Sensor (Brake Secondary Pressure) 23- Parking Brake Solenoid Valve 24- Pressure Sensor (Parking Brake) 25- Parking Brake Switch 26- Alarm 27- Transmission Warning Indicator 28- Parking Brake Indicator 29- Low Brake Oil Pressure Indicator 30- Low Steering Oil Pressure Indicator (Option)

SECTION 2 SYSTEM Group 2 Control System Low Brake Oil Pressure Indicator Control Purpose: Main Controller (MC) (3) sends a signal to column monitor controller (4) to illuminate low brake oil pressure indicator (29) on the monitor panel when the service brake pressure circuit falls below a safe level. Operation: 1. When the service brake circuit pressure is below 8.0 MPa (81.6 kgf/cm2) at brake primary pressure sensor (19), MC (3) sends OFF signal to column monitor controller (4) in 0.8 seconds. 2. Column monitor controller (4) illuminates low brake oil pressure indicator (29). 3. When the service brake circuit pressure is above 10.0 MPa (102 kgf/cm2) at brake primary pressure sensor (19), MC (3) sends ON signal to column monitor controller (4). 4. Column monitor controller (4) turns OFF low brake oil pressure indicator (29).

fNOTE: When pressure sensor (brake primary pressure) (19) malfunctions, low brake oil pressure indicator (29) illuminates and remains ON.

T2-2-58

SECTION 2 SYSTEM Group 2 Control System

26 4

27 28 29 30

Column Monitor Controller

7 Monitor

5 8

Information Controller (ICF)

6 A/C Controller

N R 18

9 ECM (mounted on the Engine)

F R

3 Main Controller (MC)

12 10 Engine

14 Regulator

11 T/M 15

16 24 25

90Z6-02-02-26

1234567891011-

12131415161718192021-

T2-2-59

SECTION 2 SYSTEM Group 2 Control System Low Steering Oil Pressure Indicator Control (Option) Purpose: The optional low steering oil pressure indicator control illuminates the steering indicator (30) on the monitor control panel when steering oil pressure is below the specified value. Operation: 1. When steering oil pressure is below the secondary steering response level threshold and triggers steering pressure switch (20) to open the circuit between the switch and Main Controller (MC) (3), MC (3) sends the OFF signal to column monitor controller (4). 2. Column monitor controller (4) illuminates low steering oil pressure indicator (30). 3. MC (3) also engages the secondary steering system, if equipped, as determined by operating conditions. (Refer to Secondary Steering Control.) 4. When steering oil pressure is above the specified level, steering pressure switch (20) closes (turns ON), providing this input to MC (3). Then, MC (3) sends ON signal to column monitor controller (4). 5. Column monitor controller (4) turns OFF low steering oil pressure indicator (30).

fNOTE: Steering pressure switch (20) is not equipped without the secondary steering system option. This control does not exist and low steering oil pressure indicator (30) keeps OFF.

T2-2-60

SECTION 2 SYSTEM Group 2 Control System

26 4

27 28 29 30

Column Monitor Controller

7 Monitor

5 8

Information Controller (ICF)

6 A/C Controller

N R 18

9 ECM (mounted on the Engine)

F R

3 Main Controller (MC)

12 10 Engine

14 Regulator

11 T/M 15

16 24 25

90Z6-02-02-27

1234567891011-

12131415161718192021-

T2-2-61

SECTION 2 SYSTEM Group 2 Control System Overrun Alarm Control Purpose: The overrun alarm control sounds an alarm (26) and give warning to the operator of excessive machine speed, to warn the operator to slow down so as not to damage the transmission. Operation: 1. Main Controller (MC) (3) receives the machine ground speed signal from machine speed sensor (15). 2. MC (3) sends a signal to column monitor controller (4) via CAN communication (5) when the machine speed exceeds the specified safe level. 3. When this occurs, column monitor controller (4) sounds alarm (26) inside the cab. 4. Alarm (26) inside the cab stops sounding when the machine speed returns to a safe speed.

fNOTE: The machine speed of the overrun alarm control is 40 km/h or more with 26.5 inch tires.

T2-2-62

SECTION 2 SYSTEM Group 2 Control System

26 4

27 28 29 30

Column Monitor Controller

7 Monitor

5 8

Information Controller (ICF)

6 A/C Controller

N R 18

9 ECM (mounted on the Engine)

F R

3 Main Controller (MC)

12 10 Engine

14 Regulator

11 T/M 15

16 24 25

90Z6-02-02-28

1234567891011-

12131415161718192021-

T2-2-63

SECTION 2 SYSTEM Group 2 Control System Lift Arm Auto Leveler Height Kickout Control (Option) Purpose: The lift arm height kickout control stops the lift arm as it is raising. It stops at any position - between where the lift arms are horizontal and fully raised - that has been preset by the operator.

6. MC (1) receives a signal from lift arm angle sensor (11). MC (1) determines the stopping position of the lift arm (pre-selected by the operator). 7. MC (1) disconnects the terminal #C03 from the ground and deenergizes lift arm raising detent coil (6) on pilot valve (5).

IMPORTANT: After replacing the lift arm angle sensor (11) or Main Controller (MC) (1), perform learning control of lift arm angle sensor (11) using MaintenancePro Dr. (2) prior to performing work.

8. Pilot pressure oil from loader pilot valve (5) shifts lift arm spool (9) of control valve (8) to the neutral position from what was previously the raise position. Then, the lift arm stops.

Operation: 1. The lift arm height kickout control position is set by lift arm auto leveler switch (height) (12), and is memorized in MC (1). Adjust the lift arm height kickout control to the required level. (Refer to the Operation and Maintenance Manual for the procedure.)

9. When lift arm auto leveler switch (height) (12) is turned OFF, the lift arm auto leveler height kickout control is deactivated.

fNOTE: When lift arm angle sensor (12) becomes

abnormal, the lift arm auto leveler height kickout control is deactivated.

2. MC (1) makes the lift arm auto leveler height kickout control effective when lift arm auto leveler switch (height) (12) is turned ON.

3. MC (1) connects the terminal #C03 to the ground, and energizes lift arm raising coil (6) of pilot valve (5).

C B

4. Pilot pressure oil is directed to lift arm spool (9) of multiple control valve (8) to put it into the raise position and it holds it in this state as the lift arm is raised/and the detent function is applied at the control lever. TNED-02-02-042

5. Pressurized oil from the main pump is supplied to the bottom end of lift arm cylinder (10) and the lift arm continues to rise.

AB-

T2-2-64

Full Height Position of Lift Arm Horizontal Position of Lift Arm

C-

Setting Range of Lift Arm Stop (For Loading Range)

SECTION 2 SYSTEM Group 2 Control System

MPDr.

(ICF)

a b c

1 (MC)

Kickout works.

9 C03

C04

5 11

90Z6-02-02-29 a-

SET

1234-

Main Controller (MC) MaintenancePro Dr. (MPDr.) Information Controller (ICF) Controller Area Network (CAN)

56789-

Pilot Valve Lift Arm Raising Coil Lift Arm Lowering Coil Multiple Control Valve Lift Arm Spool

10- Lift Arm Cylinders 11- Lift Arm Angle Sensor 12- Lift Arm Auto Leveler Switch (Height)

T2-2-65

OFF

From Fuse #16 in Fuse Box A

SECTION 2 SYSTEM Group 2 Control System Lift Arm Auto Leveler Lower Kickout Control (Option) Purpose: The lift arm lower kickout control stops the lift arm as it is lowering. It stops at any position - between where the lift arms are horizontal and fully lowered - that has been preset by the operator.

6. MC (1) receives a signal from lift arm angle sensor (11). MC (1) determines the stopping position of the lift arm (pre-selected by the operator). 7. MC (1) disconnects the terminal #C04 from the ground and deenergizes lift arm lowering detent coil (7) on pilot valve (5).

IMPORTANT: After replacing the lift arm angle sensor (11) or Main Controller (MC) (1), perform learning control of lift arm angle sensor (11) using MaintenancePro Dr. (2) prior to performing work.

8. Pilot pressure oil from loader pilot valve (5) shifts lift arm spool (9) of control valve (8) to the neutral position from what was previously the lower position. Then, the lift arm stops.

Operation: 1. The lift arm height kickout control position is set by lift arm auto leveler switch (lower) (12), and is memorized in MC (1). Adjust the lift arm lower kickout control to the required level. (Refer to the Operation and Maintenance Manual for the procedure.)

9. When lift arm auto leveler switch (lower) (12) is turned OFF, the lift arm auto leveler lower kickout control is deactivated.

fNOTE: Although terminal #C04 is disconnected from

the ground in MC (1), it is connected to the ground when the specified time has passed. Therefore, lift arm lowering coil (7) of pilot valve (5) is energized again and the lift arm float control becomes effective. (Refer to Lift Arm Float Control.)

2. MC (1) makes the lift arm auto leveler lower kickout control effective when lift arm auto leveler switch (lower) (12) is turned ON. 3. MC (1) connects the terminal #C04 to the ground, and energizes lift arm lowering coil (7) of pilot valve (5).

fNOTE: When lift arm angle sensor (11) becomes

abnormal, the lift arm auto leveler height kickout control is deactivated.

4. Pilot pressure oil is directed to lift arm spool (9) of multiple control valve (8) to put it into the lower position and it holds it in this state as the lift arm is lowered/and the detent function is applied at the control lever. 5. Pressurized oil from the main pump is supplied to the rod end of lift arm cylinder (10) and the lift arm continues to lower.

B C

A TNED-02-02-043 AB-

T2-2-66

Lowered Position of Lift Arm Horizontal Position of Lift Arm

C-

Setting Range of Lift Arm Stop (For Return To Dig Position)

SECTION 2 SYSTEM Group 2 Control System

MPDr.

(ICF)

a b c

1 (MC) Kickout works.

9 C03 C04

5 11

90Z6-02-02-30 a-

SET

1234-

Main Controller (MC) MaintenancePro Dr. (MPDr.) Information Controller (ICF) Controller Area Network (CAN)

56789-

Pilot Valve Lift Arm Raising Coil Lift Arm Lowering Coil Multiple Control Valve Lift Arm Spool

10- Lift Arm Cylinders 11- Lift Arm Angle Sensor 12- Lift Arm Auto Leveler Switch (Lower)

T2-2-67

OFF

From Fuse #16 in Fuse Box A

SECTION 2 SYSTEM Group 2 Control System Quick Power Mode Control Purpose: 5. MC (3) sends the power mode status signal to column monitor controller (4) via CAN communication (5) as the changes are happening.

Applying quick P (power) mode switch (32) temporarily changes the work mode to the power mode for greater power with the power mode switch OFF (E mode). This provides better digging power and greater breakout force.

6. Column monitor controller (4) lights power mode indicator (38).

Operation: 1. Main Controller (MC) (3) receives signals from power mode switch (33) and quick power switch (32). 2. When MC (3) receives input signal from quick power switch (32), the power mode is activated. 3. The power mode remains activated until quick P switch (32) is released. (Quick P mode applies the normal Power mode function.) 4. When any of the following items listed under the topic below of "Deactivation Conditions" exists, MC (3) deactivates the quick P mode control. Deactivation Conditions:  Quick Power Switch (32): Pushed once more  Speed-shift up during automatic speed shift  Selected speed shift and torque converter rotation speed ratio: Specified value (Reference: 0.8) or more  Power Mode Switch (33): Operated  Forward/Reverse Lever (21): Neutral Position (23) or when operated

fNOTE: Quick P mode control is deactivated by the

signal of optional forward/reverse switch (25) when it is in use on the machine.

T2-2-68

SECTION 2 SYSTEM Group 2 Control System

38 4

SW1 SW2 1

Column Monitor Controller

6 Monitor

3 4

21 22 23 24

5 7

Information Controller (ICF)

F N R

25 22

8 ECM (mounted on the Engine)

12 13

3 Main Controller (MC)

26 32 33 37 36 35 34

15 9 Engine

A1 M

Regulator

14 T/M 18

30 31

90Z6-02-02-31

12345-

Accelerator Pedal Accelerator Pedal Sensor Main Controller (MC) Column Monitor Controller Controller Area Network (CAN) 6- Monitor 7- Information Controller (ICF) 8- Engine Control Module (ECM) 9- Engine 10- Hydraulic Main Pump 11- Boost Temperature Sensor 12- Engine Revolution Sensor

13- Coolant Temperature Sensor 14- Transmission 15- Torque Converter Oil Temperature Sensor 16- Torque Converter Input Speed Sensor 17- Torque Converter Output Speed Sensor 18- Machine Speed Sensor 19- Machine Speed Sensor (Backup) 20- Shift Switch 21- Forward/Reverse Lever

2223242526272829-

T2-2-69

Forward Position Neutral Position Reverse Position Forward/Reverse Switch (Option) Forward/Reverse Selector Switch (Option) Pump Delivery Pressure Sensor Torque Control Solenoid Valve Parking Brake Solenoid Valve

30- Pressure Sensor (Parking Brake) 31- Parking Brake Switch 32- Quick Power Switch 33- Power Mode Switch 34- Travel Mode Selector Switch 35- AUTO 2 Mode 36- Manual Mode 37- AUTO 1 Mode 38- Power Mode Indicator

SECTION 2 SYSTEM Group 2 Control System Secondary Steering Control Purpose: The secondary steering is used to steer the machine in the event that the engine stops running. The secondary steering control uses an electric motor to drive an auxiliary pump to provide oil to steer the machine. Automatic operation check when the engine starts:

Normal operation:

1. In the event of low steering pressure, Main Controller (MC) (1) receives a signal from secondary steering pump delivery pressure sensor (16).

1. MC (1) receives a signal from steering pressure switch (15). (Refer to Low Steering Oil Pressure Indicator Control.)

2. 3 seconds after the engine starts, MC (1) automatically turns secondary steering pump relay (19) ON for a maximum of 5 seconds.

2. Transmission Control Unit (TCU) (10) receives a signal from machine speed sensor (12). TCU (10) sends a signal to MC (1) via CAN communication (5).

3. Secondary steering motor (20), and then secondary steering pump (21) operate for a maximum of 2 seconds.

3. If the steering cannot be operated, MC (1) activates secondary steering motor (20) to turn and operates secondary steering pump (21) ON for 60 seconds. The machine speed must be at or over 5 Km/h (3.1 mph) to operate (If it is not at or above this pressure, steering pressure switch (15) turns OFF).

4. MC (1) turns secondary steering pump relay (19) OFF when secondary steering pump delivery pressure rises above 4.8 MPa (49 kgf/cm2, 696 psi) or more (normal pressure range) with secondary steering pump (21) operating.

4. Pressurized oil from secondary steering pump (21) is supplied to the steering circuit and makes the steering operation possible for 60 seconds.

5. When secondary steering pump relay (19) is ON, column display controller (2) lights secondary steering indicator (22) to indicate that it is operating.

5. While the above items are occurring, MC (1) sends the signals to column display controller (2) via CAN communication (5).

6. Column display controller (2) blinks secondary steering indicator (22) to indicate that the secondary steering pump delivery pressure is below 4.7 MPa (48 kgf/cm2, 681) psi or less (abnormal pressure) while secondary steering pump (21) is in operation.

6. Column display controller (2) lights secondary steering indicator (22) to indicate that the secondary steering is operating.

f NOTE: Secondary steering is an optional equipment for

fNOTE: When secondary steering pump delivery

pressure sensor (16) malfunctions, column display controller (4) blinks secondary steering indicator (22).

fNOTE: Secondary steering pump operation can be

checked with secondary steering operation check switch (14) (option). IMPORTANT: Large amount of electricity is required to operate secondary steering pump (21). Refer to Operation and Maintenance Manual for this check switch.

T2-2-70

EXP. Spec. machines (S/N 0101~).

SECTION 2 SYSTEM Group 2 Control System

22 2 Column Monitor Controller

3 Monitor 4

15 16

Information Controller (ICF)

6 ECM (mounted on the Engine)

Main Controller (MC)

7 Engine

Regulator

11 T/M

90Z6-02-02-32 a-

To Steering Pilot Valve

12345678-

Main Controller (MC) Column Monitor Controller Monitor Information Controller Controller Area Network (CAN) Engine Control Module (ECM) Engine -

91011121314-

Engine Revolution Sensor Transmission Machine Speed Sensor Pump Delivery Pressure Sensor Secondary Steering Check Switch (Option)

15- Steering Pressure Switch (Option) 16- Secondary Steering Pump Delivery Pressure Sensor (Option) 17- Accelerator Pedal 18- Accelerator Pedal Sensor

T2-2-71

19- Secondary Steering Pump Relay (Option) 20- Secondary Steering Motor (Option) 21- Secondary Steering Pump (Option) 22- Secondary Steering Indicator (Option)

SECTION 2 SYSTEM Group 2 Control System (Blank)

T2-2-72

SECTION 2 SYSTEM Group 2 Control System Combined Electric and Hydraulic Control Circuit The combined electric and hydraulic control circuits have the following controls.  Bucket Auto Leveler Control  Lift Arm Float Control  Lift Arm Lift Kickout Control

T2-2-73

SECTION 2 SYSTEM Group 2 Control System Bucket Auto Leveler Control Purpose: The bucket auto leveler control automatically levels the bucket horizontal to start digging in a pile, and permits bucket roll back while engaging the pile and filling the bucket. Operation: 1. Bar (3) is located to the front of bucket proximity switch (2) while dumping the bucket. 2. When the bucket control lever is moved from the dump position (bar 3 is close to the proximity switch while dumping) to the level position by tilting it back (roll back), bar (3) moves past the bucket proximity switch (2). With bar (3) in front of the bucket proximity switch (2), the electrical detent circuit is energized by current (a) from fuse #16 in fuse box A. Note that proximity switch (2) detects the position of the bar, turns ON the bucket leveler relay, and turns ON electromagnet (5) in pilot control valve (4) when the bar is close to it. 3. Therefore, the bucket control lever is held by electromagnet (5) on the bucket roll back side, and pressurized oil from pilot valve (4) moves bucket spool (9) in multiple control valve (7). 4. Pressurized oil from main pump (10) flows to bucket cylinder (1) through bucket spool (9) in multiple control valve (7) and tilts the bucket. 5. When bar (3) is moved away from bucket proximity switch (2), bucket proximity switch (2) turns OFF. Electromagnet (5) on the bucket roll back side turns OFF and the bucket control lever returns to the neutral position. 6. Therefore, when bucket spool (9) in multiple control valve (7) returns to the neutral position, bucket cylinder (1) stops. 7. This automatically permits the bucket to be leveled.

T2-2-74

SECTION 2 SYSTEM Group 2 Control System

8 11

90Z6-02-02-33

From Fuse Box A (Fuse #16)

Pilot Pressure (From Pilot Pump via Charging Block)

123-

Bucket Cylinder Bucket Proximity Switch Bar

Pilot Valve (Bucket Control Lever) Electromagnet on Bucket Roll Back Side

78910-

T2-2-75

Multiple Control Valve Lift Arm Spool Bucket Spool Main Pump

11- Hydraulic Tank

SECTION 2 SYSTEM Group 2 Control System Lift Arm Float Control Purpose: Permits floating up and down movement of the lift arm in response to the ground level external loads for snow removing and road cleaning Operation: 1. When the lift arm control lever is moved to the float position (farther position than the lift arm lowering position), the Main Controller (MC) turns ON, and electromagnet (2) on the lift arm lowering side is turned ON by current (a) from fuse #16 in fuse box A. 2. Therefore, the lift arm control lever is held by electromagnet (2) on the lift arm lowering side. 3. Pressurized oil from pilot valve (3) moves lift arm spool (8) in multiple control valve (7) right to the float position. 4. Pressurized oil from main pump (10), and from lift arm cylinder (1) at both base and rod ends are all routed to hydraulic tank (11) through lift arm spool (8). 5. Therefore, as the circuit is opened between lift arm cylinder (1) and hydraulic tank (11), the lift arm can move freely up and down depending on the external forces on the lift arm. 6. The lift arm control lever returns to the neutral position when it is pulled more strongly than the magnetic force of electromagnet (2) on the lift arm lowering side. 7. Therefore, lift arm spool (8) in multiple control valve (7) returns to the neutral position and the lift arm float control is deactivated.

T2-2-76

SECTION 2 SYSTEM Group 2 Control System

9 a

8 11 10

90Z6-02-02-34

From Fuse Box A (Fuse #16)

Pilot Pressure (From Pilot Pump via Charging Block)

12-

Lift Arm Cylinder Electromagnet on Lift Arm Lowering Side

Pilot Valve (Lift Arm Control Lever) Multiple Control Valve

8- Lift Arm Spool 9- Bucket Spool 10- Main Pump

T2-2-77

11- Hydraulic Tank

SECTION 2 SYSTEM Group 2 Control System Lift Arm Lift Kickout Control Purpose: The lift arm lift kickout control raises and automatically stops the lift arm to the highest position. Operation: 1. Plate (3) is located to the front of lift arm proximity switch (2) while lowering the bucket. 2. When the lift arm control lever is moved from the raise position to the higher position, plate (3) moves past the lift arm proximity switch (2). With plate (3) in front of the lift arm proximity switch (2), the electrical detent circuit is energized by current (a) from fuse #16 in fuse box A. Note that proximity switch (2) detects the position of the plate, turns ON lift arm kickout relay (12), and turns ON electromagnet (5) in pilot control valve (4) when the plate is close to it. 3. Therefore, the lift arm control lever is held by electromagnet (5) on the lift arm raising side, and pressurized oil from pilot valve (4) moves lift arm spool (9) in control valve (7). 4. Pressurized oil from main pump (10) flows to lift arm cylinder (1) through lift arm spool (9) in control valve (7) and raises the lift arm. 5. When plate (3) is moved away from lift arm proximity switch (2), lift arm proximity switch (2) turns OFF. Electromagnet (5) on the lift arm raising side turns OFF and the lift arm control lever returns to the neutral position. 6. Therefore, when lift arm spool (9) in control valve (7) returns to the neutral position, lift arm cylinder (1) stops. 7. This automatically permits the lift arm to be stopped.

T2-2-78

SECTION 2 SYSTEM Group 2 Control System

11 1

7 10 9

90Z6-02-02-35

From Fuse Box A (Fuse #16)

Pilot Pressure (From Pilot Pump via Charging Block)

123-

Lift Arm Cylinder Lift Arm Proximity Switch Plate

Pilot Valve (Lift Arm Control Lever) Electromagnet on Lift Arm Raising Side

6789-

T2-2-79

Control Valve Lift Arm Spool Bucket Spool Main Pump

10- Hydraulic Oil Tank 11- Lift Arm Kickout Relay

SECTION 2 SYSTEM Group 2 Control System (Blank)

T2-2-80

SECTION 2 SYSTEM Group 3 ECM System Outline Engine Control Module (ECM) (9) receives signals from the sensors and Main Controller (MC) (10). ECM (9) processes this information and activate solenoid valve (4) for fuel injection control.

ECM cooling plate (8) is installed behind ECM (9) prevents malfunctions of ECM (9) due to heat generation by cooling with circulating fuel.

Fuel pump (6) sends high-pressure fuel to unit injector (3) for each engine cylinder to inject the fuel to power the engine. 4

11 12 13 14

15 16 5

18 19

1 (Fuel Tank)

(ECM)

10 (MC)

8 90Z6-02-03-01

1234567-

Fuel Tank Fuel Cooler Unit Injector Solenoid Valve Fuel Filter Fuel Pump Fuel Shut-Off Valve

891011121314-

ECM Cooling Plate ECM (Engine Control Module) MC (Main Controller) Atmospheric Pressure Sensor Rail Pressure Sensor Crankshaft Angle Sensor Engine Position Sensor

15- Coolant Temperature Sensor 16- Engine Oil Pressure and Temperature Sensor 17- Intake Manifold Pressure Sensor 18- Intake Manifold Temperature Sensor

T2-3-1

19- Controller Area Network (CAN)

SECTION 2 SYSTEM Group 3 ECM System Fuel Injection Control Engine Control Module (ECM) (9) monitors the engine operation status according to the signals from each sensor and Main Controller (MC) (10), and provides outputs for fuel injection control. ECM (9) sends a signal to solenoid valve (4) in unit injector (3) to inject fuel. ECM always compensates the level and timing of the output signal depending on the engine operating condition to effectively adjust the engine speed to the target value. This controls fuel injection timing and injection pressure. This realizes the stable engine output, while avoiding redundant use of fuel and reducing nitrogen oxide (NOx) generation.

T2-3-2

SECTION 2 SYSTEM Group 3 ECM System

24 23

SW1 SW2 1 25

2 3 4 10 (MC)

11 12 13 14

15 16 5

18 19

1 (Fuel Tank)

(ECM)

8 90Z6-02-03-02

12345678-

Fuel Tank Fuel Cooler Unit Injector Solenoid Valve Fuel Filter Fuel Pump Fuel Shut-Off Valve ECM Cooling Plate

9101112131415-

ECM (Engine Control Module) MC (Main Controller) Atmospheric Pressure Sensor Rail Pressure Sensor Crankshaft Angle Sensor Engine Position Sensor Coolant Temperature Sensor

16- Engine Oil Pressure and Temperature Sensor 17- Intake Manifold Pressure Sensor 18- Intake Manifold Temperature Sensor 19- Controller Area Network (CAN)

T2-3-3

202122232425-

Column Monitor Controller Accelerator Pedal Accelerator Pedal Sensor Machine Speed Sensor Shift Switch Power Mode Switch

SECTION 2 SYSTEM Group 3 ECM System Operation of Fuel Injection Fuel pressure from fuel pump (6) is always applied at the inlet of unit injector (3) and the un-injected fuel returns to the fuel tank.

When solenoid valve (4) is energized by the signal from ECM (9), the valve is turned ON and the fuel is injected from the injector by the reciprocating movement of the piston inside unit injector (3) moving in conjunction with the camshaft rotation. IMPORTANT: No disassembly or part replacement is required with unit injector (3) for repair. Replace the entire assembly when necessary.

Camshaft

90Z6-02-03-04

Fuel Flow Diagram

Fuel drain from injector

13-

Fuel Tank Unit Injector

Solenoid Valve (Injector Control Valve)

Fuel supply from tank (1)

90Z6-02-03-03

5 56-

T2-3-4

Fuel Filter Fuel Pump

ECM Cooling Plate

SECTION 2 SYSTEM Group 3 ECM System 1. Fuel Supply Process

 Before Injection

As the camshaft rotates, timing plunger return spring (1) forces timing plunger (4) upward.

Connected to Camshaft

Fuel flows into metering chamber (3). This flow continues as long as timing plunger (5) is moving upward, and injector control valve (2) is closed.

The ECM determines the end of metering when timing plunger (4) and metering plunger (6) stop moving upward, and opens control valve (2) to supply the fuel from fuel pump into timing chamber (5).

4 5

The fuel pressure increases to the level that the timing chamber inner pressure, metering chamber inner pressure, and metering plunger spring force are balanced.

3 6

2. Before-Injection Timing plunger (4) begins its downward travel by the cam operation, and the fuel is allowed to flow from timing chamber (5), through control solenoid valve (2), and into fuel supply passage (a).

90Z6-02-03-05

At the appropriate time determined by the ECM, injector control valve (2) closes, trapping fuel in timing chamber (5). This trapped fuel creates a solid hydraulic link between timing plunger (4) and metering plunger (6).

123-

As a result, metering plunger (6) is forced to move downward with timing plunger (4), increasing pressure in metering chamber (3).

Return Spring Solenoid Valve (Injector Control Valve) Metering Chamber

456-

Timing Plunger Timing Chamber Metering Plunger

 During Injection

3. Injection When this pressure reaches approximately 34,474 kPa, nozzle spring (8) begins to be forced upward. The result is that fuel is forced past the opened needle valve (7), and out into the combustion chamber. 9

4. After-Injection Metering plunger (6) begins downward travel at the same time with the fuel injection, and the spill passage of the metering plunger passes metering spill port (10). Metering chamber pressure drops rapidly.

Immediately after metering spill port (10) is opened, the metering plunger passes timing spill port (9). Timing plunger (4) is forced fully to the downward by the cam operation. This allows the fuel in timing chamber (5) to be sent to fuel drain.

90Z6-02-03-06 78-

T2-3-5

Needle Valve Nozzle Spring

9- Timing Spill Port 10- Metering Spill Port

SECTION 2 SYSTEM Group 3 ECM System (Blank)

T2-3-6

SECTION 2 SYSTEM Group 4 Hydraulic System Outline Hydraulic system is divided into the main circuit, pilot circuit, steering circuit, and fan circuit. Main Circuit: Power Source Main Pump

Pilot Circuit: Power Source Pilot Pump

Steering Circuit: Power Source Main Pump Pilot Pump Secondary Steering Pump (Option)

Oil Control Method Priority Valve Loading Control Valve

Supplied to Steering Cylinder Lift Arm / Bucket Cylinder

Oil Control Method Charging Block Loading Pilot Valve Pump Regulator Ride Control Valve (Option)

Supplied to Service Brake Circuit Lift Arm / Bucket Operation Control Circuit Pump Control Circuit Ride Control Circuit (Option)

Oil Control Method Steering Valve Priority Valve Steering Pilot Valve

Supplied to Steering Cylinder

fNOTE: The steering circuit is a combined circuit of main circuit and pilot circuit.

Fan Circuit: Power Source Fan Pump

Oil Control Method Fan Speed Control Solenoid Valve Fan Valve (Option)

T2-4-1

Supplied to Fan Motor

SECTION 2 SYSTEM Group 4 Hydraulic System Main Circuit Outline 1. Main pump (1) draws hydraulic oil from hydraulic oil tank (2) through suction filter (3) and delivers it to steering valve (6) and multiple control valve (9) via priority valve (5). 2. Priority valve (5) delivers pressurized oil from main pump (1) according to the steering wheel operation. (Refer to Priority Valve Circuit.) 3. Pressurized oil in steering valve (6) moves steering cylinders (8) at right and left by shifting steering spool (7). Returning oil from steering cylinders (8) returns to hydraulic oil tank (2) through steering valve (6) via return filter (4). (Refer to Steering Circuit.) 4. Pressurized oil in multiple control valve (9) moves lift arm cylinders (12) and bucket cylinder (13) by shifting lift arm spool (10) and bucket spool (11). Returning oil from bucket cylinder (13) and lift arm cylinders (12) returns to hydraulic oil tank (2) through multiple control valve (9) via return filter (4). (Refer to Lift Arm / Bucket Circuit.)

T2-4-2

SECTION 2 SYSTEM Group 4 Hydraulic System

8 13

11 6

5 2 3

90Z6-02-04-01

1234-

Main Pump Hydraulic Oil Tank Suction Filter Return Filter

5678-

Priority Valve Steering Valve Steering Spool Steering Cylinders

9101112-

T2-4-3

Multiple Control Valve Lift Arm Spool Bucket Spool Lift Arm Cylinders

13- Bucket Cylinder

SECTION 2 SYSTEM Group 4 Hydraulic System Priority Valve Circuit  When steering is in neutral

 When steering wheel is operated

1. When the engine is stopped, steering priority spool (3) in priority valve (2) is moved right by the spring force.

1. When operating the steering wheel, steering spool (8) moves and the tank port connected with priority spool circuit (LS2) is closed.

2. When the engine starts, pressurized oil from main pump (1) is supplied to steering valve (7) through steering priority spool (3).

2. Then, pressurized oil from main pump (1) flows to steering cylinders (9) through steering spool (8) via LS port.

3. Pressurized oil (CF) flows to port (LS1) through orifice 1 (4) and to port (LS2) through orifice 2 (5).

3. The pressure in priority spool circuit (LS2) increases in proportion to the movement of steering spool (8) in steering valve (7).

4. When not operating the steering wheel, pressurized oil from priority spool circuit (LS2) flows to hydraulic oil tank (15) through orifice 3 (6) and steering spool (8) in steering valve (7). Then, pressure in priority spool circuit (LS2) decreases.

4. When the combined force of priority valve (2) spring and this LS2 circuit pressure becomes larger than pressure in priority spool circuit (LS1), steering priority spool (3) of priority valve (2) moves to the right, and limit the oil flow to multiple control valve (10).

5. When the pressure at the port (LS2) side and the spring force lowers the pressure at the port (LS1) side, steering priority spool (3) moves left.

5. Thus, more oil from main pump (1) flows to steering valve (7).

6. Consequently, more pressurized oil from main pump (1) is supplied via port (EF) to the port (P) of multiple control valve (10) according to the movement (left) of steering priority spool (3).

f NOTE: Orifice 2 (5) of priority valve (2) permits the

priority spool operating pilot oil (LS) to flow to hydraulic oil tank (15) with steering spool (8) in the neutral position. This helps to warm up the oil in the priority spool circuit quickly as the orifice 2 (5) diameter is small. The reduced pressure has no effect on operation of steering priority spool (3).

7. Steering priority spool (3) has the notch in the oil passages between the main pump (1) output port and port (CF) and port (EF), which always connect the pressurized oil delivery circuit to steering priority spool (3). 8. When steering priority spool (3) moves left, pressurized oil routed to steering priority spool (3) from priority spool circuit (LS1) balances with the spring force at the position where the oil passage of port (CF) is minimal. Then, steering priority spool (3) stops moving.

T2-4-4

SECTION 2 SYSTEM Group 4 Hydraulic System  When not operating steering wheel or control levers (with engine running) 14

engine

: Tank line (Steering: Neutral) : Steering line : Loading line

4 Spring LS2

12345-

When the engine is stopped

LS1

90Z6-02-04-02

Main Pump Priority Valve Steering Priority Spool Orifice 1 Orifice 2

678910-

Orifice 3 Steering Valve Steering Spool Steering Cylinders Multiple Control Valve

1112131415-

T2-4-5

Lift Arm Spool Bucket Spool Lift Arm Cylinders Bucket Cylinder Hydraulic Oil Tank

SECTION 2 SYSTEM Group 4 Hydraulic System Neutral Circuit

Single Operation Circuit

< Loading Circuit >

1. Pressurized oil (EF) from priority valve (2) is supplied to multiple control valve (3).

1. During single operation of lift arm or bucket, pressurized oil (EF) in multiple control valve (3) flows to lift arm spool (4) and bucket spool (5) through load check valves (10, 11), and moves lift arm cylinder (6) and bucket cylinder (7).

2. When the front loading attachment levers are in neutral (when lift arm spool (4) and bucket spool (5) are in the neutral position), pressurized oil (EF) in multiple control valve (3) returns to hydraulic oil tank (8) through neutral circuit (9).

2. Load check valves (10, 11) prevent pressurized oil which has been supplied to lift arm spool (4) and bucket spool (5) from flowing reversely.

< Steering Circuit >

fNOTE: Refer to Priority Valve Circuit (When steering is in

fNOTE: Refer to Priority Valve Circuit (When steering

neutral).

T2-4-6

wheel is operated).

SECTION 2 SYSTEM Group 4 Hydraulic System

5 11 6

90Z6-02-04-03

1234-

Main Pump Priority Valve Multiple Control Valve Lift Arm Spool

5678-

Bucket Spool Lift Arm Cylinders Bucket Cylinder Hydraulic Oil Tank

9- Neutral Circuit 10- Load Check Valve (Lift Arm) 11- Load Check Valve (Bucket)

T2-4-7

SECTION 2 SYSTEM Group 4 Hydraulic System Combined Operation Circuit  Combined operation of lift arm raise and bucket dump

f NOTE: The lift arm raise and bucket dump operation when not operating the steering is explained here.

1. Pilot pressure oil (a1) from the pilot valve shifts lift arm spool (8) in control valve (7) during bucket dump with the lift arm raised. Pilot pressure oil (b2) shifts bucket spool (9) at the same time. 2. The pilot pressure (a1) also shifts selector valve spool (16) downward. 3. Pump pressure is applied to Port LS1 of priority valve (2) but Port LS2 is not pressurized because it is connected to hydraulic tank (12). 4. Pressure at Port LS1 increases and overcomes the spring force of priority valve (2), and moves steering priority spool (3) to the left. 5. Pressurized oil (EF) flows to lift arm spool (8) and moves lift arm cylinders (10) and raises the lift arms. 6. Pressurized oil (EF) also flows through flow rate control valve (17), and flows to bucket spool (9). This moves bucket cylinder (15) and dumps the bucket. 7. The pressure inside spring chamber (18) increases during the bucket dumping operation by shifted selector valve spool (16), limiting the movement of flow rate control valve (17). Thus, pressurized oil supplied to bucket spool (9) is restricted. 8. Consequently, more pressurized oil (EF) is supplied to the lift arm circuit with higher load so that combined operation of lift arm/bucket is made effectively.

T2-4-8

SECTION 2 SYSTEM Group 4 Hydraulic System

11 Dump

9 15 10

18 16

13 12

LS2

12345-

LS1

90Z6-02-04-04

Main Pump Priority Valve Steering Priority Spool Steering Valve Steering Spool

678910-

Steering Cylinders Multiple Control Valve Lift Arm Spool Bucket Spool Lift Arm Cylinders

1112131415-

T2-4-9

Bucket Cylinder Hydraulic Oil Tank Neutral Circuit Load Check Valve (Lift Arm) Load Check Valve (Bucket)

16- Selector Valve Spool 17- Flow Rate Control Valve 18- Spring Chamber

SECTION 2 SYSTEM Group 4 Hydraulic System  Combined operation of steering (right) and lift arm raise

fNOTE: Operation of lift arm raise and steering (right) combined is explained here.

1. When turning the steering wheel right, pilot pressure oil (Pb) shifts steering spool (5) in steering valve (4). 2. Pressurized oil (CF) from priority valve (2) flows to steering cylinders (6) through steering spool (5) via LS port in proportion to the movement of steering priority spool (3) in priority valve (2). (Refer to Priority Valve Circuit.) 3. Pressurized oil (CF) flowing to steering spool (5) moves steering cylinders (5) at right and left and the machine turns right. (Refer to Steering Circuit.) 4. The rest amount of pressurized oil (EF) from priority valve (2) is sent to multiple control valve (7) through check valve (17). 5. Pilot pressure oil (a1) shifts lift arm spool (8) in multiple control valve (7) when the front attachment control lever is set to lift arm raise operation. 6. Pressurized oil (EF) flowing to lift arm spool (7) moves lift arm cylinder (10) and raises the lift arm. 7. Therefore, steering (right) operation and lift arm raise operation are simultaneously made.

fNOTE: When the steering wheel is turned rapidly,

priority valve spool (3) largely moves left, and more pressure oil from main pump (1) is supplied to steering valve (4), resulting in delay of the front attachment movement.

T2-4-10

SECTION 2 SYSTEM Group 4 Hydraulic System

9 15 10 8

14 4

17 12

LS2

12345-

LS1

90Z6-02-04-05

Main Pump Priority Valve Steering Priority Spool Steering Valve Steering Spool

678910-

Steering Cylinders Multiple Control Valve Lift Arm Spool Bucket Spool Lift Arm Cylinders

1112131415-

T2-4-11

Bucket Cylinder Hydraulic Oil Tank Neutral Circuit Load Check Valve (Lift Arm) Load Check Valve (Bucket)

16- Selector Valve Spool 17- Check Valve

SECTION 2 SYSTEM Group 4 Hydraulic System Pilot Circuit Outline Pressure oil from pilot pump (9) is used in order to operate the following circuits.  Charging Circuit (Brake Priority Circuit)  Lift Arm / Bucket Operation Control Circuit  Pump Control Circuit  Service Brake Circuit  Parking Brake Circuit  Ride Control Circuit (Option)

T2-4-12

SECTION 2 SYSTEM Group 4 Hydraulic System

Front Loading Circuit

12 Brake Circuit 13

Pump Control Circuit

Ride Control Circuit (Option)

6 16 Charging Circuit (Brake Priority Circuit)

7 90Z6-02-04-10

12345-

Multiple Control Valve Pilot Shutoff Valve Bucket Pilot Valve Lift Arm Pilot Valve Auxiliary Pilot Valve (Option)

678910-

Charging Block Hydraulic Oil Tank Suction Filter Pilot Pump Pilot Filter

1112131415-

T2-4-13

Brake Valve Service Brake Parking Brake Pump Regulator Ride Control Valve (Option)

16- Ride Control Solenoid Valve (Option) 17- Ride Control Spool (Option)

SECTION 2 SYSTEM Group 4 Hydraulic System Charging Circuit (Brake Priority Circuit) Purpose: The pilot circuit supplies pressurized oil from pilot pump (1) preferentially to service brake circuits (A, B) through charging block (2) and maintains the brake performance. Charging block (2) also supplies pressurized oil from pilot pump (1) to the other pilot circuits.  Outline 8. Pressurized oil from pilot pump (1) is distributed by priority valve (3) to each port of charging block (2) connected to the respective pilot circuits.

1. When starting the engine, pressurized oil from pilot pump (1) is supplied to charging block (2).

fNOTE: When pressure in the pilot circuit rises higher

2. If the accumulated pressure in service brake accumulators (5, 6) is low, charge relief valve (4) is closed.

than a certain amount, pilot relief valve (9) opens, and prevents components of the pilot circuit from being damaged.

3. Then, pilot pressure is applied to Port B of brake priority valve (3), while pilot pressure and the spring force are applied to Port A. 4. This moves priority valve (3) right, limiting the amount of pressurized oil flowing to the following circuit. 5. Pressurized oil from pilot pump (1) flows toward the service brake circuit through check valves (7), and service brake accumulators (5, 6) (front and rear) are charged with pressurized oil for brake circuits.

fNOTE: Priority valve (3) is not fully closed by the spring

force to assure a certain amount of pressurized oil being supplied to the downstream circuits in the minimum opening condition.

6. When brake accumulators (5, 6) are pressurized to a certain level, charge relief valve (4) opens to release pressure by connecting priority valve (3) Port A to hydraulic oil tank (10). 7. Therefore, the pressure at Port A side (with spring (11)) of priority valve (3) decreases. When this combined force of pressure at Port A side and the spring force become lower than the pressure at Port B side, brake priority valve (3) moves left.

9. Pressurized oil (PS1) flows to the steering valve through the steering pilot valve (Orbitrol), to actuate the steering valve spool. (Refer to Steering Circuit.) 10. Pressurized oil (PB) is supplied as parking brake (13) release pressure when parking brake solenoid valve (12) is operated. (Refer to Parking Brake Circuit) 11. Pressurized oil (X) changes its flow in response to the stroke of pump torque control solenoid valve (14), which is controlled by the signal from the Main Controller (MC), to control the main pump regulator. (Refer to Pump Control Circuit.) 12. Pilot pressure oil (PS2) is supplied to control the servo piston of the main pump (Refer to Pump Control Circuit), and to the optional ride control valve when equipped (Refer to Ride Control Circuit.). 13. Pilot pressure oil (PP) enters each pilot valve through the pilot shutoff valve, and is supplied to the desired control valve to operate its spool. (Refer to Lift Arm / Bucket Operation Control Circuit)

T2-4-14

SECTION 2 SYSTEM Group 4 Hydraulic System  Charging Circuit (when pressure in service brake circuit is lowered) 5

Service Brake circuit A

7 Service Brake circuit B

11 4

PB X

10 12

PP PS1

PS2

90Z6-02-04-11

MF- To Service Brake Circuit A (Front) MR- To Service Brake Circuit B (Rear) PS1- To Steering Pilot Valve (Steering Circuit)

PS2- To Pump Regulator (Pump Control Circuit), Ride Control Circuit (Option) PP- To Loading Pilot Valve (Lift Arm/Bucket Control Circuit)

PB- To Parking Brake Circuit X- To Pump Regulator (Pump Control Circuit)

12345-

678910-

11121314-

Pilot Pump Charging Block Brake Priority Valve Charge Relief Valve Service Brake Accumulator (Front)

Service Brake Accumulator (Rear) Check Valve Brake Valve Pilot Relief Valve Hydraulic Oil Tank

T2-4-15

Spring Parking Brake Solenoid Valve Parking Brake Pump Torque Control Solenoid Valve

SECTION 2 SYSTEM Group 4 Hydraulic System Lift Arm/Bucket Operation Control Circuit

fNOTE: Refer to COMPONENT OPERATION / Pilot Valve and Control Valve.

1. Pilot pressure oil (PP) from pilot pump (1) enters loading pilot valve (3) through charging block (4) and pilot shutoff valve (6), and is supplied to the desired control valve to operate its spool.

fNOTE: Charging block (4) supplies pressurized oil from pilot pump (1) preferentially to service brake circuits. (Refer to Charging Circuit (Brake Priority Circuit).)

2. Pilot shutoff valve (6) is manually operated type. When valve (6) is closed by operating the control lever lock handle, pressurized oil flow to pilot valve (3) is blocked and this prevents accidents due to unexpected or improper operation of front control levers. 3. Pilot valve (3) supplies the pilot pressure oil to multiple control valve (9) according to the operation of lift arm control lever (7) and bucket control lever (8). 4. Then, pressurized oil from main pump (2) moves the right and left lift arm cylinders (12), and bucket cylinder (13) through shifted lift arm spool (10) and bucket spool (11). 5. The lift arm and bucket are operated by the right and left lift arm cylinders (12), and bucket cylinder (13). (Refer to Main Circuit.) 6. When stopping lift arm or bucket operation, slow return valve (14) reduces the returning pilot oil from lift arm cylinders (12) or bucket cylinder (13). Consequently, quick movement of lift arm spool (10) or bucket spool (11) is dampened so as not to suddenly come to a stop and shock the machine with inertia energy caused from a sudden stop.

T2-4-16

SECTION 2 SYSTEM Group 4 Hydraulic System  Loading Circuit (Accumulators are charged and priority valve (5) opens, but pilot valve is in neutral condition.) 13

9 11 14

b1 a1

10 5 8 1

4 PP

15 7

90Z6-02-04-12

PP- Pilot Pressure Oil from Charging Block

a1- Pilot Pressure Oil (Lift Arm Raise) b1- Pilot Pressure Oil (Lift Arm Lower)

a2- Pilot Pressure Oil (Bucket Roll Back) b2- Pilot Pressure Oil (Bucket Dump)

12345-

678910-

1112131415-

Pilot Pump Main Pump Loading Pilot Valve Charging Block Brake Priority Valve

Pilot Shutoff Valve Lift Arm Control Lever Bucket Control Lever Multiple Control Valve Lift Arm Spool

T2-4-17

Bucket Spool Lift Arm Cylinders Bucket Cylinder Slow Return Valve Hydraulic Oil Tank

SECTION 2 SYSTEM Group 4 Hydraulic System Pump Control Circuit  Pump Control by Torque Control Solenoid Valve

 Pump Control by Servo Piston Control Pressure (PS2)

1. Torque control solenoid valve (9) is activated by the signal from Main Controller (MC).

Pilot pressure oil (PS2) is supplied from charging block (10) to control servo piston (8) of main pump (1). This actuate servo piston (8).

2. Pressurized oil from pilot pump (2) is supplied to regulator (7) in main pump (1) as torque control pressure X. 3. Regulator (7) controls the pump delivery flow rate in proportion to torque control pressure X.

 Pump Delivery Flow Rate Control by Pump Control Pressure (Pi1, Pi2) 1. When not operating the lift arm and bucket, pressurized oil from main pump (1) flows through neutral circuit (5) in multiple control valve (3).

fNOTE: Refer to Control System / Pump Control.

2. Pump control valve (4) is provided in neutral circuit (5). The circuit for controlling the pump delivery flow rate is provided at front and back of orifice (6) in pump control valve (4). 3. Pressurized oil from main pump (1) is supplied to regulator (7) in main pump (1) through the circuit for controlling the pump delivery flow rate at front and back of orifice (6) as pump control pressure Pi1 and Pi2. 4. Regulator (7) controls the pump delivery flow rate in proportion to pump control pressure Pi1 and Pi2. 5. When flow rate of pressurized oil flowing through neutral circuit (5) increases, the pressure difference at front and back of orifice (6) increases. 6. Therefore, the pressure difference of pump control pressure Pi1 and Pi2 increases and regulator (7) reduces the pump delivery flow rate. 7. Consequently, flow rate of pressurized oil flowing to multiple control valve (3) is reduced.

fNOTE: Refer to COMPONENT OPERATION / Pump Device.

T2-4-18

SECTION 2 SYSTEM Group 4 Hydraulic System  Pump Control Circuit 4

Pi1

Pi2

PS2

MC X

2 7

10 11

PS2

90Z6-02-04-13 PS2- From Charging Block (Pilot Pressure Oil) X- Torque Control Pressure

Pi1- Pump Control Pressure Pi2- Pump Control Pressure

MC- Solenoid ON/OFF Signal from Main Controller

123-

456-

789-

Main Pump Pilot Pump Multiple Control Valve

Pump Control Valve Neutral Circuit Orifice

T2-4-19

Regulator Servo Piston Torque Control Solenoid Valve

10- Charging Block 11- Hydraulic Oil Tank

SECTION 2 SYSTEM Group 4 Hydraulic System Service Brake Circuit  When the service brake is applied

 When the service brake is released

1. Pressurized oil from the pilot pump is charged in the brake accumulators via the charging block. By depressing brake pedal (1), the accumulated pressure is supplied to brake valve (2). 2. Brake spools (3, 4) on top and bottom of brake valve (2) are connected by spring (5) and move according to brake pedal (1) application angle. 3. Brake circuit oil (A, B) is supplied to front/rear brakes (7, 6) according to brake pedal (1) application angle. Therefore, front/rear brakes (6, 7) are applied. 4. When the brake pedal is applied several times, pressure inside the service brake accumulators decreases. Then, the brake relief valve in the charging block is closed and the priority valve spool moves right to supply constant pressure to the service brake circuit.

fNOTE: Refer to Charging Circuit (Brake Priority Circuit) for the operation of the charging block.

fNOTE: Front/rear brake units (6, 7) are housed in the front/rear axles. (Refer to COMPONENT OPERATION / Axle.)

T2-4-20

1. The brake circuit oil (A, B) from the charging block is blocked by brake spools (3, 4) on top and bottom of brake valve (2). 2. When brake pedal (1) is not applied, brake operating pressure oil (A, B) returns to hydraulic oil tank (8) through front/rear brakes (6, 7) and brake spools (3, 4) of brake valve (2). 3. Therefore, front/rear brakes (6, 7) are released.

SECTION 2 SYSTEM Group 4 Hydraulic System  When service brake is applied 7

8 A

5 B

4 2 90Z6-02-04-14

 When service brake is released 7 1

6 3 8 A

2 90Z6-02-04-15 A-

From Charging Block (Front Brake Operating Pressure Oil)

B-

From Charging Block (Rear Brake Operating Pressure Oil)

12-

Brake Pedal Brake Valve

34-

Brake Spool (Top) Brake Spool (Bottom)

56-

T2-4-21

Spring Front Brake

78-

Rear Brake Hydraulic Oil Tank

SECTION 2 SYSTEM Group 4 Hydraulic System Parking Brake Circuit Pressurized oil from pilot pump (1) is supplied to the parking brake circuit through the charging block to activate parking brake solenoid valve.

 When parking brake is applied (parking brake SW: ON) 1. When the parking brake switch is turned ON, parking brake solenoid valve (2) is deenergized. Spool (3) is moved to the left by the spring (4) force.

f NOTE: The parking brake releases when the parking brake solenoid valve (2) is energized (parking brake switch is turned OFF).

2. Parking brake releasing pressure oil is blocked by parking brake solenoid valve (2) and is not supplied to parking brake (5).

f NOTE: Parking brake accumulator (7) and check valves (8) keep the pressure (supply side) in the parking brake circuit above the specified level (equal to the spring (4) force).

3. Pressure oil in parking brake (5) returns to hydraulic oil tank (9) through parking brake solenoid valve (2).

NOTE: When the engine is stopped, pressurized oil from pilot pump (1) (parking brake releasing pressure oil) is not supplied to parking brake (5). Parking brake (5) cannot be released as spring (6) works to apply parking brake.

4. Therefore, parking brake (5) is applied by the spring (6) force.

 When parking brake is released (parking brake SW: OFF) 1. When the parking brake switch is turned OFF, parking brake solenoid valve (2) is energized. Spool (3) compresses spring (4) and moves to the right. 2. Parking brake oil flows through parking brake solenoid valve (2) to parking brake (5). 3. Therefore, parking brake (5) is released as spring (6) is compressed.

T2-4-22

SECTION 2 SYSTEM Group 4 Hydraulic System  When parking brake is applied (parking brake SW: ON)

Apply

1 6 9

Solenoid is not energized. (parking brake SW: ON)

(a)

90Z6-02-04-16

 When parking brake is released (parking brake SW: OFF)

Release

1 6 9

Solenoid is energized. (parking brake SW: OFF)

8 (a)

ON/OFF Signal from Parking Brake Switch

123-

Pilot Pump Parking Brake Solenoid Valve Spool

456-

Spring Parking Brake Spring

90Z6-02-04-17

789-

T2-4-23

Parking Brake Accumulator Check Valve Hydraulic Oil Tank

SECTION 2 SYSTEM Group 4 Hydraulic System Ride Control Circuit (Option)  Ride control operation

 Accumulating ride control accumulator (2) 1. Pressurized oil from the main pump moves lift arm cylinders (4) by lift arm spool operation. Pressurized oil (A1) sent to lift arm cylinder (4) also flows to ride control valve (1).

1. When the ride control switch is ON and the machine travelling speed reaches more than 7 km/h, ride control activation signal from Main Controller (MC) (a) shifts ride control solenoid valve (3).

2. When ride control solenoid valve (3) is deactivated, pressurized oil (A1) in the bottom side circuit of lift arm cylinder (4) flows through charge-cut spool (7) and is contained in ride control accumulator (2).

2. Pressurized oil from pilot pump (5) flows through ride control solenoid valve (3) and shifts ride control spool (8). 3. Pressurized oil in the bottom end circuit of lift arm cylinder (4) (A1) is connected to ride control accumulator (2) via ride control spool (8).

f NOTE: Accumulated pressure in ride control

accumulator (2) prevents unexpected movement of the lift arm when ride control solenoid valve (3) is energized.

4. Pressurized oil in the rod side circuit of lift arm cylinder (4) (B1) is connected to hydraulic tank (6) via ride control spool (8). 5. When the force pushing down the lift arm occurs, pressurized oil in the bottom end circuit of lift arm cylinder (4) (A1) is accumulated in ride control accumulator (2) through ride control spool (8). Accumulator (2) absorbs the oil pressure fluctuations in the lift arm cylinder (4) bottom end. 6. When the force pushing up the lift arm occurs, pressurized oil in the bottom end circuit of lift arm cylinder (4) (A1) is released to hydraulic oil tank (6) through ride control spool (8). 7. Thus, fore and aft pitching of the machine is reduced by reducing pressure difference between base end circuit (A1) and rod side circuit (B1) of lift arm cylinder (4).

f NOTE: When the ride control is deactivated, the fore

and aft pitching of the machine occurs when driving on rough roads.

T2-4-24

SECTION 2 SYSTEM Group 4 Hydraulic System  Ride control circuit (when the ride control switch is ON)

3 A1 B1

(a)

90Z6-02-04-22

A1- Lift Arm Cylinder Bottom Side Circuit

B1- Lift Arm Cylinder Rod Side Circuit

Activation Signal from Main Controller (MC)

12-

345-

678-

Hydraulic Oil Tank Charge-Cut Spool Ride Control Spool

Ride Control Valve (Option) Ride Control Accumulator (Option)

Ride Control Solenoid Valve Lift Arm Cylinders Pilot Pump

T2-4-25

SECTION 2 SYSTEM Group 4 Hydraulic System Steering Circuit (When steering is operated) 1. When not operating steering wheel (1), pressurized oil from priority spool circuit (LS2) of priority valve (3) flows to hydraulic oil tank (5). Then, pressure (LS2) decreases and the pressure at the port (LS1) side moves steering priority spool (4) left.

5. Pressurized oil from main pump (2) flows to steering valve (9) through steering priority spool (4). 6. Pressurized oil in steering valve (9) flows to steering cylinders (11).

2. Consequently, pressurized oil from main pump (2) is supplied to the multiple control valve port. (Refer to Main Circuit/Priority Valve Circuit.) 3. When operating steering wheel (1), spool (7) in steering pilot valve (6) is moved. This allows pressurized oil from pilot pump (13) through steering pilot valve (6) to move steering spool (10) in steering valve (9).

7. Rotor (8) works as a hydraulic motor and delivers pressurized oil. This pressurized oil is combined with pressurized oil from steering spool and moves steering cylinders (11).

f NOTE: As rotor (8) is connected to the middle shaft of steering pilot valve (6), the powered steering effect is generated.

fNOTE: When steering wheel (1) is quickly turned,

orifices in steering valve (9) open widely and more pressurized oil flows from steering pilot valve (6) to the end of steering spool (10) in steering valve (9).

4. The pressure in priority spool circuit (LS2) increases in proportion to the movement of steering spool (10). This pressure (LS2) combined with spring force moves steering priority spool (4) of priority valve (3) to right.

T2-4-26

SECTION 2 SYSTEM Group 4 Hydraulic System  When operating steering wheel (1) (Right turn) 7 6

1 8

12 11

9 4

3 5 LS2

LS1

LS1- Priority Spool Circuit

LS2- Priority Spool Circuit

EF- To Multiple Control Valve

12345-

678910-

11- Steering Cylinders 12- Steering Accumulators 13- Pilot Pump

Steering Wheel Main Pump Priority Valve Steering Priority Spool Hydraulic Oil Tank

Steering Pilot Valve Spool Rotor Steering Valve Steering Spool

T2-4-27

90Z6-02-04-18

SECTION 2 SYSTEM Group 4 Hydraulic System Steering Shock Dampening Function  When steering wheel is stopped

 When steering wheel is turned 1. When steering wheel (1) is turned, the machine turns by operating steering cylinders (11) at right and left. (Refer to Steering Circuit.)

1. When steering wheel (1) is stopped, the machine stops turning because steering cylinders (11) stop moving.

2. Steering spool (10) is pushed by pilot oil pressure due to the pressure difference generated at both ends of steering spool (10).

2. The base end oil pressure of steering cylinders (11) momentarily increases when the steering stops. 3. Steering accumulators (12) are provided in the bottom side circuits of steering cylinders (11) to absorb this momentary pressure rise.

3. When steering wheel (1) is rapidly rotated, the pressure in the steering pilot supply line increases and quickly moves steering spool (10). 4. When the pilot steering pressure and volume applied to steering spool (10) increases, the moving speed of steering spool (10) becomes faster and the machine steering may move too quickly, that would be excessively rapid machine steering motion for the operator. 5. The pressure at both ends of steering spool (10) is reduced when the pilot oil flows through steering orifice (14). This helps to decrease uncomfortable steering movement and provide smoother steering and better modulation. 6. This dampening effect results in good steering and the steering shock is decreased.

T2-4-28

4. Therefore, when steering wheel is stopped, the reaction force of left and right steering cylinders (11) is controlled and the jerking of the machine is reduced.

SECTION 2 SYSTEM Group 4 Hydraulic System

7 6

1 8

12 11

14 4

3 5

LS1- Priority Spool Circuit

LS2- Priority Spool Circuit

EF- To Multiple Control Valve

12345-

678910-

11121314-

Steering Wheel Main Pump Priority Valve Steering Priority Spool Hydraulic Oil Tank

Steering Pilot Valve Spool Rotor Steering Valve Steering Spool

T2-4-29

Steering Cylinders Steering Accumulators Pilot Pump Steering Orifice

90Z6-02-04-19

SECTION 2 SYSTEM Group 4 Hydraulic System Steering Stop Circuit (When steering cylinder is at stroke end) 1. When steering wheel (1) is fully turned and steering cylinders (11) fully move to the stroke end, machine articulates and stop valve (14) contacts with the chassis. 2. Stop valve (14) closes to block pressurized oil (Pb) from steering pilot valve (6) to steering valve (9). 3. Steering spool (10) is set to the neutral position, and pressurized oil supply from main pump (2) to steering cylinders (11) is blocked by steering spool (10).

T2-4-30

SECTION 2 SYSTEM Group 4 Hydraulic System

7 6

1 8

(a)

12 11

9 4

3 5

External Force by Contact

12345-

Steering Wheel Main Pump Priority Valve Steering Priority Spool Hydraulic Oil Tank

678910-

Steering Pilot Valve Spool Rotor Steering Valve Steering Spool

11121314-

T2-4-31

Steering Cylinders Steering Accumulators Pilot Pump Stop Valve

90Z6-02-04-20

SECTION 2 SYSTEM Group 4 Hydraulic System Secondary Steering Circuit 1. When pressurized oil from main pump (1) becomes below the specified value due to the engine failure and traveling over 5 km/h (3.1 mph), steering pressure switch (10) is turned OFF. 2. The Main Controller (MC) activates secondary steering motor (3) according to the OFF signal of steering pressure switch (10). 3. Secondary steering pump (4) is activated by activating secondary steering motor (3). 4. Secondary steering pump (4) draws hydraulic oil from hydraulic tank (5) and delivers it to steering valve (8). 5. Steering valve (8) shifts steering spool (9) according to pressurized oil from Orbitrol (steering pilot valve) (12). 6. Pressurized oil from secondary steering pump (4) is supplied to right and left steering cylinders (11) by shifting steering spool (9). 7. Right and left steering cylinders (11) are operated by pressurized oil from secondary steering pump (4) and the machine turns. 8. Check valve (13) prevents the pressure from main pump (1) from being applied to secondary steering pump (4) when the secondary steering should not be used. 9. Relief valve (14) prevents the pressure in the circuit between secondary steering pump (4) and steering valve (8) from increasing over the set pressure when secondary steering pump (4) is operated.

f NOTE: Secondary steering is an optional equipment for EXP. Spec. machines (S/N 0101~).

f NOTE: The operation limit time of secondary steering pump (4) is maximum 60 seconds.

fNOTE: Refer to Control System / Secondary Steering Control.

T2-4-32

SECTION 2 SYSTEM Group 4 Hydraulic System

13 6 7

4 3

14 2 5 90Z6-02-04-21

12345-

Main Pump Main Pump Delivery (Output) Pressure Sensor Secondary Steering Motor (Option) Secondary Steering Pump (Option) Hydraulic Oil Tank

6789-

Secondary Steering Block (Option) Secondary Steering Pump Delivery Pressure Sensor (Option) Steering Valve Steering Spool

T2-4-33

10- Pressure Switch (Secondary Steering) (Option) 11- Steering Cylinder 12- Steering Pilot Valve (Orbitrol) 13- Check Valve 14- Relief Valve

SECTION 2 SYSTEM Group 4 Hydraulic System Fan Speed Control Circuit 1. Pressurized oil from fan pump (1) is directly supplied to fan motor (2).

2. Main Controller (MC) sends signal (a) and activates fan speed control solenoid valve (3) according to the signal from the coolant temperature sensor and hydraulic oil temperature sensor.

(a)

3. When hydraulic oil temperature is low, fan speed control solenoid valve (3) controls the main relief valve (4) set pressure lower.

4. Pressurized oil from fan pump (1) flows to hydraulic tank (5) through main relief valve (4), reducing the fan rotation speed.

90Z6-02-04-06 123-

T2-4-34

Fan Pump (mounted on the engine) Fan Motor Assy Fan Speed Control Solenoid Valve

45-

Relief Valve Hydraulic Tank

SECTION 2 SYSTEM Group 4 Hydraulic System (Blank)

T2-4-35

SECTION 2 SYSTEM Group 4 Hydraulic System Reversing Fan Circuit (Option) 1. Pressurized oil from fan pump (A) is supplied to the port (P1) side of fan motor (2) through fan reversing spool (4) in fan valve (1). Fan motor (2) rotates in normal. 2. When the fan reversing switch (option) is turned ON, fan reverse rotation control solenoid valve (5) is shifted by signal (a) from the Main Controller (MC).

10. Anti-void valve (8) is provided in the fan motor circuit. 11. Anti-void valve (8) refills hydraulic oil from the returning oil and prevents cavitation from occurring when the pressure in the fan circuit decreases (the fan motor speed change, engine shutdown, etc.) 12. Returning oil from fan motor (2) returns to hydraulic tank (6) through the oil cooler.

3. Pressurized oil from fan reverse rotation control solenoid valve (5) shifts fan reversing spool (4). 4. Therefore, pressurized oil from fan pump (A) is supplied to the port (P2) side of fan motor (2) and fan motor (2) rotates in reverse. 5. MC sends signal (b) and activates fan speed control solenoid valve (3) according to the signals from coolant temperature sensor and hydraulic oil temperature sensor. 6. When hydraulic oil temperature is low, pressurized oil from fan pump (A) flows to hydraulic tank (6) through fan speed control solenoid valve (3). 7. Therefore, the pressure at orifices (9, 10) sides decreases and relief valve (7) is shifted. 8. Excess pressurized oil from fan pump (A) returns to hydraulic tank (6) through relief valve (7). 9. Consequently, the fan motor (2) speed decreases.

T2-4-36

SECTION 2 SYSTEM Group 4 Hydraulic System  Normal rotation

 Reverse rotation

6 (a)

7 3

9 A

90Z6-02-04-07

6 90Z6-02-04-08

 Normal rotation when relieving 2

6 (a) 7 (b) 3

A 90Z6-02-04-09 123-

Fan Valve (Option) Fan Motor Assy Fan Speed Control Solenoid Valve

456-

Fan Reversing Spool Fan Reverse Rotation Control Solenoid Valve Hydraulic Tank

78910-

T2-4-37

Relief Valve Anti-Void Valve Orifice Orifice

SECTION 2 SYSTEM Group 4 Hydraulic System (Blank)

T2-4-38

SECTION 2 SYSTEM Group 5 Electrical System Outline The electrical circuit is generally divided into the main circuit, lighting circuit (monitor and switches), and control circuit.  Main Circuit: Operates the engine and the accessory related circuits.  Accessory Circuit: Operates during machine operation. Turns on/off the lights, sounds horn, applying parking brake, operates wipers, by controlling relays and switches.  Control Circuit: Controls the engine, pump, transmission, and loading control valve. Consists of the actuators such as solenoid valves, Main Controller (MC), Engine Control Module (ECM), Information Control Unit (ICF), monitor unit, sensors, and switches. (Refer to SYSTEM / Control System.)

T2-5-1

SECTION 2 SYSTEM Group 5 Electrical System Main Circuit The major functions and circuits in the main circuit are as follows.  Controller Area Network (CAN) Circuit: Performs communication between each controller.  Electric Power Circuit: Supplies all electric power to all electrical systems on the machine.  Accessory Circuit: Is operated when the key switch is in the ACC position.  Starting Circuit: Starts the engine.  Charging Circuit: Supplies electric power to the batteries and charges them.  Surge Voltage Prevention Circuit: Prevents the occurrence of surge voltage developed when stopping the engine.  Engine Stop Circuit (Key switch: OFF): Stops the engine by using Engine Control Module (ECM).

T2-5-2

SECTION 2 SYSTEM Group 5 Electrical System CAN Circuit CAN (Controller Area Network) is ISO Standards of the serial communication protocol. CAN is used for the engine control and for the accessories. CAN consists of two harnesses, CAN-H (High) (1) and CAN-L (Low) (2). Each controller judges the CAN level due to potential difference between CAN-H (High) (1) and CAN-L (Low) (2). Each controller arranges the CAN level and sends the signal and data to other controllers. In addition, termination resistors (120 Ω) (3) are installed to both ends of CAN.

1 Monitor

MPDr. ICF

GSM

A/C

INSITE

Rear View Monitor

Opt CAN

ECM

3 2 90Z6-02-05-02

T2-5-3

SECTION 2 SYSTEM Group 5 Electrical System Electric Power Circuit (Key Switch: OFF) The battery (1) minus terminal is grounded to the chassis. Current from the battery (1) plus terminal flows as shown below when key switch (4) is in the OFF position. Battery (1)

Fusible Link A (70A) Key Switch (4) Terminal B Fuse Box A (10) Terminal #4 (3) Terminal #5 Terminal #6 Terminal #7 Terminal #8 Terminal #9 Terminal #10 Fuse Box B (5) Terminal #11

T2-5-4

Lighting Switch Auxiliary Horn Flasher Relay Main Controller ECM Power 1 ECM Power 2 Radio CAB Dome Lamp

SECTION 2 SYSTEM Group 5 Electrical System

6 4 Starter Switch (4) Preheat OFF ACC ON Start

FA8 FA9 FA10 FA4 FA5 FA6

FA7 FB11

8 9 10 11 7 12 13 14 15 16 17 18 19 20 90Z6-02-05-01

123456-

Battery Battery Relay Fusible Link A (70 A) Key Switch Fuse Box B Load Dump 1 Relay

78-

Main Controller (MC) (Power) Information Controller (ICF) (Power) 9- Monitor (Power) 10- Load Dump 2 Relay 11- GSM/GPS (Power)

12- Engine Control Module (ECM) (Power 1) 13- ECM (Power 2) 14- Lighting Switch 15- Auxiliary (Power) 16- Horn (Power)

T2-5-5

1718192021-

Flasher Relay Hazard Flasher Switch Dome Lamp Radio (Backup Power) Fuse Box A

SECTION 2 SYSTEM Group 5 Electrical System Accessory Circuit (Key Switch: ACC) 1. When key switch (4) is set to ACC position (5), terminal B is connected to terminal ACC (6) in key switch (4). 2. Current from terminal ACC (6) in key switch (4) flows to fuse #1 in fuse box B (8). 3. This makes radio (9) operable.

T2-5-6

SECTION 2 SYSTEM Group 5 Electrical System

4 Starter Switch (4)

8 FB1

Preheat OFF ACC ON Start

FB11 5A

90Z6-02-05-03

123-

Battery Battery Relay Fusible Link A (70 A)

456-

Key Switch ACC Position Terminal ACC

789-

T2-5-7

Fuse Box A Fuse Box B Radio

SECTION 2 SYSTEM Group 5 Electrical System Starting Circuit (Key Switch: START)  Forward/Reverse Lever at Neutral Position

fNOTE: Only when key switch (4) is set to START position (5) with forward/reverse lever (10) set in neutral (N) position (20), the starter motor rotates and the engine starts. (Refer to Neutral Engine Start Circuit.)

1. When key switch (4) is set to START position (5), terminal B is connected to terminal M (6) and terminal ST (7) in key switch (4).

9. At the same time, current from terminal ST (7) in key switch (4) flows to terminal C in starter (14) through neutral relay (11) and voltage relay (12).

2. Current from terminal M (6) in key switch (4) excites battery relay (2).

10. Current flows to the coil of magnetic switch (13) to turn in ON.

Current from battery (1) is routed to terminal B of starter motor (15) and magnetic switch (13) through battery relay (2) and terminal B of starter (14).

11. Current from magnetic switch (13) flows to terminal C in starter motor (15), and the motor rotates.

3. Current from terminal M (6) in key switch (4) flows to fuse #13 in fuse box A (8). 4. Current from fuse #13 in fuse box A (8) flows to column monitor controller (16), information controller (ICF) (17), and Main Controller (MC) (18) as a signal indicating that key switch (4) is in ON or START position (5). 5. Current from fuse #13 in fuse box A (8) flows to neutral relay (11) in relay box B. 6. When forward/reverse lever (10) is in neutral (N) position (20), the current from neutral relay (11) does not flow to the ground. Then, neutral relay (11) is turned OFF. 7. Current from terminal M (6) in key switch (4) flows to ECM (9) terminal #38 through fuse #13 in fuse box A (8), and the ECM (9) main power is turned ON. 8. ECM (9) makes the engine starting condition.

T2-5-8

SECTION 2 SYSTEM Group 5 Electrical System

4 Starter Switch (4)

FA13 10A

Preheat OFF ACC ON Start

15 10

20 13

FA14

5A 11

16 17 18

90Z6-02-05-04

123456-

Battery Battery Relay Fusible Link A (70 A) Key Switch START Position Terminal M

789101112-

Terminal ST Fuse Box A Engine Control Module (ECM) Shift Lever Neutral Relay Voltage Relay

131415161718-

T2-5-9

Magnetic Switch Starter Assy Starter Motor Column Monitor Controller Information Controller (ICF) Main Controller (MC)

19- Forward (F) Position 20- Neutral (N) Position 21- Reverse (R) Position

SECTION 2 SYSTEM Group 5 Electrical System Neutral Engine Start Circuit The engine does not start with forward/reverse lever (10) set in forward (F) position (19) or reverse (R) position (21). Therefore, the engine is protected from unexpectedly starting out.  Forward/Reverse Lever (10) at Forward (F) Position (19) 1. When key switch is set to START position (5), the current from fuse #14 in fuse box A (8) flows to forward/reverse lever (10). 2. When forward/reverse lever (10) is in forward (F) position (19), the current from forward/reverse lever (10) flows to the coil in neutral relay (11) and flows to the ground. 3. Therefore, neutral relay (11) is turned ON. 4. When neutral relay (11) is turned ON, current from terminal ST (7) in key switch (4) stops flowing to voltage relay (12). 5. Consequently, magnetic switch (13) is turned OFF. Even if key switch (4) is set to START position (5), the starter motor does not rotate and the engine does not start.

T2-5-10

SECTION 2 SYSTEM Group 5 Electrical System

4 Starter Switch (4)

FA13 10A

Preheat OFF ACC ON Start

15 10

20 13

FA14

5A 11

16 17 18

90Z6-02-05-05

123456-

Battery Battery Relay Fusible Link A (70 A) Key Switch START Position Terminal M

789101112-

Terminal ST Fuse Box A Engine Control Module (ECM) Shift Lever Neutral Relay Voltage Relay

131415161718-

T2-5-11

Magnetic Switch Starter Assy Starter Motor Column Monitor Controller Information Controller (ICF) Main Controller (MC)

19- Forward (F) Position 20- Neutral (N) Position 21- Reverse (R) Position

SECTION 2 SYSTEM Group 5 Electrical System Charging Circuit (Key Switch: ON) 1. After the engine starts and key switch (4) is released, key switch (4) is returned to the ON position. 2. Terminal B is connected to terminal ACC (7) and terminal M (8) in key switch (4) with key switch (4) set in the ON position. 3. Current from terminal M (8) turns ON battery relay (2) through terminal #13 in fuse box A (6). 4. Alternator (5) starts generating electricity with the engine running. Current from alternator (5) terminal-B flows to battery (1) through fusible link (100A) (9) and battery relay (2), and charges battery (1). 5. In addition, current from alternator (5) terminal-I flows to column monitor controller (16), information controller (ICF) (17), and communication terminal (18). 6. Column monitor controller (16) detects the alternator (5) generating electricity according to the current from terminal-I of alternator (5) and turns OFF the charging alarm indicator on the monitor display.

T2-5-12

SECTION 2 SYSTEM Group 5 Electrical System

Starter Switch (4)

FA13 8

Preheat OFF ACC ON Start

10A

7 2

16 17 18

90Z6-02-05-06

1234-

Battery Battery Relay Fusible Link A (70A) Key Switch

5678-

Alternator Fuse Box A Terminal ACC Terminal M

9- Fusible Link (100 A) 16- Column Monitor Controller 17- Information Controller (ICF)

T2-5-13

18- Communication Terminal (GSM, GPS)(Opt)

SECTION 2 SYSTEM Group 5 Electrical System Surge Voltage Prevention Circuit 1. When the engine is stopped (key switch (4): OFF), current from terminal M (8) in key switch (4) disappears and battery relay (2) is turned OFF. 2. The engine continues to rotate due to inertia force just after key switch (4) is turned OFF so that alternator (5) continues to generate electricity. 3. As the generating current cannot flow to battery (1), surge voltage arises in the circuit and failures of the electronic components, such as the controller, possibly cause. For this reason, the surge voltage prevention circuit is provided. 4. When alternator (5) is generating electricity, the generating current from alternator (5) terminal-I flows to terminal #2-28 of column monitor controller (16). Column monitor controller (16) connects terminal #2-17 to the ground. 5. Therefore, current flows to the exciting circuit in load dump 1 relay (10) and load dump 1 relay (10) is turned ON. 6. Consequently, even if key switch (4) is turned OFF with the engine running, current (f ) from battery (1) continues to excite battery relay (2) through load dump 1 relay (10). 7. In addition, when a fixed time has passed since alternator (5) stops generating electricity, column monitor controller (16) disconnect terminal #228 from the ground. Therefore, battery relay (2) is turned OFF.

T2-5-14

SECTION 2 SYSTEM Group 5 Electrical System

4 Starter Switch (4)

10 FA13 8

Preheat OFF ACC ON Start

10A 6 2

FA8 10A 5

6 11 9

}

ECM Relay

90Z6-02-05-07

123-

Battery Battery Relay Fusible Link A (70A)

456-

Key Switch Alternator Fuse Box A

789-

T2-5-15

Terminal ACC Terminal M Fusible Link (100 A)

10- Load Dump 1 Relay 11- Load Dump 2 Relay 16- Column Monitor Controller

SECTION 2 SYSTEM Group 5 Electrical System Engine Stop Circuit 1. When key switch (4) is set to the OFF position from the ON position, current indicating that key switch (4) is in ON position stops flowing to terminal #38 of ECM (12) from terminal M (8) in key switch (4). 2. ECM (12) stops fuel injection of the injector and stops the engine. 3. The engine continues to rotate due to inertia force just after key switch (4) is turned OFF so that alternator (5) continues to generate electricity. 4. During the charging, current from alternator (5) I-Terminal flows to terminal #2-28 in column monitor controller (16). 5. Column monitor controller (16) connects terminal #2-16 to the ground. Then, the current flows to the load dump 2 relay (11) circuit to turn ON the relay. 6. Accordingly, the current from battery (1) flows to ECM relay 1 (13) and ECM relay 2 (14) through load dump 2 relay (11) after setting key switch (4) to the OFF position. Therefore, current flows to terminals #7, 8, 17, 18, and 28 of ECM (12) and ECM (12) is kept ON. 7. Column monitor controller (16) disconnect terminal #2-28 from ground 10 seconds after stopping alternator (5) power generation, and load dump 2 relay (11) is stopped. 8. Then, ECM relay 1 (13) and ECM relay 2 (14) are turned OFF and ECM (12) is powered OFF.

T2-5-16

SECTION 2 SYSTEM Group 5 Electrical System 1

4 Starter Switch (4)

10 FA13 10A

Preheat OFF ACC ON Start

FA8 10A 5 14 11 9 FA10 10A

FA9

10A 6 90Z6-02-05-08

1234-

Battery Battery Relay Fusible Link A (70A) Key Switch

5678-

Alternator Fuse Box A Terminal ACC Terminal M

9101112-

T2-5-17

Fusible Link (100 A) Load Dump 1 Relay Load Dump 2 Relay ECM

13- ECM 1 Relay 14- ECM 2 Relay 16- Column Monitor Controller

SECTION 2 SYSTEM Group 5 Electrical System (Blank)

T2-5-18

SECTION 2 SYSTEM Group 5 Electrical System Accessory Circuit The major functions and circuits in the accessory circuit are as follows.  Head Light Circuit Turns on/off the head lights, clearance lights, license lights, and tail lights.  Hazard Light Circuit Turns on/off the hazard lights.  Turn Signal Light Circuit Turns on/off the turn signal lights.  Horn Circuit Sounds the horn.  Reverse Light/Buzzer Circuit Turns on/off the reverse lights and reverse buzzer.  Brake Light Circuit Turns on/off the brake lights.  Parking Brake Circuit Applies and releases the parking brake.  Working Light Circuit Turns on/off the working light.  Wiper Circuit Operates the wiper and the washer.  Cab Light Circuit Turns on/off the cab light by shifting the switch or by opening/closing the door.

T2-5-19

SECTION 2 SYSTEM Group 5 Electrical System Head Light Circuit Clearance Light, License Light, Tail Light Circuit (Light Switch: Clearance Light Position) 1. Current (a) from the battery flows to light switch (2) through fuse #4 in fuse box A (1). 2. When light switch (2) is set to clearance light position (4), current from fuse #4 in fuse box A (1) flows to fuse #11 in fuse box A (1) through light switch (2). 3. Current from fuse #11 flows to tail lights (8, 9) and clearance lights (10, 11), and connects to ground. 4. Therefore, tail lights (8, 9) and clearance lights (10, 11) are turned on. 5. The current from fuse #11 in fuse box A (1) also flows to terminal #1-25 in column monitor controller (12) through light switch (2). 6. Therefore, monitor controller (12) turns on clearance light indicator (13).

T2-5-20

SECTION 2 SYSTEM Group 5 Electrical System 2

Lighting Switch

6 4

FA3 10A

FA19 10A

FA4 10A

FA11 2

10A

8 9 10

13 90Z6-02-05-09 a-

From Battery

12345-

Fuse Box A Light Switch Dimmer Switch Clearance Light Position Head Light Position

678910-

High Beam Position Low Beam Position Tail Light (Right) Tail Light (Left) Clearance Light (Right)

11- Clearance Light (Left) 12- Column Monitor Controller 13- Clearance Light Indicator

T2-5-21

SECTION 2 SYSTEM Group 5 Electrical System Head Light Circuit

fNOTE: The operation with dimmer switch (3) set in low beam position (7) is explained here.

1. When light switch (2) is set to head light position (5), current from fuse #4 in fuse box A (1) flows to dimmer switch (3) through light switch (2). 2. When dimmer switch (3) is set to low beam position (7), current from fuse #4 in fuse box A (1) flows to the coil in head light relay (14) through dimmer switch (3), and connects to ground. 3. Therefore, head light relay (14) is turned ON. 4. When head light relay (14) is turned ON, current from fuse #3 in fuse box A (1) flows to head lights (right and left) (16, 17) through head light relay (14), and connects to ground. 5. Therefore, head lights (right and left) (16, 17) turn on.

fNOTE: When light switch (2) is turned on with the

head lights in the on position (5), head lights (16, 17), clearance lights (10, 11), and tail lights (8, 9) are turned on.

T2-5-22

SECTION 2 SYSTEM Group 5 Electrical System 2

Lighting Switch

6 4

14 3

FA3 (Lo)

10A

(Hi)

1 FA19 10A

(Lo) (Hi)

FA4 10A

FA11 2

10A

8 9 10

13 90Z6-02-05-10 a-

From Battery

12345-

Fuse Box A Light Switch Dimmer Switch Clearance Light Position Head Light Position

678910-

High Beam Position Low Beam Position Tail Light (Right) Tail Light (Left) Clearance Light (Right)

1112131415-

T2-5-23

Clearance Light (Left) Column Monitor Controller Clearance Light Indicator Head Light Relay High Beam Relay

16- Head Light (Right) 17- Head Light (Left)

SECTION 2 SYSTEM Group 5 Electrical System High-Beam Circuit

fNOTE: When the turn signal lever is lowered with head

fNOTE: The high beam circuit operation with light

lights (16, 17) turned on, dimmer switch (3) is set to highbeam position (6) and high beam (18) is turned on.

switch (2) set in head light on position (5) is explained here.

1. When dimmer switch (3) is set to high-beam position (6), current from fuse #4 in fuse box A (1) flows to the coil in high-beam relay (15), and connects to ground. 2. Therefore, high-beam relay (15) is turned ON. 3. When high-beam relay (15) is turned ON, current from fuse #19 in fuse box A (1) flows to high beam (18) in head lights (right and left) (16, 17) through high-beam relay (15), and connects to ground. 4. Therefore, high beams (18) in head lights (16, 17) is turned on. 5. In addition, current from fuse #19 in fuse box A (1) flows to column monitor controller (12) terminal #213 through high-beam relay (15). 6. Therefore, column monitor controller (12) turns on high-beam indicator (19).

T2-5-24

SECTION 2 SYSTEM Group 5 Electrical System 2

Lighting Switch

6 4

14 3

FA3 10A

(Lo) 18 (Hi)

FA19 10A

a 1

FA4

(Lo) (Hi)

10A

FA11 2

10A

8 9 10

13 90Z6-02-05-11 a-

From Battery

12345-

Fuse Box A Light Switch Dimmer Switch Clearance Light Position Head Light Position

678910-

High Beam Position Low Beam Position Tail Light (Right) Tail Light (Left) Clearance Light (Right)

1112131415-

T2-5-25

Clearance Light (Left) Column Monitor Controller Clearance Light Indicator Head Light Relay High Beam Relay

16171819-

Head Light (Right) Head Light (Left) High Beam High Beam Indicator

SECTION 2 SYSTEM Group 5 Electrical System Hazard Light Circuit (Key Switch: OFF) 1. Current (a) from the battery flows to flasher relay (2) and hazard light switch (3) through fuse #7 in fuse box A (1), and connects to ground.

9. In addition, current from fuse #7 in fuse box A (1) flows to hazard light switch (3), and connects to ground.

2. Current from fuse #7 in fuse box A (1) flows to right and left turn signal light relays (4, 5) through flasher relay (2) terminal L.

10. Therefore, the indicator of hazard light switch (3) is turned on.

fNOTE: The hazard light circuit can be activated even if

3. When hazard light switch (3) is set to the ON position, current from fuse #7 in fuse box A (1) flows to the coils in right and left turn signal light relays (4, 5) through hazard light switch (3), and connects to ground. 4. Therefore, right and left turn signal light relays (4, 5) are turned ON. 5. When right and left turn signal light relays (4, 5) are turned ON, current from flasher relay (2) terminal L flows to all turn signal lights (6, 7, 8, and 9) through right and left turn signal light relays (4, 5) intermittently, and connects to ground. 6. Therefore, all turn signal lights (6, 7, 8, and 9) blink. 7. At the same time, current from flasher relay (2) terminal L flows to terminals #2-15 and #2-14 in column monitor controller (10) intermittently. 8. Therefore, monitor controller (10) blinks right and left turn signal indicators (17, 18).

T2-5-26

the key switch is in the OFF position.

SECTION 2 SYSTEM Group 5 Electrical System

2 FA7 10A

Front turn signal (R)

Rear turn signal (R)

Front turn signal (L)

Rear turn signal (L)

10 17 18

5 3

FA2 5A

90Z6-02-05-12 a-

From Battery

12345-

Fuse Box A Flasher Relay Hazard Light Switch Right Turn Signal Light Relay Left Turn Signal Light Relay

678910-

Turn Signal Light (Right Front) Turn Signal Light (Right Rear) Turn Signal Light (Left Front) Turn Signal Light (Left Rear) Column Monitor Controller

1112131415-

T2-5-27

Turn Signal Lever Left-Hand Position Neutral Position Right-Hand Position Diode R

16- Diode L 17- Right Turn Signal Light Indicator 18- Left Turn Signal Light Indicator

SECTION 2 SYSTEM Group 5 Electrical System Turn Signal Light Circuit left-turn position (12) is explained here.

9. At the same time, current from flasher relay (2) terminal L flows to terminal #2-14 in column monitor controller (10).

1. Current (a) from the battery flows to flasher relay (2) through fuse #7 in fuse box A (1), and connects to ground.

10. Therefore, column monitor controller (10) blinks left turn signal light indicator (18).

fNOTE: The operation with turn signal lever (11) set in

2. Current from flasher relay (2) terminal L flows to left turn signal light relay (5) and right turn signal light relay (4).

fNOTE: When turn signal lever (11) is set in right-hand

3. When the key switch is in the ON position, current from the battery flows to fuse #2 in fuse box A (1) through the battery relay and the main fuse (100 A). 4. Current from fuse #2 in fuse box A (1) flows to turn signal lever (11). 5. When turn signal lever (11) is set in left-hand position (12), current from fuse #2 in fuse box A (1) flows to the coil in left turn signal light relay (5) through turn signal lever (11) and diode L (16), and connects to ground. 6. Therefore, left turn signal light relay (5) is turned ON. 7. When turn signal light relay (5) is turned ON, current from flasher relay (2) terminal L flows to left turn signal lights (8, 9) at front and rear through left turn signal light relay (5) intermittently, and connects to ground. 8. Therefore, left turn signal lights (8, 9) at front and rear blink.

T2-5-28

position (14), right turn signal lights (6, 7) at front and rear blink. At the same time, column monitor controller (10) blinks right turn signal light indicator (17).

SECTION 2 SYSTEM Group 5 Electrical System

2 FA7 10A

Front turn signal (R)

Rear turn signal (R)

Front turn signal (L)

Rear turn signal (L)

10 17 18

5 3

FA2 5A 11

90Z6-02-05-13 a-

From Battery

12345-

Fuse Box A Flasher Relay Hazard Light Switch Right Turn Signal Light Relay Left Turn Signal Light Relay

678910-

Turn Signal Light (Right Front) Turn Signal Light (Right Rear) Turn Signal Light (Left Front) Turn Signal Light (Left Rear) Column Monitor Controller

1112131415-

T2-5-29

Turn Signal Lever Left-Hand Position Neutral Position Right-Hand Position Diode R

16- Diode L 17- Right Turn Signal Light Indicator 18- Left Turn Signal Light Indicator

SECTION 2 SYSTEM Group 5 Electrical System Horn Circuit (Key Switch: OFF) 1. Current (a) from the battery flows to horn relay (2) through fuse #5 in fuse box B (1). 2. When horn switches (3, 6) are pushed, current flowing to the coil in horn relay (2) connects to ground. 3. Therefore, horn relay (2) is turned ON. 4. When horn relay (2) is turned ON, current from fuse #5 in fuse box B (1) operates horns (4, 5).

fNOTE: The horn circuit can be activated even if the key switch is in the OFF position.

T2-5-30

SECTION 2 SYSTEM Group 5 Electrical System

2 a

4 FA6 10A 3

5 6

90Z6-02-05-14 a-

From Battery

12-

Fuse Box A Horn Relay

34-

Horn Switch Horn (HIGH)

56-

T2-5-31

Horn (LOW) Horn Switch (Side)

SECTION 2 SYSTEM Group 5 Electrical System Reverse Light/Buzzer Circuit 1. When key switch (1) is in the ON position, current from battery (2) flows to fuse #1 in fuse box A (15) through battery relay (3) and main fuse (100 A) (4). 2. Current from fuse #1 in fuse box A (15) flows to reverse light/buzzer relay (5). 3. Current from key switch (1) terminal M flows to fuse #13 in fuse box A (15). Current from fuse #13 in fuse box A (15) flows to the coil in reverse light/buzzer relay (5), and flows to Main Controller (MC) (9) terminal #C17. 4. When forward/reverse lever (10) or forward/reverse switch (option) (14) is set to reverse position (13), MC (6) terminal #E15 is connected to ground. 5. When input signal to MC (9) terminal #E15 or #D13 is detected, terminal #C17 is connected to ground in MC (9). 6. Therefore, reverse light/buzzer relay (5) is turned ON. 7. When reverse light/buzzer relay (5) is turned ON, current from fuse #1 in fuse box A (15) flows to reverse lights (7, 8), and connects to ground. 8. Therefore, reverse lights (7, 8) on both sides are turned on. 9. At the same time, current from fuse #1 in fuse box A (15) operates back buzzer (6).

T2-5-32

SECTION 2 SYSTEM Group 5 Electrical System

FA13 10A

Shift Lever (FNR)

9 11

12 15

4 13

5 6

FA14

FA1

5A Monitor controller (1-24)

7 Reverse Light (RH)

8 Reverse Light (LH) FA2 5A

90Z6-02-05-15

From Battery Relay

12345-

Key Switch Battery Battery Relay Fusible Link (100 A) Reverse Light/Buzzer Relay

678910-

Back Buzzer Reverse Light (Right) Reverse Light (Left) Main Controller (MC) Forward/Reverse Lever

11121314-

T2-5-33

Forward Position Neutral Position Reverse Position Forward/Reverse Switch (Option)

15- Fuse Box A

SECTION 2 SYSTEM Group 5 Electrical System Brake Light Circuit 1. When key switch (1) is in the ON position, current from battery (2) flows to fuse #2 in fuse box A (10) through battery relay (3) and main fuse (100 A) (4). 2. Current from fuse #2 in fuse box A (10) flows to brake light relay (5). 3. When the brake pedal is operated, brake light switch (6) is turned ON. 4. When brake light switch (5) is turned ON, current from fuse #2 in fuse box A (10) flows to the coil in brake light relay (5), and connects to ground. 5. Therefore, brake light relay (5) is turned ON. 6. When brake light relay (5) is turned ON, current from fuse #2 in fuse box A (10) flows to brake lights (7, 8) on both sides, and connects to ground. 7. Therefore, brake lights (7, 8) on both sides are turned on.

T2-5-34

SECTION 2 SYSTEM Group 5 Electrical System

FA13 10A

Shift Lever (FNR)

a 10

FA1 5A

FA2

7 Brake Light (RH) 8 Brake Light (LH)

90Z6-02-05-16

From Battery Relay

123-

Key Switch Battery Battery Relay

456-

Fusible Link (100 A) Brake Light Relay Brake Light Switch

789-

T2-5-35

Brake Light (Right) Brake Light (Left) Main Controller (MC)

10- Fuse Box A

SECTION 2 SYSTEM Group 5 Electrical System Parking Brake Circuit Parking Brake: Applied (Parking Brake Switch: Apply Position)

fNOTE: This parking brake system is spring applied,

1. Current from key switch (1) terminal M flows to fuse #13 in fuse box A (2). 2. Current from fuse #13 in fuse box A (2) flows to the coil side of parking brake relay 1 (4), and flows to terminal #1 in parking brake switch (3). 3. When parking brake switch (3) is set to Apply position (ON1), terminal #1 in parking brake switch (3) is connected to ground. 4. Therefore, parking brake relay 1 (2) is turned ON. 5. When parking brake relay 1 (2) is turned ON, current from parking brake relay 1 (2) (supply side) stops flowing to the coil of parking brake relay 2 (5). 6. Therefore, parking brake solenoid valve (6) ground circuit is disconnected. 7. Consequently, parking brake solenoid valve (6) is turned OFF (not energized). 8. Pressurized oil from the pilot pump (parking brake release pressurized oil) is blocked by parking brake solenoid valve (6). In addition, pressurized oil in the parking brake returns to the hydraulic tank. 9. Therefore, the parking brake is applied by the spring force.

T2-5-36

oil release type. As pressurized oil from the pilot pump (parking brake release pressurized oil) is not supplied to the parking brake with the engine stopped, the parking brake is applied by the spring force. Therefore, the parking brake can not be released with the engine stopped.

SECTION 2 SYSTEM Group 5 Electrical System

FA13 10A

4 5

ON1

ON1: Alternate (Apply brake) (ON2): Momentary (Release)

(ON2)

ON1 (ON2)

FA18 5A Parking brake is applied by spring force.

7 5 Not energized

90Z6-02-05-17 12-

Key Switch Fuse Box A

34-

Parking Brake Switch Parking Brake Relay 1

56-

T2-5-37

Parking Brake Relay 2 Parking Brake Solenoid Valve

78-

Diode G Diode F

SECTION 2 SYSTEM Group 5 Electrical System Parking Brake: Released (Parking Brake Switch: Release Position) IMPORTANT: The parking brake can be released only while the engine runs. 1. When parking brake switch (3) is set to Release position (ON2), parking brake relay 1 (4) grounding circuit is disconnected.

11. Parking brake switch (3) returns to Neutral position automatically when released.

fNOTE: Parking brake switch (3) is a three position

switch which has release position, neutral position, and apply position. When parking brake switch set in apply position, it stay in apply position. When parking brake switch (3) is set in release position and released, it returns to neutral position.

2. This turns OFF parking brake relay 1 (4). 3. When parking brake relay 1 (4) is turned OFF, the current from fuse #13 in fuse box A (2) flows to terminal #4 in parking brake switch (3) through parking brake relay 1 (4) (supply side) and the coil in parking brake relay 2 (5). 4. When parking brake switch (3) is set to Release position, terminals #4 and #6 are connected within parking brake switch (3). Terminal #6 is connected to ground.

12. Then, current from terminal #4 in parking brake switch (3) stops flowing to terminal #6. 13. However, as the self-exciting circuit is formed in parking brake relay 2 (5), parking brake solenoid valve (6) continues to be operated. 14. Consequently, parking brake solenoid valve (6) continues to be operated until parking brake switch (3) is set to Apply position.

5. This turns ON parking brake relay 2 (5). 6. When parking brake relay 2 (5) is turned ON, current from fuse #18 in fuse box A (2) flows to ground through parking brake solenoid (6). 7. This activates parking brake solenoid valve (6). 8. At the same time, current from parking brake relay 2 (5) (coil) flows to parking brake relay 2 (5) (contact) through diode G (7), and the self-exciting circuit is formed. 9. Pressurized oil from the pilot pump (parking brake release pressurized oil) is supplied to the parking brake through parking brake solenoid valve (6). 10. Therefore, the spring of parking brake is pushed back and the parking brake is released.

T2-5-38

SECTION 2 SYSTEM Group 5 Electrical System

FA13 10A

4 5

ON1

ON1: Alternate (Apply brake) (ON2): Momentary (Release)

(ON2)

ON1 (ON2)

FA18 5A Parking brake is released by supplied oil pressure.

7 5

Energized

90Z6-02-05-18 12-

Key Switch Fuse Box A

34-

Parking Brake Switch Parking Brake Relay 1

56-

T2-5-39

Parking Brake Relay 2 Parking Brake Solenoid Valve

78-

Diode G Diode F

SECTION 2 SYSTEM Group 5 Electrical System Work Light Circuit 7. At the same time, current from fuse #4 in fuse box B (6) flows to terminal #2-12 in column monitor controller (18). Terminal #2-12 is connected to ground in column display controller (18).

fNOTE: The operation with work light switch (4) set in ON 2 position is explained here.

1. When key switch (1) is in the ON position, current (a) from battery (2) flows to fuse #4 in fuse box B (6) and fuse #17 in fuse box A (5) through battery relay (3) and fusible link (100 A) (4).

8. Therefore, column display controller (18) turns on working light indicator (17). 9. In addition, current from fuse #11 in fuse box A (5) flows to terminal #8 in work light switch (8) and turns on the indicator backlight.

2. Current from fuse #4 in fuse box B (6) flows to work light (front) relay (9). Current from fuse #17 in fuse box A (5) flows to work light (rear) relay (10). 3. When light switch (7) is set to clearance light position (15), current (b) from fuse #4 in fuse box A (5) flows to terminal #1 and terminal #4 in work light switch (8).

fNOTE: When work light switch (4) is set to ON 1

position, work lights (11,12, 13, and 14) at front and rear are turned on.

fNOTE: Work lights (11,12, 13, and 14) at front and

4. When work light switch (8) is set to ON 2 position, current from fuse #4 in fuse box A (5) flows to the coil in work light (front) relay (9) through terminal #3 in work light switch (8), and connects to ground. 5. Then, work light (front) relay (9) is turned ON. 6. When work light (front) relay (9) is turned ON, current from fuse #4 in fuse box B (6) turns on work light (front, right) (11) and work light (front, left) (12).

T2-5-40

rear are turned on only when light switch (7) is set to clearance light position (15) or to head light position (16).

SECTION 2 SYSTEM Group 5 Electrical System 2

Lighting Switch

FA13 10A

FA4

10A 5

FB4 20A

5 6

Front working light (RH)

Front working light (LH)

FA11 10A

CAB front working light (RH) (Opt)

CAB front working light (LH) (Opt)

FA17 20A

13 14

From Battery Relay

From Battery

12345-

Key Switch Battery Battery Relay Fusible Link (100 A) Fuse Box A

678910-

Fuse Box B Light Switch Work Light Switch Work Light (Front) Relay Work Light (Rear) Relay

90Z6-02-05-19

1112131415-

T2-5-41

Work Light (Front, Right) Work Light (Front, Left) Work Light (Rear, Right) Work Light (Rear, Left) Clearance Light Position

16- Head Light Position 17- Working Light Indicator 18- Column Monitor Controller

SECTION 2 SYSTEM Group 5 Electrical System Wiper Circuit Front Wiper Circuit

fNOTE: The operation with front wiper/washer switch (8) set in intermittent (INT.) position (15) is explained here.

1. Current from fuse #3 in fuse box B (2) flows to terminal #2-19 in column monitor controller (14) through the coil in front wiper relay 1 (5). 2. When front wiper/washer switch (8) is set to INT. position (15), current from column display controller (14) terminal #1-20 flows to terminal #1 through terminal #7 in front wiper/washer switch (8), and connects to ground. 3. When terminal #1-20 is connected to the ground, column display controller (14) connects terminal #2-19 to ground in it intermittently. 4. Therefore, front wiper relay 1 (5) is turned ON or OFF intermittently. 5. When front wiper relay 1 (5) is turned ON, current from fuse #3 in fuse box B (2) flows to front wiper relay 1 (5) through slow speed circuit (18) in front wiper motor (3), front wiper relay 2 (4), and connects to ground. 6. Therefore, the front wiper is operated at slow speed and intermittently.

T2-5-42

SECTION 2 SYSTEM Group 5 Electrical System

2 3

FB3

15A

FRONT 15

OFF INT. LOW HIGH WASHER

8 7

12 10

FB5 10A

REAR

9 WASHER OFF LOW WASHER LOW

13 90Z6-02-05-20

12345-

Fuse Box A Fuse Box B Front Wiper Motor Front Wiper Relay 2 Front Wiper Relay 1

678910-

Front Washer Motor Front Washer Relay Front Wiper/Washer Switch Rear Wiper/Washer Switch Rear Wiper Motor

1112131415-

T2-5-43

Rear Washer Motor Rear Wiper Relay Rear Washer Relay Column Display Controller Intermittent (INT.) Position

SECTION 2 SYSTEM Group 5 Electrical System Rear Wiper Circuit

fNOTE: The operation with rear wiper/washer switch (9) set in LOW position (16) is explained here.

1. When rear wiper/washer switch (9) is set to LOW position (16), terminal #9 is connected to terminal #1 inside rear wiper/washer switch (9). 2. Current from fuse #5 in fuse box B (2) flows to terminal #9 in rear wiper/washer switch (9) through the coil in rear wiper relay (12), and connects to the ground. 3. Therefore, rear wiper relay (12) is turned ON. 4. When rear wiper relay (12) is turned ON, current from fuse #5 in fuse box B (2) flows to rear wiper motor (10) and operates the rear wiper at slow speed.

T2-5-44

SECTION 2 SYSTEM Group 5 Electrical System

2 3

FB3 15A

FRONT OFF INT. LOW HIGH WASHER

8 7

12 10

FB5 10A

REAR

9 16

WASHER OFF LOW WASHER LOW

13 90Z6-02-05-21

12345-

Fuse Box A Fuse Box B Front Wiper Motor Front Wiper Relay 2 Front Wiper Relay 1

678910-

Front Washer Motor Front Washer Relay Front Wiper/Washer Switch Rear Wiper/Washer Switch Rear Wiper Motor

1112131415-

T2-5-45

Rear Washer Motor Rear Wiper Relay Rear Washer Relay Column Display Controller -

16- LOW Position

SECTION 2 SYSTEM Group 5 Electrical System Washer Circuit

fNOTE: The operation of front washer is explained here. 1. While front wiper/washer switch (8) is pushed, current from column monitor controller (14) terminal #1-34 flows to terminal #6 in front wiper/ washer switch (8) through diode H (17), bridges within switch (8) to terminal 1, and connects to ground. 2. Current from fuse #3 in fuse box B (2) flows to the coil in front washer relay (7), flows to terminal #6 in front wiper/washer switch (8) through diode H (17), bridges within switch (8) to terminal 1, and connects to ground. 3. Therefore, front washer relay (7) is turned ON. 4. When front washer relay (7) is turned ON, current from fuse #3 in fuse box B (2) flows to front washer motor (6) and operates the front washer.

fNOTE: The front wiper motor is activated at the same time.

T2-5-46

SECTION 2 SYSTEM Group 5 Electrical System

2 3

FB3 15A

FRONT

OFF INT. LOW HIGH WASHER

5 17 6

8 7

12 10

FB5 10A

REAR

9 WASHER OFF LOW WASHER LOW

13 90Z6-02-05-22

12345-

Fuse Box A Fuse Box B Front Wiper Motor Front Wiper Relay 2 Front Wiper Relay 1

678910-

Front Washer Motor Front Washer Relay Front Wiper/Washer Switch Rear Wiper/Washer Switch Rear Wiper Motor

1112131415-

T2-5-47

Rear Washer Motor Rear Wiper Relay Rear Washer Relay Column Display Controller Washer Position

16- 17- Diode H

SECTION 2 SYSTEM Group 5 Electrical System Cab Dome Light Circuit Cab Light Switch (4): Door Interlocking Position (5)

Rear Cab Light Switch (8): ON

1. When cab light switch (4) is set to door interlocking position (5), current from fuse #11 in fuse box B (1) flows to door open/close switch (3) through cab dome light (2).

1. When rear cab light switch (8) is set to the ON position, current from fuse #11 in fuse box B (1) flows to rear cab light (7), and connects to ground.

2. When the cab door is opened, door open/close switch (3) is turned ON and is connected to ground. 3. Therefore, current from fuse #11 in fuse box B (1) flows to door open/close switch (3) and turns on cab dome light (2). 4. When the cab door is closed, door open/close switch (3) is turned OFF and is disconnected from ground. 5. Therefore, cab dome light (2) is tuned off. 6. Consequently, when cab dome light switch (4) is in door interlocking position (5), cab dome light (2) is turned on/ off by opening/closing the cab door.

fNOTE: Consequently, cab dome light (2) is always on with cab dome light switch (4) set in ON position (6).

T2-5-48

2. Consequently, rear cab light (7) is always on with rear cab light switch (8) set in the ON position.

SECTION 2 SYSTEM Group 5 Electrical System

M4GB-01-114

MNEJ-01-019

FB11 5A 6 8

90Z6-02-05-23

12-

Fuse Box B Cab Dome Light

34-

Door Open/Close Switch Cab Dome Light Switch

56-

T2-5-49

Door Interlocking Position ON Position

78-

Rear Cab Light Rear Cab Light Switch

SECTION 2 SYSTEM Group 5 Electrical System (Blank)

T2-5-50

SECTION 3

COMPONENT OPERATION CONTENTS Group 1 Pump Device

Group 3 Cooling Fan System

Group 2 Control Valve

Group4 Steering Pilot Valve (OrbitrolTM)

Pump Device Location....................................................... T3-1-1 Main Pump Device Outline.............................................. T3-1-2 Pump Device Hydraulic Circuit Diagram............... T3-1-3 Pump Specifications...................................................... T3-1-3 Main Pump............................................................................. T3-1-4 Increasing and Decreasing Flow Rate..................... T3-1-5 Regulator................................................................................ T3-1-6 Regulator Control Function........................................ T3-1-8 Control by Pump Control Pressure.........................T3-1-10 Control by Pump Internal Delivery Pressure......T3-1-14 Control by Pilot Pressure from Torque Control Solenoid Valve............................................................T3-1-18 Steering Priority Valve......................................................T3-1-20 Steering Main Relief Valve..............................................T3-1-21 Pilot Pump............................................................................T3-1-22 Pump Delivery Pressure Sensor....................................T3-1-22

Outline..................................................................................... T3-2-1 Multiple Control Valve Location................................ T3-2-1 Multiple Control Valve Hydraulic Circuit................ T3-2-2 Control Valve Overview................................................ T3-2-3 Control Valve Cross Section Views............................ T3-2-4 Hydraulic Circuit................................................................... T3-2-6 Main Circuit...................................................................... T3-2-6 Pilot Operation Control Circuit.................................. T3-2-8 Main Relief Valve................................................................T3-2-10 Overload Relief Valve (with Make-Up Function).....T3-2-12 Relief Operation............................................................T3-2-12 Make-Up Operation.....................................................T3-2-14 Restriction Valve.................................................................T3-2-15 Pump Control Valve (Negative Control Relief Valve)....................................................................T3-2-16 Flow Rate Control Valve...................................................T3-2-18

Cooling Fan System............................................................. T3-3-1 Unit Location.................................................................... T3-3-1 Fan Pump................................................................................ T3-3-2 Pump Specifications...................................................... T3-3-2 Fan Motor............................................................................... T3-3-3 Fan Motor Specifications............................................. T3-3-3 Fan Motor (Option).............................................................. T3-3-4 Fan Motor Specifications............................................. T3-3-4 Fan Valve (Option)............................................................... T3-3-5 Fan Valve Operation...................................................... T3-3-6 Normal Rotation.......................................................... T3-3-6 Reverse Rotation.......................................................... T3-3-8 Fan Speed Control.....................................................T3-3-10 Fan Valve Make-Up Function....................................T3-3-12 Pressure Sensor (Fan Circuit Pressure)..................T3-3-13 Pressure Sensor Specifications.............................T3-3-13

Outline..................................................................................... T3-4-1 Unit Location.................................................................... T3-4-1 Overview................................................................................. T3-4-2 Structure................................................................................. T3-4-3 Operation................................................................................ T3-4-4 Steering (Left).................................................................. T3-4-5 Steering (Right)............................................................... T3-4-6 Neutral................................................................................ T3-4-6

Group 5 Steering Valve

Outline..................................................................................... T3-5-1 Unit Location.................................................................... T3-5-1 Steering Valve Overview.............................................. T3-5-2 Steering Valve Component Layout.......................... T3-5-3 Operation................................................................................ T3-5-4 Steering (Left).................................................................. T3-5-4 Steering Overload Relief Valve........................................ T3-5-6 Relief Function................................................................. T3-5-6 Make-Up Operation....................................................... T3-5-8 Steering Accumulator........................................................ T3-5-9 Steering Accumulator Specifications...................... T3-5-9

90Z6 F&S

Group 6 Pilot Valve

< Fingertip Control Type Pilot Valve > Outline..................................................................................... T3-6-1 Operation................................................................................ T3-6-2 Electromagnetic Detent.................................................... T3-6-6 Pressure Sensor (Loading Pilot Pressure).................... T3-6-7 < (Auxiliary Pilot Valve) (Option) > Outline..................................................................................... T3-6-8 Operation................................................................................ T3-6-9

Group 7 Charging Block

Outline..................................................................................... T3-7-1 Unit Location.................................................................... T3-7-1 Charging Block Hydraulic Diagram.......................... T3-7-2 Charging Block Overview............................................ T3-7-3 Charging Block Cross Section View.......................... T3-7-4 Priority Valve.......................................................................... T3-7-6 Priority Valve Operation............................................... T3-7-6 Pilot Relief Valve................................................................... T3-7-7 Relief Valve Operation.................................................. T3-7-7 Parking Brake Solenoid Valve.......................................... T3-7-8 Solenoid Valve Operation............................................ T3-7-9 Pump Torque Control Solenoid Valve.........................T3-7-10 Solenoid Valve Operation..........................................T3-7-10 Service Brake Accumulator............................................T3-7-11 Accumulator Specifications......................................T3-7-11 Pilot Accumulator..............................................................T3-7-12 Accumulator Specifications......................................T3-7-12 Service Brake Primary Pressure Sensor (Brake Pressure Alarm).............................................T3-7-13 Pressure Sensor Specifications................................T3-7-13 Parking Brake Pressure Sensor......................................T3-7-14 Pressure Sensor Specifications................................T3-7-14

Group 8 Drive Unit

Drive Unit Outline................................................................ T3-8-1 Front View of Transmission......................................... T3-8-2 Cross Section View of Transmission......................... T3-8-3 Rear View of Transmission........................................... T3-8-4 Side View of Transmission........................................... T3-8-5 Torque Converter................................................................. T3-8-6 Torque Converter Operation...................................... T3-8-6 Transmission.......................................................................... T3-8-8 Transmission Gear Pattern.......................................... T3-8-8 Number of Gear Teeth.................................................. T3-8-9 Clutch Pack...........................................................................T3-8-10 Speed Range Clutch Assy..........................................T3-8-10 Forward/Reverse Clutch Assy..................................T3-8-11 Clutch Pack Operation................................................T3-8-12 Power Flow in Transmission...........................................T3-8-14 Forward First Speed.....................................................T3-8-14 Forward Second Speed..............................................T3-8-16 Forward Third Speed...................................................T3-8-18 Forward Fourth Speed................................................T3-8-20 Reverse First Speed......................................................T3-8-22

Transmission Control Valve............................................T3-8-24 Transmission Control Valve Overview...................T3-8-25 Transmission Control Valve Operation (Modulation)...............................................................T3-8-26 Manual Operation Spool (for Emergency Travel)............................................................................T3-8-30 Clutch Solenoid Valve.................................................T3-8-32 Solenoid Valve Operation.......................................T3-8-32 Hydraulic Circuit...........................................................T3-8-33 Transmission Regulator Valve........................................T3-8-34 Transmission Regulator Valve Operation.............T3-8-35 Parking Brake.......................................................................T3-8-36 Parking Brake Operation............................................T3-8-36 Parking Brake Manual Release.................................T3-8-37

Group 9 Axle

Outline..................................................................................... T3-9-1 Differential.............................................................................. T3-9-2 Purpose of Differential.................................................. T3-9-3 Principle of Differential................................................. T3-9-4 Operation of Differential.............................................. T3-9-5 Torque Proportioning Differential (TPD)..................... T3-9-6 Limited Slip Differential (LSD) (Option)....................... T3-9-8 Service Brake.......................................................................T3-9-10 Final Drive Planetary / Axle Shaft.................................T3-9-11

Group 10 Brake Valve

Outline...................................................................................T3-10-1 Brake Valve Component Layout..............................T3-10-2 Operation..............................................................................T3-10-3 Pressure Switch (for Stop Lamp)...................................T3-10-6 Pressure Switch Specifications............................... T3-10-6 Pressure Sensor (Service Brake Secondary Pressure for Declutch)..............................................T3-10-7 Pressure Sensor Specifications............................... T3-10-7

Group 11 Ride Control Device

Ride Control Valve (Option)............................................T3-11-1 Outline..............................................................................T3-11-1 Overview.........................................................................T3-11-1 Ride Control Hydraulic Circuit Diagram...............T3-11-2 Ride Control Valve Layout.........................................T3-11-3 Ride Control Operation....................................................T3-11-4 Charge-Cut Spool..............................................................T3-11-6 Overload Relief Valve........................................................T3-11-8 Relief Operation............................................................T3-11-8 Make-Up Operation.................................................. T3-11-10 Drain Plug.......................................................................... T3-11-11 Ride Control Accumulator (Option)......................... T3-11-12 Ride Control Accumulator Specifications......... T3-11-12 Lift Arm Raise Pressure Sensor (Option)................. T3-11-13 Lift Arm Angle Sensor (Option).................................. T3-11-14

90Z6 F&S

Group 12 Others

Propeller Shaft....................................................................T3-12-1 2nd Propeller Shaft (Between Front Axle and Transmission)............T3-12-2 3rd Propeller Shaft (Between Transmission and Rear Axle)..............T3-12-2 Stop Valve.............................................................................T3-12-3 Stop Valve Operation..................................................T3-12-3 Secondary Steering Pump..............................................T3-12-4 Secondary Steering Check Block..................................T3-12-5 Axle Oil Cooler (Option)...................................................T3-12-6 Axle Oil Cooler Hydraulic System...........................T3-12-6 Axle Oil Cooler Hydraulic Circuit Diagram.......T3-12-7 Fan Pump for Axle Oil Cooler................................T3-12-7 Axle Oil Cooler Major Components.......................T3-12-8 Oil Cooler Fan.............................................................T3-12-9 Oil Filter Assembly................................................. T3-12-10 Oil Pump Assembly................................................ T3-12-11 Axle Oil Cooler Electrical System...................... T3-12-12

90Z6 F&S

(Blank)

90Z6 F&S

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pump Device Location The main pump device is mounted to transmission assembly (5).

The main pump device consists of main pump (1) and pilot pump (2).

fNOTE: Fan pump (3) is mounted on engine assy (6).

The driving force from engine (6) is transmitted to shaft (4) through the transmission input shaft and activates main pump (1) and pilot pump (2).

Refer to Group 3 Cooling Fan System.

2 5

90Z6-03-01-01

12-

Main Pump Pilot Pump

34-

Fan Pump Shaft

56-

T3-1-1

Transmission Assy Engine Assy

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Main Pump Device Outline The main pump device consists of main pump (1) and pilot pump (2).

Priority valve (3) and steering main relief valve (4) is built in main pump (1). Regulator (5) is mounted on main pump (1).

Main pump (1) is a swash-plate type variable displacement axial plunger pump. Pilot pump (2) is a gear pump.

The hydraulic pump circuit is equipped with a delivery pressure sensor (6) to read delivery pressures, and also a torque control solenoid valve to control the pump output volume. (Refer to SYSTEM / Control System.) 7 Pg

Pi2 Pi1

CF EF

6 90Z6-03-01-02

EF- Main Pump Discharge (Loading) CF- Main Pump Discharge (Steering) ST- Torque Control Pressure

Pi1- Pump Control Pressure 1 Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure

Dr- Drain Sg- Pilot Pump Inlet (Outlet port (D) is on the opposite side)

123-

456-

Main Pump Pilot Pump Priority Valve

Steering Main Relief Valve Regulator Pump Delivery Pressure Sensor

T3-1-2

Air Bleeder Plug (Tightening Torque: 80 N·m)

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pump Device Hydraulic Circuit Diagram Multiple control valve

Steering valve

Hydraulic tank

7 Charging block

1 90Z6-03-01-03

123-

Main Pump Pilot Pump Priority Valve

45-

Steering Main Relief Valve Regulator

Pump Delivery Pressure Sensor

78-

Pump Torque Control Solenoid Valve Pump Control Valve

Pump Specifications  Main Pump Type Theoretical Displacement Volume Rated Speed Rated Pressure

Swash Plate Single Pump 170 cm3/rev 2000 min-1/min 29.4 MPa

 Pilot Pump Type Theoretical Displacement Volume Rated Speed Rated Pressure

T3-1-3

Gear Pump 16.8 cm3/rev 2000 min-1/min 3.9 MPa

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Main Pump When main pump cylinder block (1) rotates, plungers (2) reciprocate in main pump cylinder block (1) due to angle of swash plate (4), and the pump draws the hydraulic oil up through the pump and delivers the oil out to the hydraulic systems. Regulator (9) controls servo piston 1 (3) and servo piston 2 (6). When the displacement angle of swash plate (4) is changed by servo piston1 (3) and servo piston 2 (6), the stroke of plunger (2) is increased or decreased, so that the delivery flow rate of main pump is regulated.

The main hydraulic pump supplies pressurized oil for operating the cylinders and other hydraulic components. The pump is equipped with a regulator (9) for controlling the delivery flow rate. Shaft (5) is connected to main pump cylinder block (1) so that shaft (5) and main pump cylinder block (1) rotate together.

T4GB-03-01-002

123-

Cylinder Block Plunger Servo Piston 1 (2 Used)

456-

Swash Plate Shaft Servo Piston 2

789-

T3-1-4

Feedback Lever Link Regulator

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Increasing and Decreasing Flow Rate The displacement angle of swash plate (4) is changed by the movement of servo piston 1 (3) and servo piston 2 (6). Movement of the servo pistons is controlled by the regulator. In addition, the displacement angle of swash plate (4) is fed back to the regulator by feedback lever (7) and link (8).

7 8 3 6

fNOTE: Refer to the following pages as for operation of

the regulator.

 Change of Swash Plate Angle 1. The center of swash plate (4) angle is located at point A in the drawings to the right.

T4GB-03-01-022

2. Pilot pressure is always routed to servo piston 2 (6). 3. Therefore, when the circuit of servo piston 1 (3) is connected to the hydraulic oil tank, swash plate (4) rotates clockwise around A.

Minimum Tilting:

4. Conversely, as there are two servo pistons 1 (3) and when pilot pressure is routed to both of servo piston 1 (3) and servo piston 2 (6), swash plate (4) rotates in the opposing direction or counterclockwise around A.

A 6

 Feedback Operation 1. End of feedback lever (7) is inserted into protrusion part (D) on the side of swash plate (4).

T4GB-03-01-023

2. When swash plate (4) rotates, protrusion part (D) is also rotated and feedback lever (7) moves together. 3. For example, when swash plate (4) is rotated from the minimum to the maximum, the center of feedback lever (7) is moved from positions B to C as illustrated to the right.

Maximum Tilting:

4. Therefore, link (8) is moved by feedback lever (7) and the movement is fed back to the regulator.

8 7

T4GB-03-01-024

T3-1-5

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Regulator Regulator controls the main pump flow rate in response to the various command signal pressure.

Pi1

The major parts of regulator are spring (1), sleeve 1 (2), sleeve 2 (7), spool 1 (3), spool 2 (6), piston (4), load piston (5), inner spring (8), and outer spring (9).

Air

Pi2

Regulator opens and closes the circuit leading to servo piston 1 (10) according to the various command signal pressure, the displacement angle of swash plate (11) is changed and the pump flow rate is controlled.

14 ST

Pd1

fNOTE: Primary pilot pressure (Pg) is constantly supplied

to servo piston 2 (12).

7 Dr 6

8, 9

10 a

12 TNDB-03-01-026

Displacement Angle Increase

Pd1- Main Pump Delivery Pressure ST- Torque Control Pressure Dr- Returning to Hydraulic Oil Tank Air- Air Bleeding Circuit

T3-1-6

Displacement Angle Decrease

Pi1- Pump Control Pressure 1 Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

TNED-03-01-025

TNED-03-01-024

12 1234-

Spring Sleeve 1 Spool 1 Piston

5678-

Load Piston Spool 2 Sleeve 2 Inner Spring

9101112-

T3-1-7

Outer Spring Servo Piston 1 (2 Used) Swash Plate Servo Piston 2

13- Piston 2 14- Piston 1

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Regulator Control Function The regulator has the following four control functions.  Control by Pump Control Pressure When a control lever is operated, the pump flow rate control valve in control valve (housed within the regulator) regulates pump control pressure (Pi1 - Pi2) in response to the control lever stroke. When the regulator receives pump control pressure (Pi1 - Pi2), the regulator controls the pump delivery flow rate in proportion to the pressure. When the control lever is operated, pump control pressure (Pi1 - Pi2) decreases and the regulator increases the pump delivery flow rate. When the control lever is returned to neutral, pump control pressure (Pi1 - Pi2) increases and the regulator decreases the pump delivery flow rate. (Refer to SYSTEM / Hydraulic System.)

0 Q-

Pi1-Pi2

Flow Rate

Pi-

Pump Control Pressure

 Control by Pumps Internal Delivery Pressure The regulator receives pumps internal delivery pressure Pd1. If the pump pressures increases over the set P-Q line, the regulator reduces pump delivery flow rate and the pump output is returned to the set P-Q line.

0 QP-

 Control by Pilot Pressure from Torque Control Solenoid Valve MC (Main Controller) calculates the operating conditions of the machine and, using the calculation, the MC sends the pump torque control solenoid the appropriate signal for correct valve. The torque control solenoid valve delivers torque control pressure ST (refer to the next page) to the regulator in response to this signal. The regulator receives pilot pressure and decreases the pump delivery flow rate.

Flow Rate Pressure

P cd-

Pressure Increase Flow Rate Decrease

0 Q-

T3-1-8

Flow Rate

P P-

Pressure

SECTION 3 COMPONENT OPERATION Group 1 Pump Device (Blank)

T3-1-9

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Control by Pump Control Pressure  Flow Rate Decrease

1. When the control lever stroke is reduced, pressure difference arising before and after the flow rate control valve (difference between pressure Pi1 and pressure Pi2) in the control valve is increased. 2. Pump control pressure Pi1 pushes spool 1 (3) through piston 1 (14) and spool 1 (3) moves toward the arrow. 3. By this movement, primary pilot pressure Pg is routed to servo piston 1 (10).

0 Q-

Pi1-Pi2

Flow Rate

4. Two servo pistons 1 (10) are located so that swash plate (11) rotates in the flow rate decrease direction.

Pi-

Pi1

Pump Control Pressure

5. Movement of swash plate (11) is transmitted to sleeve 1 (2) through feedback lever link (15). Sleeve 1 (2) is moved in the same direction as spool 1 (3).

Pi2

6. When sleeve 1 (2) is moved by the same stroke as spool 1 (3), the open part between sleeve 1 (2) and spool 1 (3) is closed and primary pilot pressure Pg routed to servo piston 1 (10) is blocked. Therefore, servo piston 1 (10) is stopped and the flow rate decreasing operation is completed.

14 ST

Pd1

12 a

b TNDB-03-01-026

Displacement Angle Increase

Displacement Angle Decrease

Pd1- Main Pump Delivery Pressure ST- Torque Control Pressure Dr- Returning to Hydraulic Oil Tank Pi1- Pump Control Pressure 1

Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

1- Spring 2- Sleeve 1 3- Spool 1 4- Piston 10 - Servo Piston 1

11 - Swash Plate 12 - Servo Piston 2 14 - Piston 1 15 - Feedback Lever Link

T3-1-10

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pump Regulator (Flow Rate Decrease) 14

Pi1

1 Pi2

Pd1

15 12

Pi1

TNDB-03-01-011

4 1 Pi2

Pd1

10 11

TNDB-03-01-012

Pd1- Main Pump Delivery Pressure ST- Torque Control Pressure

Dr- Returning to Hydraulic Oil Tank Pi1- Pump Control Pressure 1

Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

123-

4- Piston 10- Servo Piston 1 11- Swash Plate

12- Servo Piston 2 14- Piston 1 15- Feedback Lever Link

Spring Sleeve 1 Spool 1

T3-1-11

SECTION 3 COMPONENT OPERATION Group 1 Pump Device  Flow Rate Increase 1. When the control lever stroke is enlarged, pressure difference of the flow rate control valve (difference between pressure Pi1 and pressure Pi2) in the control valve is reduced.

2. Force of spring (1) and pump control pressure Pi2 pushes spool 1 (3) through piston (4) so that spool 1 (3) is moved toward the arrow. 3. By this movement, the circuit of servo piston 1 (10) is connected to the hydraulic oil tank. 4. As primary pilot pressure Pg is always supplied to servo piston 2 (12), swash plate (11) is rotated in the flow rate increase direction. 5. Movement of swash plate (11) is transmitted to sleeve 1 (2) through feedback lever link (15). Sleeve 1 (2) is moved in the same direction as spool 1 (3).

0 Q-

Pi1-Pi2

Flow Rate

6. When sleeve 1 (2) is moved by the same stroke as spool 1 (3), the circuit between servo piston 1 (10) and the hydraulic oil tank is closed so that servo piston 1 (10) is stopped and the flow rate increasing operation is completed.

Pi-

Pi1

Pump Control Pressure

Pi2 Pg ST

Pd1

12 a

b TNDB-03-01-026

Displacement Angle Increase

Displacement Angle Decrease

Pd1- Main Pump Delivery Pressure ST- Torque Control Pressure Dr- Returning to Hydraulic Oil Tank Pi1- Pump Control Pressure 1

Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

1- Spring 2- Sleeve 1 3- Spool 1 4- Piston 10 - Servo Piston 1

11 - Swash Plate 12 - Servo Piston 2 15 - Feedback Lever Link

T3-1-12

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pump Regulator (Flow Rate Increase) Pi1

4 1 Pi2

Pd1

15 12

10 11

Pi1

TNDB-03-01-013

4 1 Pi2

Pd1 Pd1

15 10

11 TNDB-03-01-014

Pd1- Own Pump Delivery Pressure ST- Torque Control Pressure

Dr- Returning to Hydraulic Oil Tank Pi1- Pump Control Pressure 1

Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

123-

4- Piston 10- Servo Piston 1 11- Swash Plate

12- Servo Piston 2 15- Feedback Lever Link

Spring Sleeve 1 Spool 1

T3-1-13

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Control by Pump Internal Delivery Pressure  Flow Rate Decrease

1. When load is applied to the pump by one operation or another, own pump delivery pressure Pd1 increases. (As done during an operation, pump control pressure (Pi1 - Pi2) remains lowered.) 2. Load piston (5) pushes spool 2 (6), inner spring (8), and outer spring (9) so that spool 2 (6) is moved to the direction of the arrow. 0

3. By this movement, primary pilot pressure Pg is routed servo piston 1 (10).

Q-

Flow Rate

P-

Pressure

4. Two servo pistons (1) are located so that swash plate (11) is rotated in the flow rate decrease direction. 5. This movement of swash plate (11) is transmitted to sleeve 2 (7) through feedback lever link (15). Sleeve 2 (7) is moved in the same direction as spool 2 (6).

Pi1

6. When sleeve 2 (7) is moved by the same stroke as spool 2 (6), the open part between sleeve 2 (7) and spool 2 (6) is closed and primary pilot pressure Pg servo piston 1 (10) is blocked so that causes servo piston 1 (10) is stopped and the flow rate decreasing operation is completed.

Pi2 Pg ST

Pd1

7 Dr 6

8, 9 15

12 a

b TNDB-03-01-026

Displacement Angle Increase

Displacement Angle Decrease

Pd1- Main Pump Delivery Pressure ST- Torque Control Pressure Dr- Returning to Hydraulic Oil Tank Pi1- Pump Control Pressure 1

Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

56789-

10 - Servo Piston 1 11 - Swash Plate 12 - Servo Piston 2 15 - Feedback Lever Link

T3-1-14

Load Piston Spool 2 Sleeve 2 Inner Spring Outer Spring

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pump Regulator (Flow Rate Decrease) 5

Pi1

7 Pi2

8 9 Pd1

15 12

Pi1

TNDB-03-01-015

7 Pi2

8 9 Pd1

15 10

TNDB-03-01-016

Pd1- Main Pump Delivery Pressure ST- Torque Control Pressure

Dr- Returning to Hydraulic Oil Tank Pi1- Pump Control Pressure 1

Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

567-

8- Inner Spring 9- Outer Spring 10- Servo Piston 1

11- Swash Plate 12- Servo Piston 2 15- Feedback Lever Link

Load Piston Spool 2 Sleeve 2

T3-1-15

SECTION 3 COMPONENT OPERATION Group 1 Pump Device  Flow Rate Increase 1. When the pump load is reduced, main pump delivery pressure Pd1 decreases. (As done during an operation, pump control pressure (Pi1 - Pi2) remains lowered.)

2. Load piston (5) and spool 2 (6) are pushed by inner spring (8) and outer spring (9) so that spool 2 (6) is moved to the direction of the arrow. 3. By this movement, the circuit from servo piston 1 (10) is connected to the hydraulic oil tank. 4. As primary pilot pressure Pg is always supplied to servo piston 2 (12), swash plate (11) is rotated in the flow rate increase direction.

0 Q-

Flow Rate

5. Movement of swash plate (11) is transmitted to sleeve 2 (7) through feedback lever link (15). Sleeve 2 (7) is moved in the same direction as spool 2 (6).

PDr

Pi1

6. When sleeve 2 (7) is moved by the same stroke as spool 2 (6), the open part between spool 2 (6) and sleeve 2 (7) is closed and the circuit between servo piston 1 (10) and the hydraulic oil tank is blocked. Therefore, servo piston 1 (10) is stopped and the flow rate increasing operation is completed.

Pressure

Pi2 Pg ST

Pd1

7 Dr 6

8, 9 15

12 a

b TNDB-03-01-026

Displacement Angle Increase

Displacement Angle Decrease

Pd1- Main Pump Delivery Pressure ST- Torque Control Pressure Dr- Returning to Hydraulic Oil Tank Pi1- Pump Control Pressure 1

Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

56789-

10111215-

T3-1-16

Load Piston Spool 2 Sleeve 2 Inner Spring Outer Spring

Servo Piston 1 Swash Plate Servo Piston 2 Feedback Lever Link

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pump Regulator (Flow Rate Increase) 5

Pi1

7 Pi2

8 9 Pd1

15 12 10 11

Pi1

TNDB-03-01-017

7 Pi2

8 9 15

Pd1

TNDB-03-01-018

Pd1- Own Pump Delivery Pressure ST- Torque Control Pressure

Dr- Returning to Hydraulic Oil Tank Pi1- Pump Control Pressure 1

Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

567-

8- Inner Spring 9- Outer Spring 10- Servo Piston 1

11- Swash Plate 12- Servo Piston 2 15- Feedback Lever Link

Load Piston Spool 2 Sleeve 2

T3-1-17

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Control by Pilot Pressure from Torque Control Solenoid Valve

 Flow Rate Decrease 1. When the torque control solenoid valve is activated by the signals from MC (Main Controller), torque control pressure ST is routed to the regulator. 2. Torque control pressure ST and own pump delivery pressure Pd1 are combined and applied to load piston (5). 3. Load piston (5) pushes spool 2 (6), inner spring (8), and outer spring (9), and spool 2 (6) is moved to the direction of the arrow.

0 Q-

Flow Rate

P-

Pi1

4. By this movement, primary pilot pressure Pg is routed to servo piston 1 (10).

Pressure

5. Two servo pistons 1 (10) are located so that swash plate (11) is rotated in the flow rate decrease direction.

Pi2 Pg

6. Movement of swash plate (11) is transmitted to sleeve 2 (7) through feedback lever link (15). Sleeve 2 (7) is moved in the same direction as spool 2 (6).

Pd1

7. When sleeve 2 (7) is moved by the same stroke as spool 2 (6), the open part between sleeve 2 (7) and spool 2 (6) is closed and primary pilot pressure Pg to servo piston 1 (10) is blocked so that servo piston 1 (10) is stopped and the flow rate decreasing operation is completed.

7 Dr 6

8, 9 15

12 a

b TNDB-03-01-026

Displacement Angle Increase

Displacement Angle Decrease

Pd1- Main Pump Delivery Pressure ST- Torque Control Pressure Dr- Returning to Hydraulic Oil Tank Pi1- Pump Control Pressure 1

Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

56789-

10111215-

T3-1-18

Load Piston Spool 2 Sleeve 2 Inner Spring Outer Spring

Servo Piston 1 Swash Plate Servo Piston 2 Feedback Lever Link

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pump Regulator (Flow Rate Decrease) 5

Pi1

7 Pi2

8 9 Pd1

Pi1

TNDB-03-01-019

7 Pi2

8 9 Pd1

15 10

TNDB-03-01-020

Pd1- Own Pump Delivery Pressure ST- Torque Control Pressure

Dr- Returning to Hydraulic Oil Tank Pi1- Pump Control Pressure 1

Pi2- Pump Control Pressure 2 Pg- Primary Pilot Pressure (From Pilot Pump)

567-

8- Inner Spring 9- Outer Spring 10- Servo Piston 1

11- Swash Plate 12- Servo Piston 2 15- Feedback Lever Link

Load Piston Spool 2 Sleeve 2

T3-1-19

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Steering Priority Valve When steering is not operated Steering priority valve is built in the main pump. Steering priority valve supplies pressurized oil from the main pump with priority to the steering valve and maintains the steering function. CF

Operation

 When steering is not operated 1

1. When steering is not operated, pressurized oil (1) from the main pump is blocked by the steering valve.

2. Pressurized oil (1) from the main pump flows to both ends of spool (2) through the inside of spool (2).

3. As pressurized oil in spring chamber (3) flows to the hydraulic oil tank through port LS and the hydraulic tank, pressure in spring chamber (3) lowers.

4. Therefore, spool (2) compresses spring (3) and moves downward. LS

5. This causes the majority of pressurized oil (1) from the main pump flows to the loading system control valve through port EF.

TNED-03-01-022

When steering is operated

 When steering is operated 1. When steering is operated and the steering valve spool moves, the passage from port LS to the hydraulic oil tank is blocked by the steering valve.

2. Pressure at port LS rises in response to the movement amount of steering valve spool.

3. Spool (2) moves upward due to pressure at port LS and the spring (3) force. 5

4. Therefore, pressure oil (1) from the main pump flows to both port EF and port CF.

5. When the steering valve spool moves to the maximum stroke, the majority of pressure oil (1) from the main pump flows to the steering valve through port CF. 3

LS LS- Line Signal CF- Controlled Flow

EF- Excess Flow

123-

456-

T3-1-20

Pressure Oil from Main Pump Spool Spring

TNED-03-01-023

To Hydraulic Tank To Control Valve To Steering Valve

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Steering Main Relief Valve Steering main relief valve is housed inside the main pump. When the steering circuit pressure exceeds the set pressure, pressurized oil is returned to the hydraulic oil tank through the main pump casing. Operation 1. When the steering circuit pressure exceeds the set pressure, poppet (1) compresses spring (2) and moves downward.

3 1

2. Therefore, pressurized oil flows to the hydraulic oil tank through the main pump casing.

fNOTE: When the steering relief valve is operated, the

priority valve spool moves to the port LS side and the majority of pressurized oil from the main pump flows to the control valve through port EF.

T4GB-03-01-021 12-

T3-1-21

Poppet Spring

To Hydraulic Tank

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pilot Pump Drive gear (1) is driven by the engine through the transmission accessory drive, which rotates driven gear (2) as they are meshed together. 1-

Drive Gear

1 a

Driven Gear

b T137-02-03-005 a-

Pump Delivery Pressure Sensor

Inlet Port

Outlet Port

This sensor detects the pump delivery pressures, which are used in order to control various operations. When oil pressure is applied to diaphragm (6), diaphragm (6) flexes slightly. The flexing of diaphragm (6) is detected as electrical signals in ohms. 34-

Ground Output

56-

3 4 5

Power Source (5V) Pressure Receiving Area (Diaphragm)

T3-1-22

6 T157-02-03-010

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Outline Multiple control valve (1), mounted on the front chassis, controls the oil pressure, flow rate, and flow direction in the hydraulic circuit.

The major parts are the main relief valve, overload relief valve, negative control valve, restriction valve, flow rate control valve, pump control valve, and spools. The spools are operated by pilot oil pressure.

Multiple Control Valve Location

90Z6-03-02-01

T3-2-1

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Multiple Control Valve Hydraulic Circuit

3 15

4 13

16 6

2 9

17 10

123456-

Flow Rate Control Valve (Logic Valve Poppet) Flow Rate Control Valve (Selector Valve) Pump Control Valve Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Restriction Valve (Bucket Roll Back)

78910111213-

90Z6-03-02-02

Overload Relief Valve (Lift Arm: Bottom Side) Restriction Valve (Lift Arm Raise) Make-Up Valve (Lift Arm: Rod Side) Main Relief Valve Load Check Valve (Lift Arm Circuit) Restriction Valve (Lift Arm Lower) Bucket Spool

T3-2-2

141516171819-

Lift Arm Spool Bucket Cylinder Lift Arm Cylinders Hydraulic Oil Tank Main Pump Low Pressure Relief Valve

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Control Valve Overview 13

5 4 12

1 7

9 4

90Z6-03-02-03

1234567891011121314-

1 4 7

8 5

6 90Z6-03-02-04

T3-2-3

Flow Rate Control Valve (Logic Valve Poppet) Pump Control Valve Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Restriction Valve (Bucket Roll Back) Overload Relief Valve (Lift Arm: Bottom Side) Restriction Valve (Lift Arm Raise) Make-Up Valve (Lift Arm: Rod Side) Main Relief Valve Restriction Valve (Lift Arm Lower) Bucket Spool Lift Arm Spool

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Control Valve Cross Section Views 14

B 13

90Z6-03-02-07

 Lift Arm Spool 11

b1 14

90Z6-03-02-05

Cross Section A-A 1

 Bucket Spool

b2 a2 13

1234-

Flow Rate Control Valve (Logic Valve Poppet) Flow Rate Control Valve (Selector Valve) Overload Relief Valve (Bucket: Rod Side)

567-

Cross Section B-B

Overload Relief Valve (Bucket: Bottom Side) Restriction Valve (Bucket Roll Back) Overload Relief Valve (Lift Arm: Bottom Side)

Restriction Valve (Lift Arm Raise) 9- Make-Up Valve (Lift Arm: Rod Side) 10- 11- Load Check Valve (Lift Arm Circuit)

T3-2-4

90Z6-03-02-06

12- Restriction Valve (Lift Arm Lower) 13- Bucket Spool 14- Lift Arm Spool

SECTION 3 COMPONENT OPERATION Group 2 Control Valve

Cross Section D-D

Cross Section C-C

3 90Z6-03-02-08

Cross Section E-E

3- Pump Control Valve 10- Main Relief Valve

13- Bucket Spool 14- Lift Arm Spool

T3-2-5

19- Low Pressure Relief Valve

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Hydraulic Circuit Main Circuit Pressurized oil from main pump (1) flows to hydraulic oil tank (3) through neutral circuit (2). Parallel circuit (4) is provided in the hydraulic loading valve main circuit and makes possible the simultaneous combining of lift arm and bucket operation. Main relief valve (5) is provided in the main circuit (between the pump and the actuator (cylinder) spools within the valve). Main relief valve (5) prevents the pressure in the main circuit from exceeding the set pressure when the spool is operated (or when the control lever is operated). Overload relief valves (6) are provided in the actuator (cylinder) circuit (between the control valve and the actuator (cylinder)) of the lift arm cylinder base end, and bucket. Overload relief valve (6) prevents pressure spikes caused by external forces in the actuator circuit from exceeding the set pressure when the spool is in neutral (with the control lever set in neutral).

T3-2-6

SECTION 3 COMPONENT OPERATION Group 2 Control Valve

3 15

4 13

2 9

17 10

90Z6-03-02-09

123456-

78910111213-

T3-2-7

141516171819-

Lift Arm Spool Bucket Cylinder Lift Arm Cylinders Hydraulic Oil Tank Main Pump Low Pressure Relief Valve

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Pilot Operation Control Circuit Pressurized oil from pilot pump (1) supplied through pilot valve (2) acts on spools (3, 4) in multiple control valve (5) in order to move the spools. When doing the following with the lift arm/bucket control levers, pressurized oil moves the spools and is routed to the following selector valves.  During lift arm raise (a1) operation, pressurized oil moves lift arm spool (3) and shifts the selector valve spool of flow rate control valve (6). In lift arm lower (b1) operation, lift arm spool (3) has two stage functions. First stage function is lift arm lower (A), and second stage function is lift arm float (B).  During bucket rollback (a2) operation, pressurized oil moves bucket spool (4).  By moving spools (3, 4), the oil passage for the desired operation is connected and pressurized oil from main pump (7) is supplied to the following circuit to move lift arm/bucket cylinders.

T3-2-8

SECTION 3 COMPONENT OPERATION Group 2 Control Valve

5 4

3 7

90Z6-03-02-10

a1- Lift Arm Raise

a2- Bucket Roll Back

b1- Lift Arm Lower

b2- Bucket Dump

12-

34-

56-

Pilot Pump Pilot Valve

Lift Arm Spool Bucket Spool

T3-2-9

Multiple Control Valve Flow Rate Control Valve

Main Pump

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Main Relief Valve The main relief valve prevents the pressure in the main circuit from exceeding the set pressure when the actuator such as the cylinder is operated. Therefore, oil leak from hose and pipe joints and breakage of the actuator are prevented. Relief Operation 1. Pressure in port P (main circuit) is routed to pilot poppet (8) through orifice A (2) in main poppet (1) and orifice B (3) in seat (4). 2. When pressure in port P reaches the set pressure of spring B (6), pilot poppet (8) is opened, pressurized oil from passage A (5) flows to port T (hydraulic oil tank) through the external circumference of sleeve (11). 3. At this time, a pressure difference is caused between port P and spring chamber (10) due to orifice A (2). 4. When this pressure difference reaches the set pressure of spring A (9), main poppet (1) is opened and pressurized oil from port P flows to port T. 5. Consequently, the main circuit pressure decreases. 6. When the main circuit pressure decreases to the specified pressure, main poppet (1) is closed by the force of spring A (9).

fNOTE: Main Relief Set Pressure: 29.4 MPa

T3-2-10

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Main Relief Valve Operation  During Normal Operation: 1

8 TNED-03-02-013

 During Relief Operation: 1

8 TNED-03-02-014

P-

From Pump

T-

To Hydraulic Tank

123-

Main Poppet Orifice A Orifice B

456-

Seat Passage A Spring B

8- Pilot Poppet 9- Spring A 10- Spring Chamber

T3-2-11

11- Sleeve

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Overload Relief Valve (with Make-Up Function) The overload relief valve is located in the lift arm raise and bucket circuits. The overload relief valve prevents each actuator circuit pressure from rising excessively when the actuators are moved by external force. In addition, when the actuator circuit pressure decreases, the overload relief valve draws pressurized oil from the hydraulic oil tank and prevents the occurrence of cavitation (make-up function). Relief Operation 1. Pressure in port P (actuator circuit) is routed to pilot poppet (8) through orifice (1) of piston (3). 2. When pressure in port P reaches the set pressure of spring B (6), pilot poppet (8) is opened, pressurized oil from passage A (5) flows to port T (hydraulic oil tank) through the external circumference of sleeve (10). 3. At this time, a pressure difference occurs between port P and spring chamber (9) due to orifice (1). 4. When this pressure difference reaches the set pressure of spring A (4), piston (3) and main poppet (2) are opened and pressurized oil from port P flows to port T. 5. Consequently, the actuator circuit pressure decreases. 6. When the actuator circuit pressure decreases to the specified pressure, piston (3) and main poppet (2) are closed by the force of spring A (4).

fNOTE: Overload Relief Set Pressure Lift Arm Raise Circuit: Bucket Circuit:

36.8 MPa 32.5 MPa

T3-2-12

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Overload Relief Valve Operation  During Normal Operation 2

T4GB-03-02-030

 During Relief Operation 2

P-

Actuator Circuit

T-

Hydraulic Oil Tank

123-

Orifice Main Poppet Piston

456-

Spring A Passage A Spring B

T4GB-03-02-031

789-

T3-2-13

Spring C Pilot Poppet Spring Chamber

10- Sleeve

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Make-Up Operation 1. When pressure in port P (actuator circuit) decreases lower than pressure in port T (hydraulic oil tank), sleeve (10) is moved to the right. 2. Hydraulic oil in port T flows to port P and cavitation is prevented. 3. When pressure in port P increases to the specified pressure, sleeve (10) is closed by the force of spring C (7). 10

7 T4GB-03-02-032

P-

Actuator Circuit

T-

Hydraulic Oil Tank

Spring C

10- Sleeve

T3-2-14

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Restriction Valve The restriction valve (slow return valve) consists of a check valve (1) and orifice (2). The restriction valve is provided in the inlet port of pilot circuit on the both ends of lift arm spool and the bucket rod end circuit.

1. If the lift arm control lever is moved to the neutral position while the lift arm cylinders are moving, pilot pressure oil supplied to the lift arm spool is drained through orifice (2) in the restriction valve.

2. Therefore, pilot pressure slowly decreases, and lift arm spool is slowly returned to the neutral position. T4GB-03-02-014

3. Thus, the vehicle shock developed by lift arm operation is reduced. 4. The restriction valve provided in the bucket rod end circuit reduces the shock when returning to the neutral after bucket roll back operation .

SP- To Spool

PV- From Pilot Valve

T3-2-15

Check Valve

Orifice

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Pump Control Valve (Negative Control Relief Valve) A negative control valve (1) is provided on the opencenter hydraulic circuit (neutral circuit) (3) of multiple control valve (2). This control valve (1) controls main pump regulator (8) in the pump device by the flow control pressures (Ps and Tdr) to regulate the pump delivery flow rate.

Operation

< Neutral > 1. When no lever operation is made (neutral), pressurized oil (P) coming through the control valve neutral circuit (3) is supplied as pump control pressure from both circuits before and after orifice (5) of negative control valve (1) installed at the downstream end of neutral circuit (3).

2. In neutral conditions, spool B of pump regulator (8) moves right because pressure (Ps) before orifice (5) is higher than pressure (Tdr) after orifice (5). 3. Therefore, pilot pressure (PS2) from pilot pump (10) via charging block (11) enters the largediameter chamber in servo piston (9) through pump regulator spools. Pilot pressure (PS2) also enters the small-diameter chamber in servo piston (9), but servo piston (9) moves right as the pressure receiving area is wider at the large-diameter chamber side.

Tdr

90Z6-03-02-11

Section View A-A 1-

Negative Control Valve (Pump Control Valve)

456-

Spring Orifice Poppet

4. Thus, the pump delivery flow is reduced. <Operation> 1. When a lever operation is made, pressurized oil is supplied to the activated loader actuators for bucket or lift arm operation, and no oil is supplied to ports Ps or Tdr.

fNOTE: In general, the hydraulic pump delivery flow rate control using the pressure difference of the orifice on such center bypass is called "negative control" control.

fNOTE: In the open-center hydraulic circuit, the oil

pressure in this center circuit (neutral circuit) decreases when operating actuators as the oil is sent to the actuators. Then, when the pressure decreases, pump regulator is controlled to increase the pump delivery rate to supply more oil to the loading circuit.

2. Then, differential pressure is lowered between the pressures (Ps and Tdr), the regulator spools do not move (the main pump is at neutral), and pump operation is not restricted, increasing pump delivery flow.

T3-2-16

SECTION 3 COMPONENT OPERATION Group 2 Control Valve

11 B A 8

90Z6-03-02-12 PS2- Pilot Pressure from Pilot Pump via Charging Block 123-

Negative Control Valve (Pump Control Valve) Multiple Control Valve Neutral Circuit

4567-

Spring Orifice Poppet Main Pump

891011-

T3-2-17

Pump Regulator Servo Piston Pilot Pump Charging Block

12- Hydraulic Tank

SECTION 3 COMPONENT OPERATION Group 2 Control Valve Flow Rate Control Valve

Pilot pressure (a1)

The flow rate control valve, provided in the parallel circuit to the bucket spool, restricts oil flow rate in the circuit during combined operation of lift arm and bucket.

 During Single Operation of Bucket Roll Back 1. Pressurized oil (P) from main pump (3) flows to bucket spool (4) through poppet valve (1) and moves bucket cylinder (6).

2. A small amount of this pressurized oil flows to selector valve (2) through check valve (8).

1 9 8

 During Combined Operation of Lift Arm Raise and Bucket Roll Back 1. Pressurized oil from main pump (3) flows both to bucket spool (4) and lift arm spool (5).

2. Pressurized oil (P) which flows to bucket spool (4) pushes to open check valve (8) in poppet valve (1), and flows to selector valve (2). 3. Pilot pressure to raise the lift arm (a1) is also applied to selector valve (2) via port SY, and the oil passage with orifice (11) is connected. 4. The pressure at the spring A (9) side of poppet valve (1) increases, and poppet valve (1) is pressed to close. 5. Oil flow supplied to bucket spool (4) is regulated, and more pressurized oil is supplied to higher load lift arm side circuit.

90Z6-03-02-13 124-

6. Consequently, operation of bucket roll back and lift arm raise are performed at the same time.

T3-2-18

Flow Rate Control Valve (Poppet Valve) Flow Rate Control Valve (Selector Valve) Bucket Spool

891013-

Check Valve Spring A Spring B Hydraulic Oil Tank

SECTION 3 COMPONENT OPERATION Group 2 Control Valve  Single Operation of Bucket Roll Back

4 7 9

90Z6-03-02-14

 Combined Operation of Lift Arm Raise and Bucket Roll Back

7 9

90Z6-03-02-15

12-

Flow Rate Control Valve (Poppet Valve) Flow Rate Control Valve (Selector Valve)

3456-

Main Pump Bucket Spool Lift Arm Spool Bucket Cylinder

78910-

T3-2-19

Lift Arm Cylinder Check Valve Spring A Spring B

11- Orifice 12- Parallel Circuit 13- Hydraulic Oil Tank

SECTION 3 COMPONENT OPERATION Group 2 Control Valve (Blank)

T3-2-20

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System Cooling Fan System Unit Location

12-

Fan Pump Engine

90Z6-03-03-01

 For Reversing Fan (Option) 5

6 90Z6-03-03-02

3456-

Fan Fan Motor Radiator Assembly Fan Speed Control Solenoid Valve

90Z6-03-03-03

78910-

T3-3-1

Fan Valve (Option) Fan Speed Control Solenoid Valve (Option) Fan Reverse Control Solenoid Valve (Option) Fan Circuit Pressure Sensor (Option)

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System Fan Pump Fan pump is a gear pump directly connected to the engine, supplies pressurized oil to the fan motor while the engine is running. Rotation Direction

Inlet Port

90Z6-03-03-04

Outlet Port

123-

Drive Gear Retainer Ring Oil Seal

456-

Bushing Body Cover

10 789-

Front Cover Gasket Gasket

Pump Specifications Type Theoretical Displacement Volume Opearation Speed Opearation Pressure (Set Relief )

Hydraulic gear pump 44.5 cm3/rev 800~2100 min-1/min 15.0 MPa

T3-3-2

90Z6-03-03-05

11 10- Driven Gear 11- Gasket

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System Fan Motor The fan motor is a gear motor, for one directional rotation.

Fan Motor Specifications

The fan motor consists of oil motor (1) with shafts (7, 8) connected with coupling (2). When pressurized oil is supplied from the fan pump, oil motor (1) turns. The end of shaft (7) is connected to the fan by woodruff key joint (6). Therefore, the rotation of motor shaft (8) via output shaft (7) is transmitted to the fan.

Type

Hydraulic gear motor

Displacement Capacity

33.1 cm3/rev

Overload Relief Pressure 14.4 Mpa Rated Speed

1650 rpm

9 2

5 3 4

6 Outlet

90Z6-03-03-06

7 7

Drain

Inlet

Arrow View A

123-

Oil Motor Coupling Lock Washer

456-

Nut Outrigger Bearing Woodruff Key

90Z6-03-03-07

Arrow View B

78-

T3-3-3

Outrigger Bearing Shaft Motor Shaft

Fan Speed Control Solenoid Valve

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System Fan Motor (Option) The fan motor is a gear motor, for bidirectional rotation. The fan motor consists of oil motor (1) with shaft (4), and outrigger bearing (3) with shaft (6), connected with coupling (2). When pressurized oil is supplied from the fan pump, oil motor (1) turns. The end of shaft (6) is connected to the fan by woodruff key joint (5). Therefore, the rotation of shaft (6) is transmitted to the fan. Hydraulic tank

Fan Motor Specifications Hydraulic gear motor Type (bidirectional rotation) Displacement Capacity 33.1 cm3/rev Rating

Pressure

14.4 MPa

Speed

1650 rpm

Fan Valve (Dr)

Drain

90Z6-03-03-09

2 3

5 1

90Z7BT03-03-01

6 12-

Oil Motor Coupling

34-

Outrigger Bearing Motor Shaft

56-

T3-3-4

Woodruff Key Outrigger Bearing Shaft

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System Fan Valve (Option) The fan valve consists of fan speed control solenoid valve (1), fan reverse rotation control solenoid valve (2), fan control valve (3), and fan reverse rotation spool (4).

fNOTE: The reversing fan is an optional equipment.

Fan speed control solenoid valve (1) is shifted by the signals from the Main Controller (MC) and controls the operation of fan control valve (3). Fan control valve (3) is shifted according to the operation of fan speed control solenoid valve (1) and returns pressurized oil to the hydraulic tank. Therefore, pressurized oil flowing to the fan motor decreases and the fan can rotate at the best speed. (Refer to SYSTEM / Control System.) In addition, when the fan reverse rotation switch is turned ON, fan reverse rotation control solenoid valve (2) is shifted by the signals from MC. Therefore, fan reverse rotation spool (4) is shifted and the fan rotates in reverse.

T 4

S 1

TNED-03-03-001

AB-

Port A Port B

P-

Port P

S-

Port S (Pressure Sensor Mounting Port)

Fan Speed Control Solenoid Valve

Fan Reverse Rotation Control Solenoid Valve

34-

Fan Control Valve Fan Reverse Rotation Spool

T3-3-5

T- Port T Dr- Drain Port

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System Fan Valve Operation  Normal Rotation 1. Pressurized oil from port P splits into three circuits. One flows to fan reverse rotation spool (2) and the other flows to poppet (3) in fan control valve (5). The other flows to fan speed control solenoid valve (7), fan reverse rotation control solenoid valve (6), and the spring (4) chamber in fan control valve (5).

2. As fan reverse rotation control solenoid valve (6) is not shifted during normal rotation, fan reverse rotation spool (2) is pushed by the spring (1) force in the direction of the heavy black arrow.

3. Pressurized oil from port P flows to the fan motor through the periphery of fan reverse rotation spool (2) and port A.

2 6

9 7

4. Therefore, the fan rotates in normal direction.

90Z7BT03-03-02 P- From Pilot Pump T- To Hydraulic Tank Dr- To Hydraulic Tank

A-

12456-

T3-3-6

Spring Fan Reverse Rotation Spool Spring Fan Control Valve Fan Reverse Rotation Control Solenoid Valve

B-

To Fan Motor (Normal Rotation Side) To Fan Motor (Reverse Rotation Side) Fan Speed Control Solenoid Valve Hydraulic Fan Circuit Pressure Sensor (Fan Pump Output Pressure Sensor)

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System  Normal Rotation

4 P

2 3

TNED-03-03-005

PT-

From Pilot Pump To Hydraulic Tank

Dr- To Hydraulic Tank

A-

To Fan Motor (Normal Rotation Side)

B-

To Fan Motor (Reverse Rotation Side)

123-

Spring Fan Reverse Rotation Spool Poppet

45-

Fan Reverse Rotation Control Solenoid Valve

Fan Speed Control Solenoid Valve

Spring Fan Control Valve

T3-3-7

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System  Reverse Rotation 1. When the fan reverse rotation switch is turned ON, fan reverse rotation control solenoid valve (6) is shifted by the signals from the Main Controller. (Refer to SYSTEM / Control System.) 2

2. Pressurized oil from port P is routed to the end of fan reverse rotation spool (2) through spool (8) of fan reverse rotation control solenoid valve (6).

3. Therefore, fan reverse rotation spool (2) moves toward the arrow. 4. Pressurized oil from port P flows to the fan motor through the periphery of fan reverse rotation spool (2) and port B.

5. Therefore, the fan rotates in reverse direction. 90Z7BT03-03-03

P- From Pilot Pump T- To Hydraulic Tank Dr- To Hydraulic Tank

A-

26-

T3-3-8

Fan Reverse Rotation Spool Fan Reverse Rotation Control Solenoid Valve Spool

B-

To Fan Motor (Normal Rotation Side) To Fan Motor (Reverse Rotation Side) Hydraulic Fan Circuit Pressure Sensor (Fan Pump Output Pressure Sensor)

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System  Reverse Rotation 8

P 2

TNED-03-03-006

PT-

From Pilot Pump To Hydraulic Tank

Dr- To Hydraulic Tank

A-

To Fan Motor (Normal Rotation Side)

Fan Reverse Rotation Spool

Spool

Fan Reverse Rotation Control Solenoid Valve

T3-3-9

B-

To Fan Motor (Reverse Rotation Side)

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System  Fan Speed Control 1. The Main Controller (MC) activates fan speed control solenoid valve (7) according to coolant temperature, torque converter oil temperature, hydraulic oil temperature, etc. (Refer to SYSTEM / Control System.) 2. Therefore, the spring (4) chamber is connected to port Dr or drain, returning oil to the hydraulic tank. 3. Pressurized oil in the spring (4) chamber flows to port Dr to the hydraulic tank through orifice (11), passage (9), and the spool (10) of fan speed control solenoid valve (7).

4 9 7

4. Therefore, the pressure in the spring (4) chamber decreases. 5. When the pressure in the spring (4) chamber is lower than the pressure at port P, poppet (3) in fan control valve (5) moves toward in the direction of the bold black arrow and pressurized oil from port P flows to port T (hydraulic tank). 6. Pressurized oil flowing to the fan motor decreases and the fan speed slows. 7. This action permits the fan to rotate at the best speed.

10 90Z7BT03-03-04

P- From Pilot Pump T- To Hydraulic Tank Dr- To Hydraulic Tank

A-

457-

9- Passage 10- Spool 11- Orifice

8. In addition, pressurized oil in the spring (4) chamber flows to port Dr (hydraulic tank) through orifice (11) in a manner that slowly bleeds it of, and permits the action to have a modulation effect. 9. Therefore, the fan speed is prevented from changing suddenly.

T3-3-10

Spring Fan Control Valve Fan Speed Control Solenoid Valve

B-

To Fan Motor (Normal Rotation Side) To Fan Motor (Reverse Rotation Side)

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System  Fan Speed Control

4 P 3 9 Dr 7

TNED-03-03-007

PT-

From Pilot Pump To Hydraulic Tank

Dr- To Hydraulic Tank

A-

345-

Poppet Spring Fan Control Valve

10- Spool 11- Orifice

Fan Speed Control Solenoid Valve Passage

T3-3-11

To Fan Motor (Normal Rotation Side)

B-

To Fan Motor (Reverse Rotation Side)

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System Fan Valve Make-Up Function The make-up valve keeps the hydraulic fan drive from developing what are known as cavitation ("voids" or vacuum pockets) when slowing down or while reversing the fan rotation. Sudden decreases in rpm’s (min-1) can cause voids (cavitation) to occur, and these voids would produce a symptom of delays in response to directional changes or delays in changes in fan speed. If a make-up valve sticks closed, these delays can occur. If it were to stick in the open position, the speed in a given direction would be affected, making the fan rotate much more slowly than normal when that direction is selected.

The following explains the make up function. 1. When pressure at port A or port B is lower than pressure at port T (hydraulic oil tank), check valve (12) moves up. 2. Hydraulic oil in port T flows to port A or port B and cavitation is prevented. 3. When pressure at the port A or port B side rises to the specified pressure, check valve (12) is closed by the spring (13) force.

TNED-03-03-008

T-

To Hydraulic Oil Tank

12- Check Valve

A-

To Fan Motor (Normal Rotation Side)

B-

13- Spring

T3-3-12

To Fan Motor (Reverse Rotation Side)

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System Pressure Sensor (Fan Circuit Pressure) When hydraulic fan circuit pressure sensor (fan pump output pressure sensor) (1) detects the decrease of circuit pressure (due to engine shut down, fan motor speed change, etc.), the anti-void valve refills hydraulic oil from the returning oil to prevent cavitation.

Radiator Fan Control Valve

Pressure Sensor Specifications Rated Voltage Power Consumption Output Voltage Operation Pressure Withstanding Pressure

5.0 VDC Max. 10 mA 0.5~4.5 V 0~49 MPa 100 MPa

1 90Z6-03-03-08

View A

90T157-02-03-10a

Hydraulic Fan Circuit Pressure Sensor (Fan Pump Output Pressure Sensor)

23-

Pressure Receiving Area (Diaphragm) Ground

T3-3-13

45-

Output Power Source (5V)

SECTION 3 COMPONENT OPERATION Group 3 Cooling Fan System (Blank)

T3-3-14

SECTION 3 COMPONENT OPERATION Group 4 Steering Pilot Valve Outline Steering pilot valve (Orbitrol) (1) is connected to hydraulic pump device (2) via charging block (3), and to steering valve (4) via stop valves (5). Orbitrol (1) sends pressurized oil from the pilot pump of pump device (2) supplied via charging block (3) to steering valve (4) in response to the movement of the steering wheel. (Refer to SYSTEM / Hydraulic System / Steering Circuit.) Unit Location 5 (RH) 4

Floorboard

Front chassis

5 (LH)

Hydraulic tank

2 3

Rear chassis 90Z6-03-04-01 P-

Pressurized Oil From Pilot Pump (via Charging Block)

T-

To Hydraulic Oil Tank (Bottom)

12-

Steering Pilot Valve (Orbitrol) Pump Device

34-

Charging Block Steering Valve

T3-4-1

Stop Valve

SECTION 3 COMPONENT OPERATION Group 4 Steering Pilot Valve Overview

90Z6-03-04-02

Steering Wheel

L-

To Steering Valve via Stop Valve (for Steering Left)

R-

To Steering Valve via Stop Valve (for Steering Right)

T3-4-2

90Z6-03-04-03

PT-

From Pilot Pump via Charging Block To Hydraulic Tank

SECTION 3 COMPONENT OPERATION Group 4 Steering Pilot Valve Structure

The steering pilot valve (Orbitrol) consists of rotor (8), drive (7), sleeve (3), spool (4), pin (5), housing (1), centering springs (2), and others. When the steering wheel is rotated, spool (4) rotates, and an oil passage is opened between spool (4) and sleeve (3). Pressurized oil from the pilot pump is controlled by spool (4) and sleeve (3), and flows to the steering valve.

Centering springs (2) are arranged in both spool (4) and sleeve (3), and returns sleeve (3) to the neutral position when the steering wheel is stopped.

T1F3-03-07-002

6 4

2 3 1

12 5

10 9

6 123-

Housing Centering Spring Sleeve

456-

Spool Pin Plate

T4GB-03-04-008 789-

T3-4-3

Drive Rotor Spacer

10- Cap 11- Check Valve 12- Hole

SECTION 3 COMPONENT OPERATION Group 4 Steering Pilot Valve Operation

Port L

Sleeve (3), spool (4), and drive (7) are all connected to each other by pin (5). When the steering wheel (spool (4)) is rotated, a relative angular difference arises between sleeve (3) and spool (4) as hole (12) of spool (4) is a lengthened one. Movement of the steering wheel is transmitted only to spool (4), and port P (from the steering pump) is connected to port R (to the steering valve) or port L through sleeve (3) and spool (4).

7 Port R

Steering Wheel

Port T

Port P

2 T4GB-03-04-007

T1F3-03-07-002

T3-4-4

SECTION 3 COMPONENT OPERATION Group 4 Steering Pilot Valve Steering (Left) 1. When the steering wheel is turned left, spool (4) rotates, and pressurized oil from pilot pump (5) flows to steerng pilot valve (9) via charging block (6) in the order of port P - sleeve (3) - spool (4) - sleeve (3) - housing (1) - rotor (8).

4. Returning oil from steering valve (10) enters port R, flows in the order of housing (1) - sleeve (3) - spool (4) - sleeve (3) - port T, and returns to hydraulic oil tank (15). 5. When pressurized oil from pilot pump (5) enters rotor (8), rotor (8) rotates left. Rotation of rotor (8) is transmitted to sleeve (3) through drive (7), and sleeve (3) rotates left similarly.

2. Pressurized oil from rotor (8) flows in the order of housing (1) - sleeve (3) - spool (4) - sleeve (3) - port L - steering valve (10), and controls steering spool (11).

6. When sleeve (3) rotates the same amount of turns as spool (4), passages of sleeve (3) and spool (4) are closed and operation of steering valve (10) is stopped.

3. Steering valve (10) activates steering cylinders (12) with pressurized oil from main pump (13) via steering priority valve (14) and turns the machine to the left.

7. Therefore, rotor (8) rotates in response to rotation of the steering wheel and steering valve (10) is operated in response to the amount of turns of the steering wheel.

16 (RH)

16 (LH) 14

5 6 1

9 3

1234-

Housing Centering Spring Sleeve Spool

5678-

Pilot Pump Charging Block Drive Rotor

90Z6-03-04-04

4 9101112-

T3-4-5

Steering Pilot Valve (Orbitrol) Steering Valve Steering Spool Steering Cylinder

13141516-

Main Pump Steering Priority Valve Hydraulic Oil Tank Stop Valve

SECTION 3 COMPONENT OPERATION Group 4 Steering Pilot Valve Steering (Right) T

1. When the steering wheel is turned right, pressurized oil from the pilot pump flows in the order of port P - port R - steering valve, activates the steering valve, and turns the machine to the right.

2. Returning oil from the steering valve flows in the order of port L - port T and returns to the hydraulic tank.

T4GB-03-04-010

Neutral 1. When the steering wheel is not rotated, pressurized oil from the pilot pump is blocked by spool (4) and does not flow to the steering valve.

2. Therefore, the steering cylinder is not operated.

T3-4-6

T4GB-03-04-011

SECTION 3 COMPONENT OPERATION Group 5 Steering Valve Outline Steering valve (1) is located between pump device (2) and steering cylinders (3). Steering valve (1) supplies pressurized oil from main pump (2) to steering cylinders (3) in response to pilot pressure of the steering pilot valve. Steering cylinders (3) are protected with the overload relief valve. Unit Location

4 1

3 (RH) 5 (RH) P Front chassis

3 (LH) 2 5 (LH) 90Z6-03-05-01 P-

Pressurized Oil From Main Pump

12-

Steering Valve Pump Device

34-

Steering Cylinder Multiple Control Valve

T3-5-1

Steering Accumulator

SECTION 3 COMPONENT OPERATION Group 5 Steering Valve Steering Valve Overview 4

4 Pa

TNED-03-05-005

5 P

TNED-03-05-001-KC

A-

B-

P-

Port A: Pressure for Steering (Left) Port P: From Main Pump

123-

Spool Overload Relief Valve Overload Relief Valve

456-

T-

Port B: Pressure for Steering (Right) Port T: Return to Hydraulic Tank

Pa- Port Pa: Pilot Pressure for Steering (Left) LS- Port LS: To Port LS of Priority Valve

Load Check Valve Variable Orifice Fixed Orifice

T3-5-2

Passage A

Pb- Port Pb: Pilot Pressure for Steering (Right)

SECTION 3 COMPONENT OPERATION Group 5 Steering Valve Steering Valve Component Layout Section A-A

TNED-03-05-003

Section B-B

2 Pa

TNED-03-05-004

Section C-C

T4GB-03-04-006

123-

Spool Overload Relief Valve Overload Relief Valve

456-

Load Check Valve Variable Orifice Fixed Orifice

T3-5-3

Passage A

SECTION 3 COMPONENT OPERATION Group 5 Steering Valve Operation

fNOTE: The operation for steering (right) is explained here.

Steering (Left) 1. When the steering wheel is turned right, pilot pressure oil from the steering pilot valve flows to port Pb and spool (1) moves left. 2. Pressurized oil from the main pump flows to passage A (7) through port P and variable orifice (5). 3. Pressurized oil in passage A (7) pushes to open load check valve (4) and flows to the steering cylinder through port B. 4. Returning oil from the steering cylinder flows to port T (hydraulic oil tank) through port A and spool (1). 5. Pilot pressure oil flowing into port Pb pushes spool (1) on the port Pb side and flows to port Pa at the same time after being depressurized by fixed orifice (6). 6. This reduces the shock caused by quick operation of the steering wheel. (Refer to SYSTEM / Hydraulic System / Steering Operation Circuit.) 7. A flow amplification notch (8) is mounted at the main steering spool to assist with modulation feel, and the oil flow that it spills to tank works in conjunction with the fixed orifice to help stabilize the spool movement and balance pilot oil flow.

fNOTE: Opening area of variable orifice (5) is

proportional to the amount of stroke of spool (1) due to pilot pressure from the steering pilot valve.

T3-5-4

SECTION 3 COMPONENT OPERATION Group 5 Steering Valve 1

8 P

TNED-03-05-006

LS A

TNED-03-05-007

P-

Port P

A-

Port A

B-

Port B

14-

Spool Load Check Valve

56-

Variable Orifice Fixed Orifice

78-

Passage A Flow Amplification Notch

T3-5-5

T-

Port T

SECTION 3 COMPONENT OPERATION Group 5 Steering Valve Steering Overload Relief Valve The steering overload relief valve is installed in the left and right steering circuits. Overload relief valve controls pressure in the respective steering circuits from pressure spikes caused by when the steering cylinder is moved by an external force. In addition, it also makes up oil (make-up function) by refilling oil from the hydraulic oil tank in order to prevent voids or cavitation when pressure in the steering circuit lowers. Relief Operation 1. Pressure at high pressure (HP) port (the steering circuit) is routed to pilot poppet (8) through orifice (11) in piston (10). 2. When pressure at the HP port reaches the set force of spring B (6), pilot poppet (8) opens and pressurized oil flows to the low pressure (LP) port (the hydraulic tank) through passage A (5) and the periphery of sleeve (3). 3. Pressure difference arises between the HP port and spring chamber (9) due to orifice (11) at this time. 4. When this pressure difference reaches the set force of spring A (4), piston (10) and main poppet (2) open and pressure oil at the HP port flows to the LP port. 5. Consequently, pressure in the steering cylinder circuit lowers. 6. If pressure in the steering cylinder circuit lowers to the specified pressure, piston (10) and main poppet (2) are closed by the force of spring A (4).

T3-5-6

SECTION 3 COMPONENT OPERATION Group 5 Steering Valve Normal Operation:

T107-02-05-019

Relief Operation:

HP - Actuator Circuit

LP - Hydraulic Tank

123-

456-

Make-Up Valve Main Poppet Sleeve

Spring A Passage A Spring B

789-

T3-5-7

T178-03-03-049

Spring C Pilot Poppet Spring Chamber

10- Piston 11- Orifice

SECTION 3 COMPONENT OPERATION Group 5 Steering Valve Make-Up Operation 1. When pressure at the HP port (the steering cylinder circuit) is lower than pressure at the LP port (the hydraulic tank), sleeve (3) moves right. 2. Hydraulic oil in the LP port flows to the HP port and cavitation is prevented. 3. When pressure at the HP port side rises to the specified pressure, sleeve (3) is closed by the force of spring C (7).

7 HP - Actuator Circuit

LP - Hydraulic Tank

Sleeve

Spring C

T3-5-8

T178-03-03-050

SECTION 3 COMPONENT OPERATION Group 5 Steering Valve Steering Accumulator Steering accumulators (1) are connected to each steering cylinder (2) to absorb the hydraulic pulsation, preventing the machine joggling when stopping the steering wheel rotation.

Nitrogen (N2) gas at 8 MPa is charged in the gas chamber. Steering Accumulator Specifications Maximum Operating Pressure N2 Gas Charging Pressure N2 Gas Capacity

35 MPa 8 MPa 0.2 L

1 90Z6 07-52-03

90Z6-03-05-02

T3-5-9

SECTION 3 COMPONENT OPERATION Group 5 Steering Valve (Blank)

T3-5-10

SECTION 3 COMPONENT OPERATION Group 6 Pilot Valve Outline (Fingertip Control Type Pilot Valve for Front Attachment) The pilot valve controls pilot pressure oil in order to move the spool in the control valve. The pilot valve delivers pilot pressure oil in proportion to the control lever stroke. This is done by using a Pressure Proportional Control (PPC) Valve which moves the spool in the control valve. Port No. 1 2 3 4

Hydraulic Symbol

Bucket Dump Bucket Roll Back Lift Arm Lower Lift Arm Raise

P T 1

4 T4GB-03-05-001

90T4GB-03-05-02

PT-

Port P (Pressure Oil from Pilot Pump) Port T (To Hydraulic Oil Tank)

T3-6-1

SECTION 3 COMPONENT OPERATION Group 6 Pilot Valve Operation Neutral (Output Curve: A to B) 1. At the neutral position of the control lever, spool (7) is completely blocking the pressurized oil from port P. Also, output port (Y) is connected to tank port (T) through notch part (Z) of spool (7), and the pressurized oil in output port (Y) is equal to the pressure in the hydraulic tank.

2. When the control lever is moved slightly, lever (1) is tilted, and push rod (2) and push rod (3) are pushed in. Push rod (3) and spring guide (4) remain mutually connected, and move downward, compressing return spring (6). 3. At this time, spool (7) is pushed by balance spring (5), and moves downward until the clearance (X) becomes zero.

T523-02-05-001 a-

4. During this movement, output port (Y) remains connected with tank port (T), and pressurized oil is not supplied to output port (Y).

fNOTE: Lever stroke during the period when the

clearance (X) becomes zero is the play of the control lever.

T3-6-2

Pilot Pressure

Control Lever Stroke

SECTION 3 COMPONENT OPERATION Group 6 Pilot Valve

1 2

4 5 6 T X

X P

7 Y

T4GB-03-05-004

T4GB-03-05-003

P-

Pilot Pressure Port

T-

Tank Port

X-

Clearance

Z-

Notch Part

12-

Lever Push Rod

34-

Push Rod Spring Guide

Y-

Output Port

56-

Balance Spring Return Spring

T3-6-3

Spool

SECTION 3 COMPONENT OPERATION Group 6 Pilot Valve While Metering Pilot Oil (Output Curve: C to D)

Full Stroke (Output Curve: E to F)

1. When the control lever is further tilted, output port (Y) is connected with pilot pressure port (P) through spool (7).

1. When the control lever is fully stroked, push rod (3) moves downward until spring guide (4) contacts the shoulder part of the casing.

2. Pressurized oil from Port P flows into output port (Y) through spool (7), and the pressure in output port (Y) is raised.

2. At this time, spool (7) is directly pushed by the bottom of push rod (3). Therefore, output port (Y) remains connected to the port P through notch part (Z) of spool (7) because even if the pressure at the output port is raised, spool (7) does not move upward.

3. Pressure in output port (Y) works spool (7), and tends to push up spool (7). 4. In case the force to push up spool (7) is less than the balance spring (5) force, balance spring (5) does not compress. The port P and output port (Y) remain connected, and the pressure in output port (Y) keeps rising.

3. As a result, the pressure at the output port end is equal to the pressure at port P. Stroke amount C of the stem determines the total stroke of the lever.

5. When the pressure in output port (Y) rises the force to push spool (7) up increases. If this force overcomes the balance spring (5) force, spool (7) moves upwards, compressing balance spring (5).

6. When spool (7) moves upward, output port (Y) is not connected any longer, and pressurized oil stops flowing from port P to output port (Y). And pressure in output port (Y) stops increasing. C

7. In this way, balance spring (5) is compressed in proportion to the amount spool (7) is pushed down, and the pressure in output port (Y) is the balanced pressure working on the spring force and spool (7).

T523-02-05-001 a-

T3-6-4

Pilot Pressure

Control Lever Stroke

SECTION 3 COMPONENT OPERATION Group 6 Pilot Valve

4 Z P

Y P-

Pilot Pressure Port

Z-

Notch Part

Push Rod

T4GB-03-05-005

T-

Tank Port

Y-

Output Port

Spring Guide

Balance Spring

T3-6-5

Spool

T4GB-03-05-006

SECTION 3 COMPONENT OPERATION Group 6 Pilot Valve Electromagnetic Detent 1. Coil for detent is installed at the push rod part of the pilot valve. 2. When one of the control levers is tilted, push rod (2) and plate (8) of the opposite side are pushed upwards by the spring force. 3. If the control lever is fully stroked, plate (8) of the opposite side (forced up side) is held by electromagnetic coil assembly (10). This holds the control lever at it’s position. 4. This electromagnetic attraction between coil assembly (10) and plate (8) continues until coil assembly (10) is deenergized or until the magnetic force is forcibly separated by operating the control lever toward the neutral direction with enough force to overcome the power of detents.

90T4GB-03-05-07 2-

Push Rod

Plate

10 - Coil Assembly

T3-6-6

SECTION 3 COMPONENT OPERATION Group 6 Pilot Valve Pressure Sensor (Loading Pilot Pressure) Sensor Specifications Rated Voltage Power Consumption Output Voltage Operation Pressure Withstanding Pressure

5.0 VDC Max. 10 mA 0.5~4.5 V 0~4.9 MPa (0~711 PSI) 6.9 MPa (1000 PSI)

(V)

Output Voltage

5 (4.5) (3.7) 3 2 (1.3)

90Z6T1-2-22

(0.5) 0

(0.98)

(3.92)

Pressure (Calibration Point)

(MPa) 90Z7-03-07-02

35830-60130 1-

GND

Output (Vout)

fNOTE: This sensor is identical to the lift arm raise pilot

pressure sensor (option) mounted to the multiple control valve. (Refer to T3-11-13.)

T3-6-7

Power Supply (5V)(Vcc)

SECTION 3 COMPONENT OPERATION Group 6 Pilot Valve Outline (Auxiliary Pilot Valve) (Option) The two-direction, four-port type (option) is adopted for the additional circuit pilot valve. Port No. 1 2

Option Option

T T

Hydraulic Symbol

P P

1 1

2 T554-02-07-009

1 P-

T3-6-8

T1LA-03-04-001

Port P (Pressurized Oil from Pilot Pump)

T-

Port T (To Hydraulic Oil Tank)

SECTION 3 COMPONENT OPERATION Group 6 Pilot Valve Operation Neutral (Output Curve: A to B) 1. At the neutral position of the control lever, spool (7) completely blocks the pressurized oil of port P. Also, outlet port (a) is connected to port T through passage (9) of spool (7), and the pressurized oil at output port (a) is equal to the pressure in the hydraulic tank.

p D

2. When the control lever is moved slightly, cam (1) is tilted. Then, pusher (2) and spring guide (4) remain mutually connected, compress return spring (6), and move downward.

C A

3. At this time, spool (7) is pushed by balance spring (5) and moves downward until clearance (A) becomes 0 mm.

b T1F3-03-09-004

Pilot Pressure

Control Lever Stroke

4. During this movement, output port (a) remains connected with port T and pressurized oil is not supplied to output port (a).

fNOTE: Pedal stroke until clearance (A) becomes 0 mm is the play of the control lever.

1 2 3 4 5 T

6 A

A: 0 P

9 a

T1LA-03-04-003

T1LA-03-04-002

PA-

Port P Clearance

TB-

Port T Notch Part

Output Port

123-

Cam Pusher Plate

456-

Spring Guide Balance Spring Return Spring

789-

Spool Hole Part Passage

T3-6-9

SECTION 3 COMPONENT OPERATION Group 6 Pilot Valve During Metering or Decompressing (Output Curve: C to D) 1. When the control lever is further tilted, hole part (8) of spool (7) is connected to notch part (B).

2. Pressurized oil of port P flows to output port (a) through hole part (8) of spool (7) and pressure at output port (a) increases.

3. Pressure in output port (a) is routed to the bottom surface of spool (7) so that spool (7) is pushed upward.

4. When the force to move spool (7) upward is smaller than the balance spring (5) force, balance spring (5) is not compressed so that spool (7) is not raised and pressure in the output port (a) increases. 5. As pressure in the output port (a) increases further, the force to move spool (7) upward increases. When this force overcomes the balance spring (5) force, spool (7) compresses balance spring (5) and moves upward.

b T1F3-03-09-004

Pilot Pressure

Control Lever Stroke

6. As spool (7) is moved upward, notch part (B) is closed so that pressurized oil from port P stops flowing to output port (a) and pressure at output port (a) stops increasing. 7. In this way, balance spring (5) is compressed by the amount that spool (7) is pushed down, and the pressure at output port (a) is the balanced pressure working on the spring force and spool (7).

5 T B P

7 a

T1LA-03-04-004

PAT-

Port P Clearance Port T

Ba-

Notch Part Output Port

12345-

Cam Pusher Plate Spring Guide Balance Spring

6789-

Return Spring Spool Hole Part Passage

T3-6-10

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Outline Charging block (1) supplies pressurized oil from pilot pump (2) with priority to service brake accumulators (3) and brake valve (4)

Charging block (1) also supplies pressurized oil from pilot pump (2) to the steering pilot valve (Orbitrol), the loading pilot valve, parking brake, and optional ride control valve. Pressurized oil to main pump regulator (5) is also supplied from charging block (1) to control pump delivery pressure.

Unit Location

1 6

90Z6-03-07-01

12-

Charging Block Pilot Pump

34-

Service Brake Accumulator Brake Valve

T3-7-1

56-

Main Pump Regulator Pilot Accumulator

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Charging Block Hydraulic Diagram

6 MF

8 10

Service Brake circuit A

7 Service Brake circuit B

7 16 15

3 4

PB X

17 2

11 PS1

PS2 90Z6-03-07-02

MF- To Brake Valve (Front Brake Circuit A) MR- To Brake Valve (Rear Brake Circuit B) PS1- To Steering Pilot Valve (Steering Circuit) X- To Pump Regulator (Pump Control Circuit)

PS2- To Pump Regulator (Pump Control Circuit), Ride Control Valve (Ride Control Circuit (Option))

PP- To Loading Pilot Valve via Pilot Shut-Off Valve (Loading Circuit) PB- To Parking Brake (Parking Brake Circuit)

123456-

789101112-

1314151617-

Pilot Pump Charging Block Brake Priority Valve Charge Relief Valve Service Brake Accumulator (Front) Service Brake Accumulator (Rear)

Check Valve Brake Valve Pilot Relief Valve Hydraulic Oil Tank Pilot Accumulator Parking Brake Solenoid Valve

T3-7-2

Check Valve Pump Torque Control Solenoid Valve Parking Brake Service Brake Primary Pressure Sensor Parking Brake Pressure Sensor

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Charging Block Overview

(ACCP) PS2

2 (ACCR)

DR X P

4 (ACCF)

90Z6-03-07-04

P- Port P (From Accessory Pump) DR- Port T (To Hydraulic Tank) MF- To Brake Valve (Front Brake Circuit A) MR- To Brake Valve (Rear Brake Circuit B) X- To Pump Regulator (Pump Control Circuit)

PS1- To Steering Pilot Valve (Steering Circuit) PS2- To Pump Regulator (Pump Control Circuit), Ride Control Valve (Ride Control Circuit (Option))

PP- To Loading Pilot Valve via Pilot Shut-Off Valve (Loading Circuit) PB- To Parking Brake (Parking Brake Circuit)

2- Charging Block 4- Charge Relief Valve 11- Pilot Accumulator

12- Parking Brake Solenoid Valve 14- Pump Torque Control Solenoid Valve 16- Service Brake Primary Pressure Sensor

17- Parking Brake Pressure Sensor

T3-7-3

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Charging Block Cross Section View

(ACCF)

(ACCR) 4

P DR X PS1

PS2

(ACCP)

90Z6-03-07-03

P- Port P (From Accessory Pump) DR- Port T (To Hydraulic Tank) MF- To Brake Valve (Front Brake Circuit A) MR- To Brake Valve (Rear Brake Circuit B) X- To Pump Regulator (Pump Control Circuit)

PS1- To Steering Pilot Valve (Steering Circuit) PS2- To Pump Regulator (Pump Control Circuit), Ride Control Valve (Ride Control Circuit (Option))

PP- To Loading Pilot Valve via Pilot Shut-Off Valve (Loading Circuit) PB- To Parking Brake (Parking Brake Circuit)

12- Parking Brake Solenoid Valve

14- Pump Torque Control Solenoid Valve

Charge Relief Valve

T3-7-4

SECTION 3 COMPONENT OPERATION Group 7 Charging Block DR

(ACCF)

(ACCR)

7 Cross Section V-V

Cross Section Z-Z S4

DR2

Adjust screw 14

Cross Section Y-Y

Cross Section U-U 17

7 12

Cross Section T-T

Cross Section X-X

13 11

Cross Section S-S

Cross Section W-W

3 90Z6-03-07-05

3479-

Brake Priority Valve Charge Relief Valve Check Valve Pilot Relief Valve

11121314-

Pilot Accumulator Parking Brake Solenoid Valve Check Valve Pump Torque Control Solenoid Valve

T3-7-5

15- Parking Brake 16- Service Brake Primary Pressure Sensor 17- Parking Brake Pressure Sensor

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Priority Valve The brake priority valve supplies pressurized oil from the pilot pump with priority to the service brake circuit, and delivers pressurized oil also to the other pilot circuits depending on the service brake accumulator pressure.

fNOTE: Refer to Section T2-4 Hydraulic System, Charging Circuit (Brake Priority Circuit).

Priority Valve Operation 1. Pressurized oil from pilot pressure port (P) applies on the both ends of the priority valve plunger (1). 2. When there is no pressure difference applied to plunger (1), plunger (1) does not move and the regulated amount of pressurized oil is supplied to each pilot circuit.

90Z6-03-07-06

3. When the service brake accumulator pressure reaches the set pressure (cut-out pressure), piston (3) of relief valve (2) pushes needle valve (4). 4. Passage (A) is connected so that pressurized oil in spring chamber (5) of plunger (1) flows to the hydraulic oil tank through port DR.

5. Pressure in spring chamber (5) decreases, and plunger (1) is moved left toward spring chamber (5). 6. Consequently, more pressurized oil in port P flows to the pilot circuit until the service brake is applied (the brake circuit pressure decreases).

7. When the brake circuit pressure decreases, spring (6) attached to needle valve (4) pushes back piston (3), the passage to port DR is closed and the pressure at the service brake accumulator port starts to increase again (cut-in pressure).

Cut-in Pressure: 11.8 MPa

90Z6-03-07-07

fNOTE: Cut-out Pressure: 14.7 MPa 123-

T3-7-6

Plunger Relief Valve Piston

45-

Needle Valve Spring Chamber

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Pilot Relief Valve The pilot relief valve keeps the pilot pump pressure to the specified set pressure during loading operation, and prevents damage to the piping and devices in the circuit. Relief Valve Operation

1. Pressurized oil from the pilot pump is supplied to each pilot circuit via the priority valve. (Refer to the previous section "Priority Valve".)

1 2

2. When the oil pressure in the pilot circuit reaches the set pressure by operating pilot actuators, such as the pilot valve, pressurized oil is applied to poppet (2) of pilot relief valve (1).

3. Poppet (2) moves to push spring (3) and the oil path to port DR is connected. 2

4. Pressurized oil in the pilot circuit returns to the hydraulic tank via port DR. The pilot circuit pressure is lowered, thus preventing the damage to the piping and devices in the circuit. 5. When the oil pressure in the pilot circuit becomes less than the set pressure, poppet (2) is returned by spring force, and the path to port DR is closed.

P 90Z6-03-07-08 12-

fNOTE: Set Pressure: 3.7 MPa (at 40 L/min)

T3-7-7

Pilot Relief Valve Poppet

Spring

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Parking Brake Solenoid Valve Pressurized oil from pilot pump is accumulated in pilot accumulator (1), and this pilot pressure is always applied to the outlet port of parking brake solenoid valve (2). When parking brake solenoid valve (2) is energized by turning ON the parking brake switch, the accumulated oil in pilot accumulator (1) enters the parking brake in the transmission through parking brake solenoid valve spool (7), and releases the parking brake.

fNOTE: The parking brake is the spring applied oil

pressure released type. Refer to Section T3-8 Drive Unit for the parking brake system.

fNOTE: Refer to p. T2-4-22 Parking Brake Circuit for the parking brake hydraulic operation.

Rear Chassis

6 3

5 2

12-

Pilot Accumulator Parking Brake Solenoid Valve

34-

Parking Brake Pressure Sensor Parking Brake

T3-7-8

56-

Charging Block Transmission

90Z6-03-07-11

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Solenoid Valve Operation

From parking brake (4)

To DR

 When parking brake solenoid is deenergized (parking brake SW: ON, parking brake is applied)

BLOCKED

1. Spool (7) is moved to the left by the spring (8) force. 2. Parking brake releasing pressure oil is blocked by spool (7) and is not supplied to parking brake (4).

3. Pressure oil in the parking brake returns to the hydraulic oil tank through parking brake solenoid valve (2).

From pilot accumulator (1)

90Z6-03-07-12

Pressure sensor (3) S3

 When parking brake solenoid is energized (parking brake SW: OFF, parking brake is released)

To parking brake (4) PB

OPEN

1. Spool (7) is moved to the right and compresses spring (8). 2. Parking brake oil flows through parking brake solenoid valve (2) to parking brake (4).

From pilot accumulator (1)

90Z6-03-07-13

4 9

5 3

7 Parking brake SW ON/OFF signal

8 90Z6-03-07-14

123-

Pilot Accumulator Parking Brake Solenoid Valve Parking Brake Pressure Sensor

456-

Parking Brake Charging Block Transmission

T3-7-9

789-

Spool Spring Pilot Pump

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Pump Torque Control Solenoid Valve

The pump torque control proportional solenoid valve controls the pilot pressure supplied to the main pump regulator for the pump delivery flow control.

DR2

Solenoid Valve Operation

X X

1. Spool (1) of the pump torque control solenoid valve is pressed by spring (2) when no activation signal is sent from Main Controller (MC).

DR2 OPEN

2. Pressurized oil from the pilot pump is supplied from port X of the charging block to port ST of the main pump regulator as torque control pressure.

90Z6-03-07-09 P

3. Torque control solenoid valve is activated by the signal from MC, and spool (1) moves in proportion to the electrical current flowing through solenoid (3).

Signal from MC

4. As spool (1) narrows the passage to port X, pressurized oil output from port X decreases.

DR2

5. When the signal from MC reaches the maximum level, spool (1) fully moves toward spring (2) and blocks the pilot pressure line. Port X and port DR2 are connected, and pilot pressure oil at port X drains to hydraulic tank.

DR2 BLOCKED

Signal

3 90Z6-03-07-10

12-

T3-7-10

Pilot Relief Valve Poppet

Spring

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Service Brake Accumulator Accumulator Specifications

Service brake accumulators (1) are installed in the accumulation circuit of charging block (2). High-pressure nitrogen gas is contained in the accumulator, and pressurized oil from the pilot pump compresses the nitrogen gas through the piston. The brake circuit pressure oil is retained by compression of the nitrogen gas.

Capacity Gas Charging Pressure Max. Operating Pressure

1.4 L 6.8 +0.2/-0.1 MPa 25 MPa

90Z6-03-07-15

T3-7-11

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Pilot Accumulator The pilot accumulator is installed in the circuit to the loading pilot valve. High-pressure nitrogen gas is contained in the accumulator, and pressurized oil from the accessory pump compresses the nitrogen gas through the diaphragm. The loading pilot circuit oil pressure is stored by compression of the nitrogen gas.

Accumulator Specifications Capacity Gas Charging Pressure Max. Operating Pressure

0.75 L 2.0 +/- 0.1 MPa 14 MPa

IMPORTANT: This accumulator cannot be disassembled. Replace the whole assembly, when needed.

90Z6-03-07-16

T3-7-12

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Service Brake Primary Pressure Sensor (Brake Pressure Alarm) When the service brake circuit (accumulator) pressure decreases to the abnormal level, the brake oil low pressure indicator turns ON. Pressure Sensor Specifications Rated Voltage Power Consumption Output Voltage Operation Pressure Withstanding Pressure

5.0 VDC Max. 10 mA 0.5~4.5 V 0~49 MPa 100 MPa (14504 PSI)

(V) Max.94%Vdd Vdd=5V

90Z6-03-07-17

Output Voltage

4.5

0.5 0

(MPa)

Pressure

90Z7-03-01-07

View A 12-

Ground Output

34-

Power Source (5V) Pressure Receiving Area (Diaphragm)

fNOTE: This sensor is identical to the secondary steering pump pressure sensor (option).

T3-7-13

90T157-02-03-10a

SECTION 3 COMPONENT OPERATION Group 7 Charging Block Parking Brake Pressure Sensor Pressure Sensor Specifications Rated Voltage Power Consumption Output Voltage Operation Pressure Withstanding Pressure

5.0 VDC Max. 10 mA 0.5~4.5 V 0~4.9 MPa (0~711 PSI) 6.9 MPa (1000 PSI)

(V)

Output Voltage

5 (4.5) (3.7) 3 2

90Z6-03-07-17

(1.3) (0.5) 0

(0.98)

(3.92)

(MPa)

Pressure (Calibration Point) 90Z7-03-07-02

4 35830-60130 12-

Ground Output (Vout)

34-

Power Supply (5V)(Vcc) Pressure Receiving Area (Diaphragm)

fNOTE: This sensor is identical to the pilot primary

pressure sensor installed to the pilot valve and the pilot secondary pressure sensor (option) installed to the multiple control valve.

T3-7-14

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Drive Unit Outline The selectable range drive unit consists of transmission (2) and torque converter (1). The selectable range drive unit is connected with the engine. The output power from the engine is transmitted to transmission (2) through the engine flywheel and torque converter (1). 1

3 d

90Z6-03-08-01

To Engine

To Main Pump

To Second Propeller Shaft

Torque Converter

Transmission

Transmission Control Valve

fNOTE: Refer to p.T1-2-11 for the main components of the drive unit.

T3-8-1

To Third Propeller Shaft

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Front View of Transmission

1 A

C 2 C

8 A 90Z6-03-08-02

f NOTE: See the next page for the cross section views. 123-

Breather Transmission Control Valve Oil Filler Port

456-

Charging Pump Torque Converter Output Speed Sensor Transmission Middle Shaft Speed Sensor

T3-8-2

78-

Machine Speed Sensor Front Output Flange (for Second Propeller Shaft)

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Cross Section View of Transmission

16 3

15 4

Cross Section B-B

11 10

9 17

18 8

Cross Section C-C

Cross Section A-A 90Z6-03-08-03

123456-

Charging Pump Main Pump Drive Shaft Forward Clutch Distributor Cap Parking Brake Front Output Flange (for Second Propeller Shaft)

789-

Output Shaft Drain Plug Rear Output Flange (for Third Propeller Shaft) 10- First & Second Speed Clutch 11- Distributor Cap 12- Idler Shaft

T3-8-3

131415161718-

Torque Converter Flexible Plate Center PTO Reverse Clutch Distributor Cap Third & Fourth Speed Clutch

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Rear View of Transmission 1

To T/C oil cooler

90Z6-03-08-04

Cross Section D-D

12-

Torque Converter Input Speed Sensor Suction Strainer

34-

Rear Output Flange (for Third Propeller Shaft) Safety Valve

T3-8-4

56-

Transmission Oil Temperature Sensor Port Torque Converter Output Pressure Port

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Side View of Transmission 2

4 5 6 7 8 9 10

90Z6-03-08-05

1234-

Regulator Valve Torque Converter Regulator Pressure Port Torque Converter Input Pressure Sensor Port Transmission Control Valve

56789-

Forward Clutch Pressure Sensor Port Reverse Clutch Pressure Sensor Port First Speed Clutch Pressure Sensor Port Second Speed Clutch Pressure Sensor Port Third Speed Clutch Pressure Sensor Port

T3-8-5

10111112-

Fourth Speed Clutch Pressure Sensor Port Parking Brake Release Pressure Inlet Parking Brake Pressure Port Suction Strainer

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Torque Converter A wet type torque converter with a flexible input plate is between the engine and transmission. The torque converter consists of pump impeller (2), turbine impeller (1), and stator (3), all in the casing filled with oil. The pump is connected to the engine flywheel, and rotates together with the engine. The turbine is connected to the torque converter output shaft to transmit the power to the transmission. Torque Converter Operation 1. Hydraulic oil is supplied from the charging pump to torque converter drive cover (6). 2. The area of the impellers is filled with oil. When the engine is started, pump impeller (2) rotates, therefore the oil will circulate to rotate turbine impeller (1) (circulation order: pump --> turbine --> stator --> pump). 3. Oil is redirected by fixed stator impeller (3) back to pump impeller (2). 4. When turbine impeller (1) rotates, the power will be transmitted to the output shaft (8). 5. If the engine speed/pump impeller speed stays the same, but the turbine impeller speed is reduced due to the transmission load, output torque is increased. This is "torque multiplication".

T3-8-6

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit

6 2

8 3 4 a

90T4GB-03-09-01K

Engine Side

Main Pump Side

123-

Turbine impeller Assy Pump Impeller Stator

456-

Stator Hub Flexible Plate Drive Cover

789-

T3-8-7

Stator Shaft Turbine Shaft Charging Pump Drive Gear

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Transmission The transmission is powered hydraulically by hydraulic engagement of speed and directional ranges. There are four clutch packs, and four forward speed shifts and four reverse speed shifts are available depending on the combination of the respective clutches. Two clutches must be engaged at the same time to move the machine. One is for direction, and the other is for speed. The input shaft has a gear to transmit torque to the forward or reverse clutch, then to the selected speed clutch gear through the idler gear. The speed clutch gear also transmits torque to the output gear by the low/high-range gear.

f NOTE: The spring applied oil pressure released type

parking brake is installed to the 1st and 2nd speed clutch shaft.

Transmission Gear Pattern (Viewed from Machine Front Side)

90T4GC-03-09-01

T3-8-8

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Number of Gear Teeth 6

5 17

18 1

4 2

9 10 13

14 12

No. 1 2 3 4 5 6 7 8 9

Gear name Input gear PTO drive gear Forward clutch gear Forward hub gear Reverse clutch gear Reverse hub gear Idler gear (for F/R gear) Idler gear (for speed gear) 2nd range hub gear

90Z6-03-08-14

Number of teeth

No.

Gear name

Number of teeth

38 72 38 41 38 41 37 27 42

10 11 12 13 14 15 16 17 18

1st range hub gear Low range gear 4th range hub gear 3rd range hub gear High range gear Output gear (for high range gear) Output gear (for low range gear) Charging pump drive gear Reverse idler gear

52 30 42 52 68 36 52 65 33

T3-8-9

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Clutch Pack A clutch shaft assembly consists of clurtch piston(s), gear(s), shaft, and some sets of clutch plates (friction disc, separation disc, and return spring). The gear of the input shaft transmits torque to the forward or reverse clutch, then to the selected speed clutch gear through the idler gear. The speed clutch gear also transmits torque to the output gear by the low/high-range gear. Speed Range Clutch Assy

A 3

2 1

17 16

A Detail

123456-

Plug Seal Ring Taper Roller Bearing Thrust Bearing Needle Bearing Spacer

90Z6-03-08-06

789101112-

Separation Disc Friction Disc Return Spring Thrust Bearing End Plate Retaining Ring

131415161718-

T3-8-10

Roller Bearing Shaft Orifice Hub Gear Clutch Piston Thrust Washer

1920212223-

Clutch Piston Hub Gear Bleed Valve D-Ring (Outer Seal Ring) D-Ring (Inner Seal Ring)

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Forward/Reverse Clutch Assy 11 17

3 T4GC-03-09-009

fNOTE: Hub gear (16) is the only difference between

the forward and reverse clutch assemblies. (The other components are identical.)

7 3

90Z6-03-08-07

123456-

Plug Seal Ring Taper Roller Bearing Thrust Bearing Needle Bearing Spacer

789101112-

Separation Disc Friction Disc Return Spring Thrust Bearing End Plate Retaining Ring

131415161718-

T3-8-11

Shaft Hub Gear Clutch Piston Thrust Washer

192021222324-

Bleed Valve D-Ring (Outer Seal Ring) D-Ring (Inner Seal Ring) Clutch Gear

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Clutch Pack Operation Clutch is operated by the pressurized oil from the transmission control valve.  In Operation 1. Pressurized oil transmitted from the transmission control valve enters chamber (A) behind piston (17) through the oil passage inside shaft (14). 2. Oil passage is blocked because the pressurized oil pushes the bleed valve (21) in piston (17), consequently presses piston (17) toward clutch discs (7, 8). 3. Piston (17) can transmit power by combining shaft (14) and hub gear (16) with compressed clutch discs (7, 8).

21 8

Pressurized Oil

Enlarged X

16 X

Oil from transmission control valve

T4GC-03-09-012

78-

Separation Disc Friction Disc

14- Shaft 16- Hub Gear

17- Clutch Piston 21- Bleed Valve

T3-8-12

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit  Not In Operation 1. When pressurized oil is not supplied from the transmission control valve, bleed valve (21) is opened by the centrifugal force of shaft (14), so the residual pressurized oil in piston (17) and others are discharged toward clutch discs (7, 8). 2. Piston (17) is pushed back by return spring (9) between clutch discs (7, 8), and this makes a clearance between clutch discs (7, 8). 3. Shaft (14) and clutch hub gear (16) rotate separately, and power is not transmitted.

Enlarged X

T4GC-03-09-013

78-

Separation Disc Friction Disc

9- Return Spring 14- Shaft

16- Hub Gear 17- Clutch Piston

T3-8-13

21- Bleed Valve

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Power Flow in Transmission Forward First Speed 3. Torque from F hub gear (4) is transmitted to 1st range hub gear (10) through F gear (3), idler gear for F/R gear (7), and idler gear for speed gear (8).

1. When first forward range is selected, the forward clutch and 1st and 2nd speed clutch are engaged. 2. Input torque from the torque converter enters input gear (1), and is transmitted to F hub gear (4).

4. Then, the torque is applied to output gear (16) through first range hub gear (10), and low-range gear (11).

90T4GC-03-09-15

Torque Transmission Drawing: Forward First Speed 13-

Input Gear Forward Gear

47-

F Hub Gear Idler Gear

8- Idler Gear 10- 1st Range Hub Gear

T3-8-14

11- Low Range Gear 16- Output Gear

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit

90T4GC-03-09-16

Gear Connection Drawing: Forward First Speed 13-

Input Gear Forward Gear

47-

F Hub Gear Idler Gear

8- Idler Gear 10- 1st Range Hub Gear

T3-8-15

11- Low Range Gear 16- Output Gear

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Forward Second Speed 1. When Second forward range is selected, the forward clutch and 1st and 2nd speed clutch are engaged. 2. Input torque from the torque converter enters input gear (1), and is transmitted to F hub gear (4). 3. Torque from F hub gear (4) is transmitted to 2nd range hub gear (9) through F gear (3), and idler gear (7). 4. Then, the torque is applied to output gear (16) through 2nd range hub gear (9), and low-range gear (11).

90T4GC-03-09-17

Torque Transmission Drawing: Forward Second Speed 13-

Input Gear Forward Gear

47-

F Hub Gear Idler Gear

9- 2nd Range Hub Gear 11- Low Range Gear

T3-8-16

16- Output Gear

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit

90T4GC-03-09-18

Gear Connection Drawing: Forward Second Speed 13-

Input Gear Forward Gear

47-

F Hub Gear Idler Gear

9- 2nd Range Hub Gear 11- Low Range Gear

T3-8-17

16- Output Gear

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Forward Third Speed 1. When third forward range is selected, the forward clutch and 3rd and 4th speed clutch are engaged. 2. Input torque from the torque converter enters input gear (1) and is transmitted to F hub gear (4). 3. Torque from F hub gear (4) is transmitted to 3rd range hub gear (13) through F gear (3), idler gear for F/R gear (7), and idler gear for speed clutch gear (8). 4. Then, the torque is applied to output gear (15) through 3rd range hub gear (13), and high-range gear (14).

90T4GC-03-09-19

Torque Transmission Drawing: Forward Third Speed 13-

Input Gear Forward Gear

47-

F Hub Gear Idler Gear

8- Idler Gear 13- 3rd Range Hub Gear

T3-8-18

14- High Range Gear 15- Output Gear

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit

Gear Connection Drawing: Forward Third Speed 13-

Input Gear Forward Gear

47-

F Hub Gear Idler Gear

8- Idler Gear 13- 3rd Range Hub Gear

T3-8-19

90T4GC-03-09-20

14- High Range Gear 15- Output Gear

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Forward Fourth Speed 1. When fourth forward range is selected, the forward clutch and 3rd and 4th speed clutch are engaged. 2. Input torque from the torque converter enters input gear (1) and is transmitted to F hub gear (4). 3. Torque from F hub gear (4) is transmitted to 4th range hub gear (12) through F gear (3) and idler gear (7). 4. Then, the torque is applied to output gear (15) through 4th range hub gear (12), and high-range gear (14).

90T4GC-03-09-21

Torque Transmission Drawing: Forward Fourth Speed 13-

Input Gear Forward Gear

47-

F Hub Gear Idler Gear

12- 4th Range Hub Gear 14- High Range Gear

T3-8-20

15- Output Gear

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit

90T4GC-03-09-22

Gear Connection Drawing: Forward Fourth Speed 13-

Input Gear Forward Gear

47-

F Hub Gear Idler Gear

12- 4th Range Hub Gear 14- High Range Gear

T3-8-21

15- Output Gear

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Reverse First Speed 1. When first reverse speed range is selected, the reverse clutch and 1st and 2nd speed clutch are engaged. 2. Input torque from the torque converter enters input gear (1), and is transmitted to R hub gear (6). 3. Torque from R hub gear (6) is transmitted to 1st range hub gear (10) through R gear (5), idler gear for F/R gear (7), and idler gear for speed gear (8). 4. Then, the torque is applied to output gear (16) through first range hub gear (10), and low-range gear (11).

90T4GC-03-09-23

Torque Transmission Drawing: Reverse First Speed 125-

Input Gear Reverse Idler Gear R Gear

678-

R Hub Gear Idler Gear Idler Gear

10- 1st Range Hub Gear 11- Low Range Gear 16- Output Gear

T3-8-22

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit

90T4GC-03-09-24

Gear Connection Drawing: Reverse First Speed 125-

Input Gear Reverse Idler Gear R Gear

678-

R Hub Gear Idler Gear Idler Gear

10- 1st Range Hub Gear 11- Low Range Gear 16- Output Gear

T3-8-23

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Transmission Control Valve Six proportional solenoid valves (1) direct oil to the respective clutch packs, and select or shift speed shift and forward/reverse travel direction. The Main Controller (MC) sends variable electric signals to proportional solenoid valves (1) for smooth clutch application. Six proportional solenoid valves (1) and spools (3) are identical to each other.

Damper valve (4) operates as an accumulator of the control circuit. Peak pressure is absorbed by damper valve (4) and smoothens the spool (3) movement. Damper valves (3) are all the same ones. When the machine moves, two clutch packs are engaged. The forward clutch, and reverse clutch are directional control packs, first speed clutch, second speed clutch, third speed clutch, and fourth speed clutch are speed control clutch packs.

 Proportional solenoid valve Y1 applies the forward clutch.  Proportional solenoid valve Y2 applies the reverse clutch.  Proportional solenoid valve Y3 applies the first speed clutch.  Proportional solenoid valve Y4 applies the second speed clutch.  Proportional solenoid valve Y5 applies the third speed clutch.  Proportional solenoid valve Y6 applies the fourth speed clutch.

90Z6-03-08-09

T3-8-24

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Transmission Control Valve Overview 2

From charging pump

90Z6-03-08-08 12-

Proportional Solenoid Valve Spring

34-

Spool Damper Valve (Piston with Spring)

T3-8-25

56-

Emergency Rod Filter

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Transmission Control Valve Operation (Modulation) Modulation mechanism prevents the shock at clutch engagement by varying the pressure increase/decrease wave in each clutch pack, depending on the machine condition, such as engine speed, machine speed, etc. 1. Main controller (MC) receives electrical signals from the engine speed sensor, machine speed sensor, and shift lever, to judge the machine condition. 2. MC sends electric signal to the desired proportional solenoid valve depending on the selected shift range. 3. Proportional solenoid valve regulates the oil pressure depending on the electrical signal from MC, and transfers oil to the modulation spool. 4. Modulation spool also regulates the clutch oil pressure depending on the oil pressure sent from the proportional solenoid valve, and transfers oil to the clutch piston.

Oil Pressure

Pressure decrease

A Pressure increase

Time T4GC-03-09-030

Transition point (When shifted)

T3-8-26

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit  In Neutral 1. Pressurized oil regulated by the regulator valve is sent to the oil passage (a) of the transmission control valve, and is distributed to proportional solenoid valve (1) via passage (b) and to modulation spool (2) via passage (c). 2. In neutral condition, the electrical signal from the Main Controller (MC) is not sent to proportional solenoid valve (1), and solenoid valve (1) blocks the oil path from passage (b) to passage (d). 3. Also, path from passage (c) to passage (e) connected to the clutch piston is blocked by spool (2), and the clutch pressure is not generated.

To clutch piston

c a

T4GC-03-09-031

From regulator valve

12-

Proportional Solenoid Valve Modulation Spool

T3-8-27

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit  Pressure Increase (Shift from Neutral to 2nd Speed) - In Process of Clutch Connection (Refer to Oil Pressure Wave Chart "A" on p. T3-8-26.) 1. When the transmission shift lever is moved, an electrical signal is sent from the Main Controller (MC) to proportional solenoid valve (1).

5. Oil transferred to the oil passage (e) enters chamber (g) of modulation spool (2), and is sent to back chamber (h) of the modulation spool (2).

2. While oil pressure is increasing (waveform A), the pressurized oil from passage (b) of proportional solenoid valve (1) is regulated in proportion to the amount of control current from MC, and is supplied to the oil passage (d).

6. Pressurized oil in chamber (h) with the force of modulation spring (3) of modulation spool (2) exceeds the oil pressure in passage (e), and modulation spool (2) moves right, closing oil passage (e) temporarily.

3. Pressurized oil transferred to oil passage (d) is transferred to pressure chamber (f ) of modulation spool (2), overcomes the force of modulation spring (3), and moves modulation spool (2) to the left.

7. Above steps 3. through 6. will repeat while the electric current from MC is becoming higher, thus the clutch oil pressure is gradually increased.

4. Oil is transferred from oil passage (c) to oil passage (e) connected to the clutch piston, and the clutch pressure is generated.

To 2nd speed clutch piston

c e

b From regulator valve

123-

Proportional Solenoid Valve Modulation Spool Modulation Spring

T3-8-28

T4GC-03-09-032

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit - End of Clutch Connection (Engaged 2nd Clutch Gear) (Refer to Oil Pressure Wave Chart "B" on p. T3-8-26.)

- Pressure Decrease (Shift Down from 2nd to 1st Speed)

fNOTE: Refer to "Pressure Increase" for the stage to shift

1. The pressure applied in chamber (f ) and chamber (h) become equal in the end of clutch connection.

up to the 1st speed clutch pressure.

1. Pressure decrease of the 2nd speed clutch pressure is operated in reverse of increasing stage, and the clutch pressure is gradually lowered by gradually lowering the electric signal (electrical current value).

2. As the spool diameter in pressure chamber (f ) is larger than that in chamber (h), pressure force is larger in chamber (h) and this tries to move modulation spool (2) to left.

2. By gradually lowering the 2nd speed clutch pressure while gradually raising the 1st speed clutch pressure, the pressure level is maintained. This eliminates torque loss at the time of shift down in digging, and achieves smooth operation.

3. When the pressure in chamber (f ) exceeds the pressure in chamber (h) combined with the spring force of spring (3), modulation spool (2) is pressed to the left end, fully opening the oil passage (c) to passage (e). 4. Consequently, the clutch pressure and the regulator pressure become equal and constant.

To 2nd speed clutch piston

c e

2 T4GC-03-09-033

123-

Proportional Solenoid Valve Modulation Spool Modulation Spring

T3-8-29

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Manual Operation Spool (for Emergency Travel) In case the solenoid valve cannot be operated due to electric troubles such as harness disconnection, the machine can be travelled in Forward 2nd or Reverse 2nd speed by manually operating the spool provided on the transmission control valve.

 Selecting Forward 2nd Speed 1. Push in emergency forward spool (3) and emergency 2nd speed spool (6) by 5 mm, and turn them 90 degrees, while keeping pushing them. 2. Regulated oil to the regulator pressure flows into passage (b) through passage (a) opened by the forward modulation spool, and flows to the forward clutch to connect the clutch.

IMPORTANT: This spool must be used for selftraveling of the machine to a safe place for repair only in an emergency case. Be sure to stop the engine before dCAUTION: using the manual spool. Operating the manual

3. Regulated oil also flows into oil passage (f ) through oil passage (e) opened by the 2nd modulation spool (7), and flows to the 2nd clutch to connect the clutch.

spool while the engine is running is dangerous because the machine starts moving.

4. Turn emergency forward spool (3) by 90 degrees, and the spool returns to the original position by the force of spring (1).

 Selecting Reverse 2nd Speed 1. Push in emergency reverse spool (5) and emergency 2nd speed spool (6) by 5 mm, and turn them 90 degrees, while keeping pushing them. 2. Regulated oil to the regulator pressure flows into oil passage (d) through oil passage (c) opened by the reverse modulation spool (4), and flows to the reverse clutch to connect the clutch. 3. Regulated oil also flows into oil passage (f ) through oil passage (e) opened by the 2nd modulation spool (7), and flows to the 2nd clutch to connect the clutch. IMPORTANT: Avoid simultaneous use of emergency forward spool (3) and emergency reverse spool (5). The clutch may be damaged.

T3-8-30

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit From regulator valve Forward Clutch

1 a

Reverse Clutch

2nd Speed Clutch

When Manual Spool Is Operated

From regulator To clutch valve

T4GC-03-09-034

123-

Modulation Spring Forward Modulation Spool Emergency Forward Spool

456-

Reverse Modulation Spool Emergency Reverse Spool Emergency 2nd Speed Spool

T3-8-31

2nd Speed Modulation Spool

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Clutch Solenoid Valve

Solenoid Valve Operation

Proportional solenoid valve is used as a pilot valve for the clutch oil pressure, and transfers oil to the modulation spool while raising or lowering the oil pressure according to the control signal from the Main Controller (MC).

 When solenoid is not energized (Neutral) Spool (1) is pushed to the right by spring (2), and outlet port S is connected with tank port T.  When solenoid is energized Solenoid valve (3) pushes spool (1) to the left with a force in proportion to the electric current flowing at the solenoid (3). Pilot pressure oil flows to output port S from port P, and the pressure at output port S increases. This pressure at port S works on the stepped part ‘a’ of spool (1). Stepped part ‘a’ has different sectional areas, which generates a force to push spool (1) to the right. When the pressure at output port S increases to make the pushing force to spool (1) to the right becomes larger than the force of solenoid (3) to push spool (1) to left, spool (1) is returned to the right, the passage between output port S and port P is blocked. The pressure at output port S stops increasing.

a 1

T107-02-07-005

Spool

Spring

T3-8-32

Solenoid

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Hydraulic Circuit

3 4th

3rd

2nd

1st

2 13

1 14

9 10 11

90Z6-03-08-12

1234-

Transmission Control Valve Proportional Solenoid Valve Emergency Spool Clutch

5678-

Spool Spring Damper Valve Regulator Valve

9- Oil Filter (On Machine) 10- Charging Pump 11- Torque Converter Safety Valve

T3-8-33

12- Torque Converter 13- Torque Converter Oil Cooler 14- T/M Bearing Lubrication

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Transmission Regulator Valve Transmission regulator valve (8) is a spring type spool valve, and controls the pressurized oil from the charging pump to be constant.

This valve supplies pressurized oil to transmission control valve (18) to operate the clutches. Oil not used for the control circuit flows to torque converter (7).

5 3 2

90Z6-03-08-09

90Z6-03-08-11

A T4GC-03-09-025

From charging pump

12-

Transmission Regulator Valve Transmission Control Valve

34-

Spool Piston

To torque converter

56-

T3-8-34

Spring Orifice

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Transmission Regulator Valve Operation  Normal Operation

 Overflow

1. Pressurized oil from the charging pump via port P goes through orifice (4) in spool (2) into chamber (5).

Excess oil goes through oil path within the transmission case to the torque converter.

2. When the oil pressure in chamber (5) increases above the set pressure by spring (1), spool (2) is shifted to the right, opens the port (A) to the torque converter, and excessive pressurized oil escapes to the torque converter. Accordingly, the flow rate entering the transmission control valve is adjusted. 3. Controlled pressurized oil from the charging pump via port P goes to the transmission control valve through the oil passage in the transmission case.

4 To transmission control valve

123-

Spring Spool Piston

Excess oil

45-

Orifice Chamber

T3-8-35

A To torque converter

Overflow

T4GC-03-09-026

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Parking Brake

Parking Brake Operation  When the parking brake is applied.

The parking brake is the spring applied oil pressure released type.

Brake discs (4) engage with the transmission shaft via disc hub (6), and separation discs (3) engages with brake housing (5).

Brake disc (friction plates) (4) and separation disc (steel plates) (3) are assembled in parking brake housing (5) and mounted to the 1st&2nd clutch shaft.

Turning on the parking switch turns off the solenoid valve for parking, drains the oil in the brake piston chamber, pushes piston (1) with spring (2). Piston (1) presses brake discs (4) and separation discs (3) each other, stops the rotation of brake discs (4), and makes the brake effective.

Number of disc Brake disc (4)

Separation disc (3)

EXP Spec.

EU Spec.

11  When the parking brake is released. Turning off the parking switch turns on the solenoid valve for parking. Pressurized oil flows into the piston chamber, pushes piston (1) overcoming spring force (2), and release the brake.

4 3

1 2

90Z6-03-08-10

123-

Brake Piston Spring (22 used) Separation Plate (Steel Plate) (7 used)

45-

Brake Disc (Friction Plate) (6 used) Housing

T3-8-36

Disc Hub (mounted to the 1st&2nd clutch gear)

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit Parking Brake Manual Release Sudden accidental movement of the dWARNING: machine could result in serious injury or death.

Before manually operating the parking brake solenoid:  Lower the lift arm and attachment to the ground.  Place chocks on both sides of the tires.  Be sure the machine is in neutral and engine is stopped.

If the parking brake cannot be released due to an engine or electrical problem, such as a failed parking brake solenoid valve coil or electrical circuit, perform the following operation.

1. Remove plug (3) from brake cover (2). 2. Disconnect the A-side of hose (4) from elbow adapter (5). Attach plug (3) on the A-side end of hose (4) to stop oil leak.

fNOTE: Prepare appropriate cloth for spilled oil. 3. Remove elbow adapter (5). 4. Loosen parking brake manual release bolt (6).

5. Insert bolt with flat washer (6) (excluding the nut) into plug hole (1). Tighten the bolt into the inside bolt hole.

1234-

6. When bolt (6) head touches brake cover (2), tighten bolt (6) further approx. two turns (approx. 2 to 3 mm) to release the parking brake.

T3-8-37

Bolt Brake Cover Plug Hose

4 56-

90Z6-03-08-13

Elbow Adapter Bolt for Parking Brake Manual Release

SECTION 3 COMPONENT OPERATION Group 8 Drive Unit (Blank)

T3-8-38

SECTION 3 COMPONENT OPERATION Group 9 Axle Outline Axle consists of differential (3), final drive (2), axle shaft (1), service brake (4), and other driveline parts.

Power from the transmission is transmitted to the front axle and the rear axle through the propeller shaft. Inside the axle, power is transmitted to differential (3), and divided to the left and right sides, and drives axle shaft (1) and the wheels through final drive planetary (2).

5 90T4GB-03-10-01

12-

Axle Shaft Final Drive

34-

Differential Service Brake

T3-9-1

Axle Oil Temperature Sensor

SECTION 3 COMPONENT OPERATION Group 9 Axle Differential The differential enables the left and right drive wheels to rotate at different speeds while steering and traveling on uneven surfaces.

90T4GB-03-10-02

123456-

Brake Ring Brake Disc Piston Side Gear (Bevel) Case A Ring Gear (Bevel)

789101112-

Pinion Gear (Bevel) Spider Case B Taper Roller Bearing Differential Body Gear & Shaft (Sun Gear)

131415161718-

T3-9-2

Adjusting Nut Bearing Retainer Pinion Shaft Taper Roller Bearing Bearing Cage Spacer

1920212223-

Taper Roller Bearing Oil Seal Flange Brake Retainer Planetary Carrier

SECTION 3 COMPONENT OPERATION Group 9 Axle Purpose of Differential 1. When the machine is steered, the inner wheel turns with a smaller radius, so the outer wheel needs to rotate faster for smooth steering. 2. Suppose driving the rear wheel by directly installing the gear to the propeller shaft with a shaft having no differential. 3. In this case, the outer wheel and the inner wheel rotate at the same rate. Therefore, when the machine is steered, the outer wheel cannot rotate more than the inner wheel. Consequently, axle strain, tire scuffing and wear takes place. In addition, due to axle shaft torsional stress and unstable transmission of drive force take place. 4. On the other hand, with a differential installed, the inner and the outer wheels can rotate at different speeds, and the problem mentioned above is eliminated.

c T202-03-05-005

Extension Line of Rear Wheel Centers

While Turning the Machine

T3-9-3

Traveling on Rough Surfaces

SECTION 3 COMPONENT OPERATION Group 9 Axle Principle of Differential Operation principle of the differential is explained here comparing it to the racks and the pinion gear in the drawing. W

1. When the load W is equally applied to rack A (1) and rack B (3), and if C is moved upward by the distance of H, rack A (1) and rack B (2) both move the same distance of H in unison with pinion (2).

W C

C H

2. If moved by removing the load from rack B (3), pinion (2) rotates on rack A (1) (with load applied) and moves upward.

3. Rack B (3) (with light load applied) moves upward by rotating pinion (2). 4. At this time, the distance that rack B (3) moves is longer than the distance that pinion (2) moves while rotating.

5. The distance that rack B (3) moves can be calculated using the equation of H+H=2H. This principle is applied to the differential.

2 T202-03-05-006

12-

T3-9-4

Rack A Pinion

Rack B

SECTION 3 COMPONENT OPERATION Group 9 Axle Operation of Differential Traveling Straight 1. In case resistances applied to axle shafts (1, 7) connected to side gear (2) by spline joint are the same or when the machine is traveling straight on a smooth flat surface, idle gear (4) does not rotate.

2. Idle gear (4) and side gear (2) are proportionally "geared together", and rotate in unison with half case (6) and half gear (3)which are connected to ring gear (8).

9 4

3. When the rate of movement of each wheel is identical on each side, the differential function of the differential does not need to work, but side gear (2), idle gear (4), and spider (5) play only the role of joints for connecting axle shafts (1, 7).

When Steering 4. When the machine turns, uneven distances are applied to the drive wheels. Therefore, idle gear (4) begins revolving on side gear (2) while rotating around spider (5) due to the difference of the distances applied to the left and right tires.

T202-03-05-007

5. Consequently, in case the resistance force applied to axle shaft (1) is great, idle gear (4) rotates in the same direction as the rotational direction on side gear (2). And the speed of axle shaft (1) is lowered and the amount of the speed reduction is applied to axle shaft (7), working the differential function. 6. Suppose ring gear (8) is driven by pinion shaft (9) at the speed of 100. In the condition that the vehicle body is traveling straight, the drive wheels on the both sides rotate at the same speed. 7. When the machine turns and the speed of the right drive wheel is lowered to 90, the left wheel turns at the speed of 100+(100-90)=110 as the speed of 10 (100-90=10) is added to the speed of the left wheel.

8. If ring gear (8) rotates at the speed of 100, the summation of the speeds of the left and right wheels becomes always 200 regardless of movement of the respective wheels.

T3-9-5

9 4

2 6

T202-03-05-008

SECTION 3 COMPONENT OPERATION Group 9 Axle Torque Proportioning Differential (TPD) A wheel loader is operated mostly on rough surfaces. With scuffing of tires, working efficiency and tire life is lessened. In order to avoid loss of working efficiency and tire life, the axle is provided with the torque proportioning differential. Differential pinion gear (2) of the torque proportioning differential has an odd number of teeth, and differential pinion gear (2) and side gears (1, 3) have special teeth in shape. If the surface resistance values of the right and left wheels differ from each other, engagement position of pinion gear (2) with left and right side gears (1, 3) will be automatically shifted to transmit different torque, to the left and right wheels. Different torque in right and left wheels prevents the tires from slipping.

Forward Rotation

12-

Left Side Gear Differential Pinion Gear

Right Side Gear

T3-9-6

T487-03-06-015

SECTION 3 COMPONENT OPERATION Group 9 Axle Traveling Straight with the Same Road Resistances to Left and Right Tires

1. In case resistances to the left and right tires are the same, distance a and distance b from differential pinion gear (2) center to the respective contact points of left and right side gears (1, 3) are the same.

2. Therefore, differential pinion gear (2) and left and right side gears (1, 3) solidly rotate toward forward, and the drive forces of the left and right tires are the same. T487-03-06-016

Traveling on Soft Roads (Different Road Resistances to Left and Right Tires) 1. While traveling on soft roads, if the left tire slips, left side gear (1) on the left tire receiving little resistance tends to rotate more forward than right side gear (3). 2. This rotation causes deviation of the contact points of differential pinion gear (2) and left and right side gears (1, 3) in the torque proportioning differential.

3. When left side gear (1) rotates slightly more forward than right side gear (3), distance a of the contact point of differential pinion gear (2) and left side gear (1) is longer than distance b of right side gear (3). Correlation of the forces at this time is as follows. T487-03-06-017

a × TA (force applied to left side gear (1)) = b × TB (force applied to right side gear (3)) 4. Until the difference of the road resistances exceeds the certain value, differential pinion gear (2) does not rotate, but left and right side gears (1, 3) rotate at the same speed solidly. 5. Besides, the left tire does not rotate redundantly and does not slip. (The right tire can have drive force larger than the left tire.) 6. Therefore, tire life is prolonged, and working efficiency is improved.

T3-9-7

SECTION 3 COMPONENT OPERATION Group 9 Axle Limited Slip Differential (LSD) (Option) LSD is so constructed so that clutch disc (5) is inserted between pressure ring (2) supporting spider (8) with the cam and case (6), which increases restriction of different movement and assists to keep the left and right side tire speeds close to the same. In addition, the left to right tractive ratio is better for traction than the TPD style differentials.

A wheel loader, as required by the kind of work, must be operated in places where skidding takes place easily like sand and muddy soil. In places like these, tires can slip even if the torque proportioning differential (TPD) is installed. Rotation is transmitted to the slipping tire, but not to the tires contacting the earth, so not only is the function of the wheel loader worsened, but the tire lives are shortened. To avoid this, a limited slip differential (LSD) (equipped with a differential and axle shaft movement restriction device) can be provided to help avoid loose movement of one side of the axle, and provide more stable tractive conditions. Drive force between the left and right side is more stable.

1 2 3

4 5 6 8

T4GB-03-10-003 12-

Ring Gear Pressure Ring

34-

Side Gear Pressure Plates

56-

T3-9-8

Clutch Discs Case

78-

Pinion Gear Spider

SECTION 3 COMPONENT OPERATION Group 9 Axle Traveling Straight with the Same Road Resistances to Left and Right Tires 1. As the differential pinion gear and the left and right pinion gears rotate together simultaneously, the drive forces of the left and right tires are the same, similar to the TPD. Traveling on Soft Roads (Different Road Resistances to Left and Right Tires)

1. Drive force is transmitted to the case, pressure ring (2), and spider (8) through the ring gear.

2. At this time, spider (8) having the cam construction pushes pressure ring (2) toward the case with thrust P. 8

3. Clutch disc (5) is geared with the case through pressure ring (2).

Thrust "P"

4. Side gears connected to clutch disc (5) by spline joint rotate solidly with the case, and the left and right side gears rotate at the same speed. 5. Therefore, the left and right axle shafts connected to the side gears by spline joint tend to rotate solidly, together with the case, and the differential movement restriction works, resulting in better overall traction and less tire slippage.

2 T4GB-03-10-004

24-

6. When the drive force provided for the skidding tire is greater than the road resistance, part of the torque of the skidding tire is added to the tire contacting the road by the differential movement restriction (because of the same rotation speed of the left and right tires), and the tire contacting the road is provided with more torque. 7. Until the difference of the resistances between the left and right tires exceeds the clutch friction gripping value (until the clutch disc begins to slip), the left and right gears solidly turn together at a constant speed. 8. On such soft roads, the drive force increases by 1.5 times the value for the TPD if the LSD is provided.

T3-9-9

Pressure Ring Pressure Plates

58-

Clutch Discs Spider

SECTION 3 COMPONENT OPERATION Group 9 Axle Service Brake The type of service brake used is a wet-type multi-disc brake and is assembled in the differential housing of the axle. All four wheels are equipped with wet disc brakes.  When brake is released 1. Pressure from the brake valve is reduced, brake piston (5) is returned by return spring (6).

When brake is applied 1. Pressure from the brake valve works on the back of brake piston (5) and moves brake piston (5), so that brake friction disc (3) and brake plate (2) are compressed.

2. Brake friction disc (3) is released and machine brakes are released.

2. The inner surface of brake disc (3) is splined to shaft (8) through disk hub (7). 3. In addition, the outer surface of brake plate (2) is fixed to differential body (4). 4. Therefore, the rotation of applied and compressed brake disc (3) stops, slowing the machine.

90T4GB-03-10-05

Pressurized Oil From Brake Valve

Return Spring Force

12-

End Plate Brake Plates

34-

Brake Discs Differential Body

56-

T3-9-10

Brake Piston Return Spring

78-

Disc Hub Shaft

SECTION 3 COMPONENT OPERATION Group 9 Axle Final Drive Planetary / Axle Shaft Final planetary drive (2) is used for gear reduction, to increase of drive output torque to the wheels in the power transmission. The power from the differential is transmitted from shaft (7) and rotates three planetary gears (4) at ring gear (3). The rotation of planetary gear (4) is transmitted to axle shaft (1) through planetary carrier (5).

90T4GB-03-10-06

123-

Axle Shaft Final Drive Ring Gear

456-

Planetary Gear Planetary Carrier Roller Bearing

789-

T3-9-11

Shaft O-Ring Retainer

10- Floating Seal 11- Taper Roller Bearing 12- Housing

SECTION 3 COMPONENT OPERATION Group 9 Axle (Blank)

T3-9-12

SECTION 3 COMPONENT OPERATION Group 10 Brake Valve Outline Brake valve (2) supplies brake pressure in proportion to the position of brake pedal (1). The oil is supplied to the front and rear axle service brakes in proportion to the brake pedal (1) depressing amount. (Refer to SYSTEM / Hydraulic System.)

4 2

90Z6-03-10-01 12-

Brake Pedal Brake Valve

Pressure Switch (For Stop Lamp)

T3-10-1

Pressure Sensor (Brake Secondary Pressure Sensor, For Declutch)

SECTION 3 COMPONENT OPERATION Group 10 Brake Valve Brake Valve Component Layout

1 2

3 4 5

6 A

Pressure switch port PA

Pressure sensor port

B PB

11 12

13 14

90Z6-03-10-03

SWA

SWB

A- To Front Axle B- To Rear Axle TA- To Hydraulic Tank

PA- From Charging Block (Port MF) PB- From Charging Block (Port MR)

9101112-

13- Spool Return Spring 14- Pressure Switch 15- Pressure Sensor

13 90Z6-03-10-02

1234-

Input Spool Spring Seat Spring Spring

5678-

Spring Bolt Spring Retainer Spool

T3-10-2

Plunger Balance Spring Spool Plunger

SECTION 3 COMPONENT OPERATION Group 10 Brake Valve Operation While the valve is not operating 1. Between input spool (1) and spools (8, 11) in the brake valve, springs (4, 5) which convert pedal pressing force into output oil pressure is installed. 2. In addition, two spools (8, 11) are installed for series in the center of the main body of the brake valve. Plungers (9, 12) which transmit the control oil pressure to spool as the hydraulic reactive force are built in each spool. 3. While the valve is not operating, each spool is returned to the non-operation position by springs (10, 13). 4. As a result, the passages from out-ports A, B, and the pressure sensor port to tank port (T) are opened, and the pressure inside the brake piston chamber becomes equivalent to the pressure in the tank.

1 T

5. In addition, oil sent from the pump is stored in the accumulator, and sent to the in-ports PA and PB. But the passages from in-ports PA, PB to out-ports A, B and pressure sensor port are shut down by each spool (8, 11), and high pressure oil from the accumulator is maintained.

5 8

A PA

B PB

12 90Z7BT03-10-03

14589-

Input Spool Spring Spring Spool Plunger

10111213-

Balance Spring Spool Plunger Spool Return Spring

fNOTE: This illustration is for the explanation purpose

only. Refer to page T3-10-2 for the actual valve internal construction.

T3-10-3

SECTION 3 COMPONENT OPERATION Group 10 Brake Valve While the valve is operating 1. When the brake pedal is pressed, input spool (1) is pushed by way of roller (14). 2. Input spool (1) lets each spool (8, 11) drop down by way of springs (4, 5). When spools (8, 11) are pushed down, at first the passage from out-port A, B, and pressure sensor port to tank port (T) are shut down. 14

3. When spools (8, 11) are further pushed down, the passages from in-ports PA, PB to out-ports A, B are opened and pressure oil from the accumulator is sent to the brake piston chamber to apply the brake. 4. Pressure oil of in-ports PA, PB side act on plungers (9, 12) inside each spool (8, 11) through the orifices and works as the hydraulic reactive force to return spools (8, 11) upward.

1 T

5. When the sum of hydraulic reactive force and the load of springs (10, 13) become balanced with those of springs (4, 5), it returns spools (8, 11) to shut down the passages PA-A and PB-B to hold the pressure.

4 5

8 A PA

6. By this operation, the load of springs (3, 4, 5) by deflection are transmitted to the operator as pedal pressing force and the pressure in proportion to the pedal pressing force is obtained.

12 13 90Z7BT03-10-05 134589-

Input Spool Spring Spring Spring Spool Plunger

1011121314-

Balance Spring Spool Plunger Spool Return Spring Roller

fNOTE: This illustration is for the explanation purpose

only. Refer to page T3-10-2 for the actual valve internal construction.

T3-10-4

SECTION 3 COMPONENT OPERATION Group 10 Brake Valve While the valve is releasing 1. When the brake pedal is released, input spool (1) is pushed back by spring (3). Compressed springs (4, 5) are extended, and spools (8, 11) are returned upward to the non-operation position by the sum of hydraulic reactive force and the load of springs (10, 13). 2. After the passages from out-ports A, B and pressure sensor port to in-ports PA, PB is shut down by spools (8, 11), the pressure of out-ports A, B and pressure sensor port is opened to tank port T, and then the brake operation is released.

1 T

3 4 5

A PA

B PB

12 90Z7BT03-10-04

134589-

Input Spool Spring Spring Spring Spool Plunger

1011121314-

Balance Spring Spool Plunger Spool Return Spring Roller

fNOTE: This illustration is for the explanation purpose

only. Refer to page T3-10-2 for the actual valve internal construction.

T3-10-5

SECTION 3 COMPONENT OPERATION Group 10 Brake Valve Pressure Switch (for Stop Lamp) Pressure Switch Specifications Contact Operating Pressure Return Pressure Rated Voltage Power Consumption

Normal Open 0.25 MPa (36.3 PSI) 0.23 MPa (33.4 PSI) 24 VDC 0.520A or less

1 2

PB 90Z6T1-2-17

35047-60790 SWA

SWB

F-

To Front Axle

123-

Pressure Switch (For Stop Lamp) Pressure Sensor (For Declutch) Brake Valve Assy

T3-10-6

R-

To Rear Axle

90Z6-03-10-02

SECTION 3 COMPONENT OPERATION Group 10 Brake Valve Pressure Sensor (Service Brake Secondary Pressure for Declutch) 1

Pressure Sensor Specifications Rated Voltage Power Consumption Output Current Operating Pressure Withstanding Pressure

5.0 VDC Max. 10 mA Max. 1.5 mA 0~5.4 MPa Max. 7 MPa

Arrow View A 35830-60140 12-

GND Output (Vout)

Power Supply (5V)(Vdd)

(V) 5 (4.5)

Output Voltage

(3.7) 3 2 (1.3)

(1.08)

Pressure

T3-10-7

(4.31)

5.4

(MPa) K80V2U52004 (Calibration Point)

SECTION 3 COMPONENT OPERATION Group 10 Brake Valve (Blank)

T3-10-8

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Ride Control Valve (Option) Outline Ride control valve (1) (option) is installed in the front chassis near the multiple control valve. Ride control makes the machine travel stable by reducing the force generated in the lift arm cylinder when driving on rough surface.

Overview Ride control valve (1) consists of ride control solenoid valve (3), ride control spool (8), charge-cut spool (7), and overload relief valve (9). (Refer to SYSTEM / Hydraulic System.)

90Z6-03-11-01

11 9

TNDB-03-12-001

Ride Control Valve

Ride Control Solenoid Valve

T3-11-1

Overload Relief Valve

11- Drain Plug

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Ride Control Hydraulic Circuit Diagram

1 3

A1 B1

9 5

10 6 8

A1- Lift Arm Cylinder Bottom Side Circuit B1- Lift Arm Cylinder Rod Side Circuit

1234-

5678-

Ride Control Valve Ride Control Accumulator Ride Control Solenoid Valve Lift Arm Cylinder

A-

90Z6-03-11-02

ON Signal from Main Controller (MC) Port A (from Lift Arm Cylinder Bottom Side)

B-

Pilot Pump Hydraulic Oil Tank Charge-Cut Spool Ride Control Spool

9- Overload Relief Valve 10- Orifice 11- Drain Plug

Pi-

T3-11-2

Port B (to Lift Arm Cylinder Rod Side) Port Pi (Pilot Pressure Oil)

SP2- Port SP2 (to Ride Control Accumulator) T- Port T (to Hydraulic Oil Tank)

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Ride Control Valve Layout 1

PS2

9 b

a A

Section a-a

TNDB-03-12-001

Section b-b

PS2

PS2 A T TNDB-03-12-003

T3-11-3

T T4GD-03-08-001

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Ride Control Operation 1. When the ride control is not activated, the oil passage between port Pi and output port (2) is blocked by spool (3) in ride control solenoid valve (4). 2. When the conditions for ride control exist, the ON signal from Main Controller (MC) excites the solenoid in ride control solenoid valve (4) and spool (3) moves right. 3. Therefore, the oil passage between port Pi and output port (2) is opened. 4. Pilot pressure oil from port Pi flows to output port (2) through spool (3) in ride control solenoid valve (4). 5. When the pressure in output port (2) exceeds the spring (7) force, ride control spool (1) moves right (to the spring (7) side). 6. Therefore, the circuit between port A (the bottom side of lift arm cylinder) and port PS2 (the ride control accumulator) is connected. 7. At the same time, the circuit between port B (the rod side of lift arm cylinder) and port T (hydraulic oil tank) is connected. 8. Consequently, when the force pushing down the lift arm cylinder occurs, the circuit pressure increases and this pressure is reduced by accumulator (6). 9. In addition, the negative pressure in the circuit due to the force pushing down the lift arm is canceled by drawing hydraulic oil supplied from port T.

T3-11-4

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device

PS2

3 2 7

A-

123-

Port A (from Lift Arm Cylinder Bottom Side)

Ride Control Spool Output Port Spool

B-

Pi-

Port B (to Lift Arm Cylinder Rod Side) Port Pi (Pilot Pressure Oil)

PS2- Port PS2 (to Ride Control Accumulator) T- Port T (to Hydraulic Oil Tank)

456-

Ride Control Solenoid Valve Pilot Pump Ride Control Accumulator

78-

T3-11-5

Spring Hydraulic Oil Tank

TNDB-03-12-006

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Charge-Cut Spool Charge-cut spool (3) makes the ride control accumulator accumulate pressurized oil up to the set pressure. 1. When the ride control is not activated, pressurized oil from the lift arm cylinder bottom side flows to port X through port A and orifice (1). 2. Pressurized oil from port X flows through chargecut spool (3), pushes to open check valve (2), and flows to port Y. 3. Pressurized oil from port Y flows to ride control accumulator and is accumulated. 4. As sectional area M (5) of charge-cut spool (3) is larger than sectional area N (6) and when the ride control accumulator pressure is accumulated to the set pressure, pressurized oil in port X pushes charge-cut spool (3) to the spring (4) side. 5. As charge-cut spool (3) moves to the spring (4) side, the oil passage between port X and port Y is closed. 6. Therefore, pressurized oil is stopped accumulating in the ride control accumulator.

T3-11-6

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device When accumulating accumulator pressure 1

PS2

T4GB-03-08-007

After accumulating accumulator pressure

To Ride Control Accumulator

A-

Port A (from Lift Arm Cylinder Bottom Side)

XY-

Port X Port Y

12-

Orifice Check Valve

34-

Charge-Cut Spool Spring

56-

Sectional Area M Sectional Area N

T3-11-7

T4GB-03-08-008

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Overload Relief Valve The overload relief valve prevents the hoses and the ride control accumulator from being damaged in case pressure in the bottom side circuit of the lift arm cylinder is suddenly raised by an external force or something during operation of the lift arm cylinder. Relief Operation 1. Pressure in port HP (actuator circuit) is routed to pilot poppet (8) through orifice A (2) in main poppet (1) and orifice B (3) in seat (4). 2. When pressure in port HP reaches the set force of spring B (6), pilot poppet (8) is opened and pressurized oil flows to port LP (the hydraulic oil tank) through passage A (5) and the periphery of sleeve (11). 3. At this time, a pressure difference is caused between port HP and spring chamber (10) due to orifice A (2). 4. When this pressure difference reaches the set pressure of spring A (9), main poppet (1) is opened and pressurized oil from port HP flows to port LP. 5. Consequently, the actuator circuit pressure decreases. 6. When the actuator circuit pressure decreases to the specified pressure, main poppet (1) is closed by the force of spring A (9).

T3-11-8

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Normal Operation: 12

T176-03-03-012

Relief Operation: 1

HP- Actuator Circuit

LP- Hydraulic Oil Tank

123-

456-

Main Poppet Orifice A Orifice B

Seat Passage A Spring B

8- Pilot Poppet 9- Spring A 10- Spring Chamber

T3-11-9

T176-03-03-013

11- Sleeve 12- Spring C 13- Make-Up Valve

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Make-Up Operation 1. When pressure in port HP (actuator circuit) decreases lower than pressure in port LP (hydraulic oil tank), make-up valve (13) moves left. 2. Hydraulic oil in port LP flows to port HP and cavitation is prevented. 3. When pressure in the port HP side increases to the specified pressure, make-up valve (13) is closed by the force of spring C (12).

TNDB-03-12-013

HP- Actuator Circuit

LP- Hydraulic Oil Tank

12- Spring C

13- Make-Up Valve

T3-11-10

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Drain Plug The ride control valve is provided with drain plug (2) in order to return pressurized oil of the ride control accumulator to hydraulic oil tank (4) at the time of maintenance or something. Pressurized oil from the ride control accumulator flows to hydraulic oil tank (4) by loosening drain plug (2). Therefore, the pressure of ride control accumulator decreases. Do not loosen drain plug (2) too much dCAUTION: as pressurized oil may spout out due to removal of drain plug (2). Do not loosen drain plug (2) more than 2 turns.

1 2 3

From Ride Control Accumulator

12-

Lock Nut Drain Plug

34-

Overload Relief Valve Hydraulic Oil Tank

T3-11-11

TNDB-03-12-010

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Ride Control Accumulator (Option) The ride control accumulator is installed in the ride control accumulation circuit. High-pressure nitrogen gas is contained in the accumulator, and pressurized oil compresses the nitrogen gas through the piston. The ride control system permits the base end of the lift arm cylinders to work the oil against the piston inside the nitrogen gas oil accumulator. This reduces fore and aft pitching of the machine. Ride Control Accumulator Specifications Maximum operating pressure N2 gas charging pressure N2 gas capacity

35 MPa 3 MPa 5L

90Z6-03-11-03

90Z6-03-11-04

T3-11-12

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Lift Arm Raise Pressure Sensor (Option) The pressure sensor to monitor the lift arm raise pilot pressure is additionally installed to the multiple control valve. This sensor is identical to the pilot pressure sensor.

fNOTE: Refer to p.T3-6-7 for the sensor specifications.

90Z6T1-2-20

T3-11-13

SECTION 3 COMPONENT OPERATION Group 11 Ride Control Device Lift Arm Angle Sensor (Option) The angle sensor to detect the lift arm angle is installed to the front chassis for the upper/lower kickout function.

fNOTE: This sensor cannot be installed when the lift arm kickout proximity switch.

1 1 90Z6-03-11-05

Position Sensor

Lever

3 90Z6-03-11-06

T3-11-14

Position Sensor Key

SECTION 3 COMPONENT OPERATION Group 12 Others Propeller Shaft Propeller shafts are installed between the transmission and the front axle, and between the transmission and the rear axle, respectively. Propeller shafts transmit the power from the transmission to the front axle and the rear axle. This uses a universal joint (1) and slip joint type spline shaft as shown in the illustration.

fNOTE: The transmission output shaft flanges are fixed type for both 2nd and 3rd propeller shaft connection.

2 3

5 90Z6-03-12-01

12-

Front Axle Second Propeller Shaft

34-

Transmission Assy Third Propeller Shaft

T3-12-1

Rear Axle

SECTION 3 COMPONENT OPERATION Group 12 Others 2nd Propeller Shaft (Between Front Axle and Transmission)

90Z6-03-12-02

3rd Propeller Shaft (Between Transmission and Rear Axle) 1

1 2

A 45°

A Arrow View A

90Z6-03-12-03 1-

Universal Joint

Grease Nipple

T3-12-2

Pillow Unit

SECTION 3 COMPONENT OPERATION Group 12 Others Stop Valve A stop valve is provided to reduce the impact caused to the chassis steering stopper block when the machine is making a full turn while the hydraulic pressure of the steering cylinder is still working.

To Steering Valve

From Orbitrol (Steering Pilot Valve)

2 B

Stop Valve Operation Shortly before a full turn, the stopper installed on the front chassis pushes the spool of the stop valve installed on the rear chassis to shut down the port A and the port B. As a result, the pilot line is closed, returning the steering valve spool to the neutral position. After a full turn, when the steering wheel is turned in the opposite direction, the spool of the stop valve remains pushed in, closing the line. As a result, the pilot oil opens the check valve and flows out.

16±0.5 mm

Installed on front chassis

Installed on rear chassis 90V2U42003

From Orbitrol

(Full stroke)

97ZV42042

A B

To Steering Valve

11 1234-

Stopper Spool Check valve Plug

10 5678-

Washer Plug Flange Spring

4 9101112-

T3-12-3

Spring Spacer Boot U-packing

95V2E42038 13- Dust seal 14- O-ring

SECTION 3 COMPONENT OPERATION Group 12 Others Secondary Steering Pump The secondary steering pump is used when the oil from the main pump is suddenly stopped. The secondary steering pump supplies pressure to the steering valve to permit the machine to move to a safe place.

The secondary steering pump consists of gear pump (2), electric motor (3), magnetic switch (4), and relief valve (1).

85V2E42052-Z7

Relief Valve

Gear Pump

fNOTE: Secondary steering is an optional equipment for EXP. Spec. machines (S/N 0101~).

T3-12-4

Electric Motor

Magnetic Switch

SECTION 3 COMPONENT OPERATION Group 12 Others Secondary Steering Check Block The secondary steering check block is installed between the main pump and the steering valve. Built-in check valve is provided to prevent delivery oil of the secondary steering pump from flowing to the main pump.

B X-X

Check Valve A

D Y-Y A

C E

E X

T4GB-03-12-007-KC

AB-

From Main Pump From Secondary Steering Pump

CD-

Pressure Switch Mounting Port To Steering Valve

T3-12-5

E-

To Hydraulic Tank

SECTION 3 COMPONENT OPERATION Group 12 Others Axle Oil Cooler (Option) The axle oil cooler system has two electric cooling fans (1, 2), mounted on the optional fender on the right hand side of hydraulic oil tank.

The hydraulic system is driven by the fan pump and controlled by the oil cooler pump.

Axle Oil Cooler Hydraulic System

Hydraulic oil tank

2 3

Fender assy

Fan motor

Hydraulic oil tank Engine

Fan valve for reversing fan (opt)

7 6

7 90Z6-03-12-05

123-

Axle Oil Cooler Fan (for Front Axle) Axle Oil Cooler Fan (for Rear Axle) Front Axle

45-

Rear Axle Oil Filter Assembly (machine RH side)

67-

T3-12-6

Axle Oil Cooler Pump Unit (machine RH side) Pilot Gear Pump

SECTION 3 COMPONENT OPERATION Group 12 Others Axle Oil Cooler Hydraulic Circuit Diagram 10

8 OUT2

OUT1

To fan motor, or fan valve (opt)

90Z6-03-12-06 1234-

Axle Oil Cooler (for Front Axle) Axle Oil Cooler (for Rear Axle) Front Axle Rear Axle

567-

Oil Filter Assembly Axle Oil Cooler Pump Unit (5.7 cm3/rev x 3) Fan Pump (52.2 cm3/rev)

8- Reducing Valve * 9- Flow Control Valve * 10- Check Valve *

fNOTE: * See the following page for locations.

Fan Pump for Axle Oil Cooler Fan pump (7) for the axle oil cooler (option) has two output ports to axle oil cooler pump (6) (OUT2), and to the fan motor or optional fan valve (OUT1). The theoretical displacement volume increases to 52.2 cm3/rev (Standard fan pump: 44.5 cm3/rev).

fNOTE: Refer to Group 3 for the standard fan pump. OUT1

OUT2 90Z6-03-12-10

T3-12-7

SECTION 3 COMPONENT OPERATION Group 12 Others Axle Oil Cooler Major Components

Hydraulic oil tank

2 1

T/C oil filter

5 6

Arrow View A

8 10 90Z6-03-12-04

1234-

Axle Oil Cooler Fan (for Front Axle) Axle Oil Cooler Fan (for Rear Axle) Front Axle Rear Axle

567-

Oil Filter Assembly Axle Oil Cooler Pump Unit -

T3-12-8

8- Reducing Valve 9- Flow Control Valve 10- Check Valve

SECTION 3 COMPONENT OPERATION Group 12 Others Oil Cooler Fan

AIR

b 2 1

95Z7-03-10-13 a-

From Pump

To Axle

Fan

Radiator

Fan Motor Specifications Supply Voltage Input Rated Current Operating Temperature

DC 24 V 76.8 W 3.2 A -25 ~ +45 °C (-13 ~ +113 °F)

T3-12-9

SECTION 3 COMPONENT OPERATION Group 12 Others Oil Filter Assembly

a c 2

90Z6-03-12-08

To Pump

From Front Axle

Front Axle Oil Filter

Rear Axle Oil Filter

From Rear Axle

The filter element filtrates 105 µm or larger particles.

T3-12-10

SECTION 3 COMPONENT OPERATION Group 12 Others Oil Pump Assembly To Oil Cooler To Oil Cooler (Rear) (Front)

From Fan Pump

From Rear Oil Filter From Front Oil Filter

Reducing Valve

90Z6-03-12-07

Flow Control Valve

Pump Specifications Theoretical displacement Motor flow (Max) Working pressure (Max.) Pump relief valve set pressure

Pump Section (Filter – Cooler) x 2 5.7 cm3 (0.35 in3)/rev 19.0 MPa (Outlet) 0.8 MPa (116 PSI)

T3-12-11

Motor Section 5.7 cm3 (0.35 in3)/rev 27.4 L (7.2 gallon)/min (Inlet) 13.7 MPa (Inlet) -

SECTION 3 COMPONENT OPERATION Group 12 Others Axle Oil Cooler Electrical System Fuse Box A A12: 20A (for option power ACC1)

5 A

7, 8

A-A

1 2

6 8

90Z6-03-12-09

123-

Cable Assy 1 Cable Assy 2 To Main Controller (MC)

456-

Oil Cooler Fan Motor (for Rear Axle) Oil Cooler Fan Motor (for Front Axle) Relay

T3-12-12

78-

Power Supply (ACC) Power Supply (Auxiliary)

INDEX 2nd Propeller Shaft.................................................................T3-12-2 3rd Propeller Shaft..................................................................T3-12-2 A Accelerator Pedal Control....................................................... T2-2-6 Accessory Circuit.....................................................................T2-5-19 Accessory Circuit (Key Switch: ACC)................................... T2-5-6 Accumulator Pilot.........................................................................................T3-7-12 Ride Control (Option).................................................... T3-11-12 Service Brake.......................................................................T3-7-11 Steering................................................................................... T3-5-9 Accumulator Specifications .............................................. T3-5-9, T3-7-11, T3-7-12, T3-11-12 Auto-Warm Up Control........................................................... T2-2-8 Auto Leveler Height Kickout Control (Option)..............T2-2-64 Auto Leveler Lower Kickout Control (Option)...............T2-2-66 Automatic Speed Shift Control..........................................T2-2-36 Auxiliary Pilot Valve (Option)................................................. T3-6-8 Operation................................................................................ T3-6-9 Axle, Outline................................................................................ T3-9-1 Axle Oil Cooler (Option)........................................................T3-12-6 Electrical System............................................................. T3-12-12 Fan...........................................................................................T3-12-9 Hydraulic Circuit Diagram...............................................T3-12-7 Hydraulic System...............................................................T3-12-6 Major Components...........................................................T3-12-8 Pump Assembly............................................................... T3-12-11 Axle Shaft...................................................................................T3-9-11 B Back Buzzer Circuit..................................................................T2-5-32 Backup Light Circuit...............................................................T2-5-32 Base Torque Control...............................................................T2-2-24 Brake Circuit, Service..............................................................T2-4-20 Brake Light Circuit...................................................................T2-5-34 Brake Pressure Alarm Sensor...............................................T3-7-13 Brake Priority Circuit...............................................................T2-4-14 Brake Priority Valve................................................................... T3-7-6 Brake Valve.................................................................................T1-2-16 Component Layout...........................................................T3-10-2 Operation..............................................................................T3-10-3 Outline...................................................................................T3-10-1 Bucket Auto Leveler Control...............................................T2-2-74 Buzzer Circuit............................................................................T2-5-32 C Cab Dome Light Circuit.........................................................T2-5-48 Cab Electrical System............................................................... T1-2-5 Cab Light Switch......................................................................T2-5-48 CAN Circuit.....................................................................T2-1-2, T2-5-3 Charge-Cut Spool....................................................................T3-11-6 Charging Block.........................................................................T1-2-15 Cross Section View............................................................... T3-7-4 Hydraulic Diagram............................................................... T3-7-2 Outline..................................................................................... T3-7-1 Overview................................................................................. T3-7-3 Unit Location......................................................................... T3-7-1

Charging Circuit, Hydraulic..................................................T2-4-14 Charging Circuit (Key Switch: ON).....................................T2-5-12 Clearance Light........................................................................T2-5-20 Clutch Assy Forward/Reverse................................................................T3-8-11 Speed Range........................................................................T3-8-10 Clutch Pack................................................................................T3-8-10 Clutch Pack Operation...........................................................T3-8-12 Clutch Solenoid Valve............................................................T3-8-32 Combined Electric and Hydraulic Control Circuit........T2-2-73 Combined Operation Circuit................................................. T2-4-8 Component Layout................................................................... T1-2-1 Component Specifications.................................................... T1-3-1 Control System, Outline.......................................................... T2-2-1 Control Valve.............................................................................T1-2-14 Cross Section Views............................................................. T3-2-4 Hydraulic Circuit................................................................... T3-2-2 Location................................................................................... T3-2-1 Outline..................................................................................... T3-2-1 Overview................................................................................. T3-2-3 Controller..................................................................................... T1-2-6 Controller, Outline..................................................................... T2-1-1 Cooling Fan System.................................................................. T3-3-1 Unit Location......................................................................... T3-3-1 D Declutch Control.....................................................................T2-2-42 Declutch Pressure Sensor.................................................... T3-10-7 Differential................................................................................... T3-9-2 Operation................................................................................ T3-9-5 Principle................................................................................... T3-9-4 Purpose.................................................................................... T3-9-3 Downshift Control...................................................................T2-2-38 Drain Plug................................................................................ T3-11-11 Drive Unit...................................................................................T1-2-12 Outline..................................................................................... T3-8-1 E ECM System, Outline................................................................ T2-3-1 Electric Component Layout (Overview)............................ T1-2-4 Electric Power Circuit (Key Switch: OFF)............................ T2-5-4 Electrical Component, Specifications................................ T1-3-9 Electrical System, Outline....................................................... T2-5-1 Electrical System (Cab)............................................................ T1-2-5 Electrical System (Relays).....................................................T1-2-10 Engine..........................................................................................T1-2-11 Specifications........................................................................ T1-3-1 Engine Accessories, Specifications...................................... T1-3-4 Engine Control............................................................................ T2-2-4 Engine Load Idle Speed Control........................................T2-2-10 Engine Speed Regulator For Digging..............................T2-2-14 Engine Stop Circuit.................................................................T2-5-16 F Fan Circuit, Reversing (Option)...........................................T2-4-36 Fan Circuit Pressure Sensor..................................................T3-3-13 Fan Control, Valve Control....................................................T2-2-47 Fan Control Valve (Option)..................................................... T3-3-5 90Z6 F&S

INDEX Fan Motor.................................................................... T1-2-16, T3-3-3 Fan Motor (Option)................................................................... T3-3-4 Fan Motor Specifications..........................................T3-3-3, T3-3-4 Fan Normal Rotation................................................................ T3-3-6 Fan Pump.................................................................... T1-2-11, T3-3-2 Fan Pump for Axle Oil Cooler..............................................T3-12-7 Fan Pump Output Pressure Sensor...................................T3-3-13 Fan Pump Specifications......................................................... T3-3-2 Fan Reverse Rotation............................................................... T3-3-8 Fan Reverse Rotation Control (Option)............................T2-2-50 Fan Speed Control..................................................T2-2-48, T3-3-10 Fan Speed Control Circuit.....................................................T2-4-34 Fan Valve (Option)..................................................................... T3-3-5 Make-Up Function.............................................................T3-3-12 Operation................................................................................ T3-3-6 Final Drive Planetary..............................................................T3-9-11 Fingertip Control Type Pilot Valve....................................... T3-6-1 Electromagnetic Detent.................................................... T3-6-6 Operation................................................................................ T3-6-2 Outline..................................................................................... T3-6-1 Flow Rate Control Valve........................................................T3-2-18 Forward 1st Speed..................................................................T3-8-14 Forward 2nd Speed................................................................T3-8-16 Forward 3rd Speed.................................................................T3-8-18 Forward 4th Speed.................................................................T3-8-20 Forward/Reverse Clutch Assy.............................................T3-8-11 Forward/Reverse Lever Priority Control (Option)........T2-2-32 Forward/Reverse Operation Engine Speed Limiter....T2-2-12 Front Axle...................................................................................T1-2-15 Front Wiper Circuit..................................................................T2-5-42 Fuel Flow Diagram.................................................................... T2-3-4 Fuel Injection, Operation........................................................ T2-3-4 Fuel Injection Control.............................................................. T2-3-2 G Gear Pattern, Transmission.................................................... T3-8-8 Gear Teeth, Number................................................................. T3-8-9 H Hazard Light Circuit (Key Switch: OFF)............................T2-5-26 Head Light Circuit..................................................T2-5-20, T2-5-22 High-Beam Circuit...................................................................T2-5-24 Horn Circuit (Key Switch: OFF)............................................T2-5-30 Hydraulic Circuit, Multiple Control Valve.......................... T3-2-6 Hydraulic Circuit, T/M Control Valve.................................T3-8-33 Hydraulic Component, Specifications............................... T1-3-5 Hydraulic Main Circuit, Outline............................................ T2-4-2 Hydraulic Pilot Circuit, Outline...........................................T2-4-12 Hydraulic Pump Device.........................................................T1-2-13 Hydraulic System, Outline...................................................... T2-4-1 I Increasing and Decreasing Flow Rate, Pump.................. T3-1-5 K Kickout Control, Lift Arm......................................................T2-2-78

L License Light.............................................................................T2-5-20 Lift Arm Angle Sensor (Option)....................................... T3-11-14 Lift Arm Auto Leveler Height Kickout Control (Option)..................................T2-2-64 Lower Kickout Control (Option)....................................T2-2-66 Lift Arm Float Control............................................................T2-2-76 Lift Arm Kickout Control.......................................................T2-2-78 Lift Arm Raise Pressure Sensor (Option)....................... T3-11-13 Lift Arm/Bucket Operation Control Circuit.....................T2-4-16 Limited Slip Differential (LSD) (Option)............................. T3-9-8 Loading Pilot Pressure Sensor.............................................. T3-6-7 Low Brake Oil Pressure Indicator Control.......................T2-2-58 Low Steering Oil Pressure Indicator Control (Option).................................................................................T2-2-60 LSD (Option)................................................................................ T3-9-8 M Machine Overheat Engine Speed Limiter.......................T2-2-18 Main Circuit, Control Valve..................................................... T3-2-6 Main Circuit, Electrical............................................................. T2-5-2 Main Circuit, Hydraulic............................................................ T2-4-2 Main Component (Overview)............................................... T1-2-1 Main Component (Travel System)....................................... T1-2-3 Main Pump.................................................................................. T3-1-4 Main Pump Device Outline.................................................... T3-1-2 Main Relief Valve......................................................................T3-2-10 Make-Up Operation..............................T3-2-14, T3-5-8, T3-11-10 Manual Operation Spool (for Emergency Travel).........T3-8-30 Manual Speed Shift Control................................................T2-2-34 Monitor......................................................................................... T1-2-8 Monitor Panel............................................................................. T1-2-9 Multiple Control Valve...........................................................T1-2-14 Cross Section Views............................................................. T3-2-4 Hydraulic Circuit................................................................... T3-2-2 Location................................................................................... T3-2-1 Outline..................................................................................... T3-2-1 Overview................................................................................. T3-2-3 N Negative Control Relief Valve..............................................T3-2-16 Neutral, Steering........................................................................ T3-4-6 Neutral Circuit, Hydraulic....................................................... T2-4-6 Neutral Control.........................................................................T2-2-30 Neutral Engine Start Circuit.................................................T2-5-10 Normal Rotation, Fan............................................................... T3-3-6 Number of Gear Teeth............................................................. T3-8-9 O Oil Filter Assembly, Axle..................................................... T3-12-10 Operation of Fuel Injection.................................................... T2-3-4 OrbitrolTM, Outline..................................................................... T3-4-1 Operation................................................................................ T3-4-4 Overview................................................................................. T3-4-2 Structure................................................................................. T3-4-3 Unit Location......................................................................... T3-4-1 Overload Relief Valve.............................................................T3-11-8 90Z6 F&S

INDEX Overload Relief Valve (with Make-Up Function)..........T3-2-12 Overload Relief Valve Make-Up Operation....................T3-2-14 Overrun Alarm Control..........................................................T2-2-62 P Parking Brake............................................................................T3-8-36 Parking Brake: Applied.....................................................T2-5-36 Parking Brake: Released...................................................T2-5-38 Parking Brake Circuit.............................................T2-4-22, T2-5-36 Parking Brake Manual Release............................................T3-8-37 Parking Brake Operation.......................................................T3-8-36 Parking Brake Pressure Sensor...........................................T3-7-14 Sensor Specifications........................................................T3-7-14 Parking Brake Solenoid Valve................................................ T3-7-8 Pilot Accumulator....................................................................T3-7-12 Pilot Accumulator Specifications.......................................T3-7-12 Pilot Circuit, Hydraulic...........................................................T2-4-12 Pilot Operation Control Circuit............................................. T3-2-8 Pilot Pressure from Torque Control Solenoid Valve.....T3-1-18 Pilot Pressure Sensor, Loading.............................................. T3-6-7 Pilot Pump..................................................................................T3-1-22 Pilot Relief Valve......................................................................... T3-7-7 Pilot Valve.................................................................... T1-2-16, T3-6-1 Electromagnetic Detent.................................................... T3-6-6 Operation..................................................................T3-6-2, T3-6-9 Outline.......................................................................T3-6-1, T3-6-8 Power Flow in Transmission.................................................T3-8-14 Pressure Sensor Fan Circuit Pressure...........................................................T3-3-13 Lift Arm Raise (Option).................................................. T3-11-13 Loading Pilot Pressure........................................................ T3-6-7 Service Brake Primary Pressure.....................................T3-7-13 Service Brake Secondary Pressure for Declutch.....T3-10-7 Pressure Sensor Specifications .............................................. T3-3-13, T3-7-13, T3-7-14, T3-10-7 Pressure Switch (for Stop Lamp)........................................T3-10-6 Pressure Switch Specifications.......................................... T3-10-6 Priority Valve, Brake.................................................................. T3-7-6 Priority Valve, Main.................................................................T3-1-20 Priority Valve Circuit................................................................. T2-4-4 Priority Valve Operation, Brake............................................. T3-7-6 Propeller Shaft..........................................................................T3-12-1 Pump Control............................................................................T2-2-23 Pump Control by Pilot Pressure from Torque Control Solenoid...........T3-1-18 Pump Control Pressure....................................................T3-1-10 Pump Internal Delivery Pressure..................................T3-1-14 Pump Control Circuit..............................................................T2-4-18 Pump Control Pressure..........................................................T3-1-10 Pump Control Valve (Negative Control Relief Valve)..T3-2-16 Pump Delivery Pressure Sensor.........................................T3-1-22 Pump Device............................................................................... T3-1-1 Pump Device Hydraulic Circuit Diagram.......................... T3-1-3 Pump Device Location............................................................ T3-1-1 Pump Internal Delivery Pressure.......................................T3-1-14 Pump Output Pressure Sensor...........................................T3-1-22 Pump Specifications................................................................. T3-1-3

Pump Specifications, Fan........................................................ T3-3-2 Pump Torque Control Solenoid Valve..............................T3-7-10 Q Quick Power Mode Control..................................................T2-2-68 R Rear Cab Light Switch............................................................T2-5-48 Rear Wiper Circuit....................................................................T2-5-44 Regulator...................................................................................... T3-1-6 Regulator Control Function................................................... T3-1-8 Relays............................................................................................. T1-2-6 Relief Function............................................................................ T3-5-6 Relief Operation......................................................T3-2-12, T3-11-8 Relief Valve Operation............................................................. T3-7-7 Restriction Valve......................................................................T3-2-15 Reverse 1st Speed...................................................................T3-8-22 Reverse Buzzer Circuit...........................................................T2-5-32 Reverse Light Circuit..............................................................T2-5-32 Reverse Rotation, Fan.............................................................. T3-3-8 Reversing Fan Circuit (Option)............................................T2-4-36 Reversing Fan Idle Speed Control.....................................T2-2-20 Ride Control (Option).............................................................T2-2-52 Ride Control Accumulator (Option)............................... T3-11-12 Ride Control Accumulator Specifications.................... T3-11-12 Ride Control Circuit (Option)...............................................T2-4-24 Ride Control Device ...............................................................T3-11-1 Ride Control Group (Option)...............................................T1-2-17 Ride Control Hydraulic Circuit Diagram..........................T3-11-2 Ride Control Operation.........................................................T3-11-4 Ride Control Valve (Option).................................................T3-11-1 Layout....................................................................................T3-11-3 Outline...................................................................................T3-11-1 Overview...............................................................................T3-11-1 Right Console.............................................................................. T1-2-7 S Secondary Steering Check Block.......................................T3-12-5 Secondary Steering Circuit..................................................T2-4-32 Secondary Steering Control................................................T2-2-70 Secondary Steering Group...................................................T1-2-18 Secondary Steering Pump..................................T1-2-18, T3-12-4 Service Brake.............................................................................T3-9-10 Service Brake Accumulator..................................................T3-7-11 Service Brake Accumulator Specifications.....................T3-7-11 Service Brake Circuit...............................................................T2-4-20 Service Brake Primary Pressure Sensor............................T3-7-13 Service Brake Secondary Pressure Sensor......................T3-10-7 Shift Holding Control.............................................................T2-2-44 Single Operation Circuit.......................................................... T2-4-6 Solenoid Valve Clutch.....................................................................................T3-8-32 Parking Brake......................................................................... T3-7-8 Pump Torque Control.......................................................T3-7-10 Solenoid Valve Operation.....................T3-7-9, T3-7-10, T3-8-32 Specifications.............................................................................. T1-1-1 Speed Limit Control with Power Mode OFF..................T2-2-16 Speed Range Clutch Assy.....................................................T3-8-10 90Z6 F&S

INDEX Speed Shift Delay Control....................................................T2-2-40 Starting Circuit (Key Switch: START)................................... T2-5-8 Steering (Left)...............................................................T3-4-5, T3-5-4 Steering (Right).......................................................................... T3-4-6 Steering Accumulator.............................................................. T3-5-9 Steering Accumulator Specifications................................. T3-5-9 Steering Circuit.........................................................................T2-4-26 Steering Main Relief Valve....................................................T3-1-21 Steering Overload Relief Valve............................................. T3-5-6 Steering Pilot Valve Operation................................................................................ T3-4-4 Outline..................................................................................... T3-4-1 Overview................................................................................. T3-4-2 Structure................................................................................. T3-4-3 Unit Location......................................................................... T3-4-1 Steering Priority Valve............................................................T3-1-20 Steering Shock Dampening Function..............................T2-4-28 Steering Stop Circuit..............................................................T2-4-30 Steering Valve...........................................................................T1-2-16 Component Layout............................................................. T3-5-3 Operation................................................................................ T3-5-4 Outline..................................................................................... T3-5-1 Overview................................................................................. T3-5-2 Unit Location......................................................................... T3-5-1 Stop Lamp Pressure Switch Specifications.................... T3-10-6 Stop Valve...................................................................................T3-12-3 Stop Valve Operation.............................................................T3-12-3 Surge Voltage Prevention Circuit.......................................T2-5-14 Switches........................................................................................ T1-2-8

W Washer Circuit...........................................................................T2-5-46 Weight of Main Components................................................ T1-1-2 Wiper Circuit..............................................................................T2-5-42 Work Light Circuit....................................................................T2-5-40

T T/M Control Valve....................................................................T3-8-24 Tail Light Circuit.......................................................................T2-5-20 Torque Control Solenoid Valve, Pump Control.............T3-1-18 Torque Converter..................................................... T1-2-12, T3-8-6 Torque Converter Operation................................................. T3-8-6 Torque Decrease Control While Dumping Bucket.......T2-2-26 Torque Proportioning Differential (TPD)........................... T3-9-6 TPD................................................................................................. T3-9-6 Transmission............................................................................... T3-8-8 Control...................................................................................T2-2-28 Cross Section View............................................................... T3-8-3 Front View............................................................................... T3-8-2 Rear View................................................................................ T3-8-4 Side View................................................................................. T3-8-5 Transmission Alarm Control................................................T2-2-56 Transmission Assembly.........................................................T1-2-12 Transmission Control Valve..................................................T3-8-24 Transmission Control Valve Operation (Modulation)........................................................................T3-8-26 Transmission Control Valve Overview..............................T3-8-25 Transmission Gear Pattern..................................................... T3-8-8 Transmission Power Flow.....................................................T3-8-14 Transmission Regulator Valve.............................................T3-8-34 Transmission Regulator Valve Operation........................T3-8-35 Turn Signal Light Circuit........................................................T2-5-28 90Z6 F&S

DIAGRAMS

― CONTENTS ― Electrical Connection Diagram (1/2) ......................................................................................... 2 Electrical Connection Diagram (2/2) ......................................................................................... 3 Fuses and Relays .................................................................................................................... 4 Front Chassis Wiring Diagram ................................................................................................. 5 Rear Chassis Cable Layout (1/2) ............................................................................................. 6 Rear Chassis Cable Layout (2/2) ............................................................................................. 7 Rear Chassis Wiring Diagram (1/2)(S/N 0101~0102) ............................................................... 8 Rear Chassis Wiring Diagram (2/2) (S/N 0101~0102) .............................................................. 9 Rear Chassis Wiring Diagram (1/2)(S/N 0103~) ......................................................................10 Rear Chassis Wiring Diagram (2/2) (S/N 0103~) ..................................................................... 11 Rear Chassis Wiring Diagram (Transmission) .........................................................................12 Front Console Cable Layout ...................................................................................................13 Front Console Wiring Diagram (1/2) ........................................................................................14 Front Console Wiring Diagram (2/2) ........................................................................................15 Floor Cable Layout (Rear and Side Console) (1/2)..................................................................16 Floor Cable Layout (Rear and Side Console) (2/2)..................................................................17 Floor Wiring Diagram (Rear Console) (1/5) .............................................................................18 Floor Wiring Diagram (Rear Console) (2/5) .............................................................................19 Floor Wiring Diagram (Rear Console) (3/5) .............................................................................20 Floor Wiring Diagram (Rear Console) (4/5) .............................................................................21 Floor Wiring Diagram (Rear Console) (5/5) .............................................................................22 Floor Wiring Diagram (Side Console 1) ...................................................................................23 Floor Wiring Diagram (Side Console 2) ...................................................................................24 A/C Control Panel Harness .....................................................................................................24 Hydraulic Circuit Diagram .......................................................................................................25

90Z6 F&S

90Z6 Electrical Connection Diagram (1/2) J-A ICF (C1,C2) Monitor (1-1) GSM(16,17), GPS(A-2) Load dump1,2 relay

Starter switch B M ACC G1 G2 ST Preheat OFF ACC ON Start

B (912-c)

(912-b)[W]

(912)[W]

12V

(921) (911)[R] 100 [R]

70A

Power supply (main)

Battery disconnect SW (opt)

12V

(920) 100 [R]

Secondary steering motor (opt)

FA8

100

(G)(125)

C13 (Y)(128)

(701) WB

Lift arm raise pilot pressure sensor (opt)

10A ST

C14

(906) G

FB1

10A

FB12 (032) WL

Battery relay [R]15

(001) GR

J-A

(922) [R] B

100

Voltage relay (704)

(705) YB

F26 (+5V) (BrY)(137) F09

Steering pressure switch (opt) Lift arm angle sensor (opt)

(Y)(135)

Hydraulic fan circuit pressure sensor (opt)

Magnetic SW FB11 (5A, Radio, Dome lamp)

(902-b) [W] FA4 (10A, Lighting switch)

1.5A

FA5 ((15A), Option battery)

(799)WL

(912-c) [W] FA8 (10A, Controller)

100A

FA6 (10A, Horn) FA7 (10A, Flasher)

100A 100A

FA9 (10A, ECM1) FA10 (10A, ECM2)

Monitor (2-28) ICF(C8) GPS(A-3) GSM(32)

12V,150mA

Alternator(75A)

(962) [R] 20

I E

(707)GW

Parking brake pressure (low) sensor

D09 D15

(YB)(126)

Service brake secondary pressure sensor (for declutch)

(GY)(138)

(P)(129) (709) Air heater [B]15

(963) [R]15

(708)BL

Secondary steering check pressure sensor (opt)

E (965-g) [R]

FA1 (5A, Back lamp) FA2 (5A, Brake lamp) FA3 (10A, Head lamp) (965-e) [R] (965-b) R

(965-f) [R]

(965-c) R (965-h) R (965-d) [R] (965-j) [R] (965-k) R

FA12 ((20A), Opt (ACC2)) FA14 (5A, Neutral relay) FA15 (10A, MC PPV power)

T/M oil temp. sensor

Hydraulic oil temperature sensor

T/C input rev. sensor (E/G speed)

(965-a) [R]

FA19 (10A, Hi beam) FA20 (5A, Secondary steering)

D17 D18 D19 C01

C08

(YL)(105) (GB)(184)

E17 E07 E18 E08

(LW)(102)

T/C output rev. sensor

(YB)(186)

A03 A02 A08 A09 A11 A10

A04 A05 A16 A17 B16 B15 A19 A18

T/M intermediate shaft speed sensor (Machine speed backup)

A-17 A-18

F solenoid valve

(BW)(352) L

(L)(353)

C-5 C-11

R solenoid valve

(WR)(103) (LB)(188)

(YG)(581) (LR)(584) (WB)(585) (RL)(583) (WG)(594)

+5V TXD RXD GND RTS CTS

(LW)(355)

(GW)(356)

A10

(Battery) FA8

A10

2nd solenoid valve

(BY)(358) (RW)(359) (BL)(360) R

(BR)(362) (RY)(321)

(RW)(598)

B-9 (YR)(597) B-1 (Gr)(596) B-2

4th solenoid valve

(Gr)(579)

A-20 (YR)(577) A-19

Cooling fan solenoid valve

(YR)(327)

Cooling fan solenoid valve (reverse) (opt)

(GY)(328)

(Y)(021)

(Key SW M) FA13 (Battery) FA8 Alternator (L)

Shift hold switch Shift lever (gear) Downshift switch 1 6 8 7 Downshift switch 2 1 2 3 Shift lever (gear) 4 Shift lever (FNR) 1 4 3 2 F N R

(M) (M)

(R)(011) (GW)(707)

A-10

(Br)(578)

(912-c) (009) [W] FA9 YB A1

A-20(RTS)

Y(021)

A-9(TXD) C-4 (WAKE UP)

(BY) (593)

A-11 A-12 A-15

A-3

ICF

Shift lever (FNR)

3 2

(LY)(247)

8 7

(BrY)(248)

F (WR)(241) N (LY)(242) R (GW)(243)

BR (965-b) R

FA14

(033) (O)

E16(1) E21(2)

Ride control (opt)

(M)

(WB)(332)

(Key SW M) (Y)(021) 15 FA13 (R) 16 (Battery) (011) 17 FA8 (GW)(707) 32 Alternator (L)

(BrY)(535) (LY)(536)

(RW) (455)

Lift arm height kickout (opt) Lift arm lower kickout (opt) (Br) (068)

FA20 (965-c) R

C-4 (WAKE UP)

(Gr)(578)

A-8(RXD)

(BY) (593)

ICF

Secondary steering pump relay (opt)

(LB)(405)

(GR)(595)

(Br)(456)

BY(896)

(YB)(246)

(Br)(249)

Declutch position switch (Y)(021) FA13 (Key SW M)

Lift arm auto leveler up SW (opt)

D11 E11(D) E03(N)

Axle oil cooler relay (opt)

(M)

Monitor (1-19) Low steering oil pressure alarm indicator (opt) Monitor (1-6) Parking brake indicator Monitor (1-32) Brake oil low pressure indicator Monitor (1-23) T/M trouble (1) alarm lamp

AUTO1 AUTO2

Open: active

(WL)(272) (RL)(151)

Secondary steering operation check switch (opt)

(LB)(295) (WY)(296)

F18(ON) F19(SET)

V(592)

(YB)(153)

Engine oil pressure (2) ECM (8) Overheat (2) ECM (27) Engine failure ECM (6) Heater (1) ECM (4) (BrW)(254) (V)(255)

(M)

(WL)(252)

(M)

(PW)(259)

F23(MODE2) F22(MODE1) D23 F07

D02 D03

(Gr)(251)

Quick power switch

(RY)(258)

F11

(LY)(257)

F21(AUTO)

(GR)(270)

F10

S1H S1L S1S

CAN1

Front washer SW Front wiper SW (Lo) Front wiper SW (Hi) Front wiper SW (Int) Alternator (L)

D24

Transmission learning switch

(PB)(299)

E12

Arm angle learning switch

(GW)(298)

E24

E (Y)(021)

S1L

D04 D05

(M)

Neutral relay Parking brake MC(C10) Steering pressure alarm MC(C09) Service brake alarm MC(C06) Transmission failure (1) MC(B17)

S1H

F08

(M)

1-1 1-2

1-28

1-3 1-18

Power mode selector

Shift up delay switch (opt) F13(ON) F14(SET)

Monitor (1-11) Overheat (2) warning lamp Monitor (1-12) E/G oil pressure (2) warning lamp

GY(591)

1-17 1-4 1-5

Model select 1 (factory use only) Model select 2 (factory use only)

(LB)(253)

(Key SW M) FA13 E

Y(021)

Hourmeter stop SW Air cleaner clogging SW Hydraulic oil level sensor

Ride control switch (Auto) (opt)

(GrL)(293) (WG)(294)

Heater relay

BL(708)

E R(011)

(Battery) FA8 (Key SW M) FA13

Shift up delay indicator (SW built-in)

Fan reverse switch (Manual) (opt)

(BrY)(218) (LY)(217)

(M)

Lift arm auto leveler down SW (opt)

(GY)(268) (WG)(267)

6 19

GW(710)

(Key SW M) FA13

Fuel level sensor

D12(F) D13(R)

YB(724)

ECM (31 poles)

(Y)(021)

Fan reverse switch (Auto) (opt) (BrW)(279)

(B) (472)

Auto/manual selection switch

(O)(278)

10 11

Coolant level L SW

(WR)(555) (V)(542)

Monitor (1-22) E/G failure lamp STOP WARNING MAINTENANCE

Br(554)

5 7

Coolant level H SW

(RB)(552)

(O)(553)

6 16 5

ECM (50 poles)

(WL)(244)

14 24

BR(895)

GSM

WAIT TO START Monitor (1-21) Glow (1) lamp

WR(566)

43 20

ON1 ON2

LgR(718)

E04

B01 B08 B10 B20

MC (Main Controller)

CAN1

45 2

A-10 (DG_IN1) 22 33 34

INSITE

23 25 9 WB(721) 10

(451) (PB)

Forward/reverse selector switch (opt)

RY(770) R(769)

A-9(TXD)

(YR)(577)

S1L

S1S

(543)(YR)

Forward/reverse switch (opt)

INC

Inc/Dec SW

(Gr)(579)

S1H

S1L

Alternate droop

(YB) (331)

29 30 39 40 50 46 37 36

R(715)

(Gr)(154)

E14(F) (YG)(262) E13(N) (WL)(263) E15(R)

B F J A G H C D E

W(716)

WR(712)

Diagnostic SW

(RL)(261)

Alternate droop relay BR Monitor (1-24)

C10 C06 B17

7 8 17

48 21 B(717) 49

Remote throttle

Back lamp relay

C09

(2-16)

S1H

E22

(PW)(236)

18 28

(Key SW M) FA13

A-10 (DG_IN1)

A-2

LW(713)

A-8(RXD)

A-1

RW(711)

10A

A-21(CTS) A-31

GPS

E23

Neutral relay

(GR)(235)

ECM1 relay

DEC

C12 (M)

FA10(013) Gr

3rd solenoid valve

(WB)(325) (BR)(326)

[W]

10A

Pump swash plate tilt solenoid valve

(LY)(322)

B (912-c)

E E

ECM2 relay

CAN1

S1L

A07 A06

C05

E C1

S1S (RL)(357)

B06 B07

C17

(458) (O)

(462) (V) Monitor

S1L

A30 A31

C11

(457) (P)

S1H

A26 A27

C03 C04

(011)(R)

S1H

1st solenoid valve

B22 B21

A25 A24

Y(021)

(Key SW M) FA13 MPDr. RS232C

Load dump2 relay

(LR)(525)

E20 E10

(P)(582)

(GB)(354)

E19 E09

-2-

A15 A14

(W)(351)

FB10 (20A, A/C 2) FB13 ((15A), Opt (ACC3)) FB14 ((10A), Opt (ACC4))

A12 A13

F17(-)

(YL)(101)

FB6 (10A, A/C 1) FB7 (10A, DC/DC converter)

Declutch SW Shift up delay indicator C2 relay (back-up lamp relay) A1,C1 relay (ECM main relay) A/C control unit (21) Buzzer (monitor) ICF(C-7) ECM (38) GSM(15),GPS(A-1) MC(E04) Monitor (1-2) B1 relay (Parking brake) Steering pressure switch (opt) J-A

(GB)(124)

(WB)(182)

FB4 (20A, Front working lamp) FB5 (10A, Rear wiper)

(LR)(143)

D16

C02 (Br)(141) C07

Axle oil temperature sensor Atmospheric temperature sensor

T/M output shaft rev. sensor FA16 (10A, Loader control) (Machine speed) FA17 (20A, Rear working lamp) FA18 (5A, Parking brake)

FB2 (10A, 24V socket) FB3 (15A, Front wiper)

(WL)(142) (BW)(113)

FB8 (15A, Seat heater) FB9 (10A, Revolving lamp) (965-l) R

(LW)(136)

ECM(11)

(965) [R]x4

A-5 A-7 A-6 A-28

(RL)(127)

Service brake primary pressure sensor

D08

A/C gas pressure sensor

(10)

(Gy)(139)

Heater relay ECM (710)GW

C-15 C-9

(R)(361)

(W)(123)

G 100

Radio

(907) LB

(GW)(707)

F04 F05 F06

F16(-) D06 D07

Starter Starter motor

(961) [R]20

D28

(RL)(131) (V)(122)

(901) O

(905) YG

(912-d) [W]

D14

ACC

(902-a) W

Pump output pressure sensor

(2-17)

(021) (923) LY FA13 (Y)

E01 E02

F25(+5V)

(PB)(134) BY

(471)(RW)

M B

Throttle pedal

Loading primary pilot pressure sensor

(901-a) W

F01 F02 F03 (P)(121)

(461) L Monitor

(Battery)

(065)RL

10A

Load dump1 relay (011) (R)

(965-b) FA15 R

Power supply (proportional valve)

100 (923)[R]

E05 E06

10A

(Y)(021)

(Key SW M) FA13 Alternator (L)

C-1 A-19 C-2 A-29 C-7 A-30 C-8 C-14

Battery

(011)(R)

(000) 100

100

FA8

[W]

E (R)(011)

(Battery) FA8

Lighting switch Turn signal (R) Turn signal (L) High beam Working lamp

(V)(592) (GY)(591) (Br)(554) (WR)(556)

(YR)(543) (WR)(555) (RB)(552) (O)(553) (V)(542)

(GL)(226) (PB)(228) (BrY)(229) (BY)(227) (GW)(707) (YR)(514) (LR)(501) (RL)(502) (GY)(511) (LW)(517)

(Key SW M) FA13 Buzzer

(LR)(529)

(Y)(021)

(461)(L)

Load dump1 relay Load dump2 relay Wiper relay (Lo)(F1) Wiper relay (Hi)(F2)

2-35 2-36

2-5

1-12 1-11 1-22 1-21

2-17 (462)(V) 2-16 (447)(RW) 2-19 (448)(PB) 2-18

1-24 1-6 1-19 1-32 1-23 1-34 1-29 1-30 1-20 2-28

2-30 S1H

1-25 2-29 2-15 2-14 2-13

S1L S1H S1L

CAN1

S1S

2-12

MONITOR 09708-07621

90Z6 Electrical Connection Diagram (2/2) Lighting SW (Light)

(Key SW M) FA13

B (912-b) FA4 10A

(016) Br

(421)(RY)

(422)(Gr)

(514) (464) YR (PB)

(626) (BR)

Head lamp relay

M MRF

(426)(RW)

Front working lamp relay

Front working lamp relay (opt)

Rear working lamp relay

C4 (515) P

FA11 10A

4 14 24

(627) (WR)

Inside/outside air servo motor

28 27

(622)(Gr)

Rear working lamp relay (opt)

(620)(YR)

ACM

10W

(222)(GR)

(605)(RY)

22W

Lock valve solenoid (opt)

MV (431) (WR)

A/M servo motor

(612)(P)

(215) (LR)

(618) (BY)

THAM (605)(LW)

SPHL

Lift arm height kickout detent

(208) (RG)

Atmospheric temp. thermistor AC gas Hi/Lo pressure SW

8 9

[W]

FB11

S1H

B1 B1

(202) (GO) (406) (Gr)

(409) (402) (RW) (Y)

(965-h) [R3] FB2

(087) WR

(965-f) [R5]

(BW) Parking solenoid

FA18 (061) 5A

(407) (P)

(965-j) [R3]

FB7

(088) WB

10A

Coupler PUSH

(965-g) (062) [R3] FA2 (LB)

S1H

CAN1

S1L S1S

FA12

(808) WR2

(20A) (965-a) [R3]

OPT CAN

(416)(WR)

(539) GL

FB8 15A

(089) LR2

FB13

(812) WB1.25

(965-g) [W3]

(965-a) [R3]

FB14 (10A)

S1L

FA1

(063)(V)

3.8A

(965-h) (082) [R3] FB3 G1.25

(965-g) [R3]

FA3

(072) R

(512) YB

0.5A

(505) (506) (BrW) (WG)

2~15A

Back-up alarm

15A

Head lamp (LH)(Lo) Head lamp (LH)(Hi)

70W

Cigar lighter (+12V)

10A

(965-c) R2

FA19

(073) P

(511) GY

(965-d) [R5]

FB4

(074) P2

(517) LW

70W

Opt power (ACC3) (075) W2

(518) GW

BR C4

(520) G

Cab front working lamp (RH)

(965-d) [R5] FB5

Cab front working lamp (LH)

(224)(BrW) (227)(BY) (228)(PB) (229)(BrY)

Cab front working lamp(LH)(opt)

(231)(RW)

B10

(232)(LY)

Rear wiper SW

Washer OFF Low Washer low

9 10

(446)RG

7 3

Rear wiper SW

(083) WR

Cab rear working lamp (RH)

70W

7 OFF Int Low High Washer

Front wiper SW

(LW)

10A

55W

70W

Front wiper SW

Monitor (2-18)

Cab front working lamp(RH)(opt)

55W

(443) V

Front washer motor (531)WL 1.6A M

9 10 11

1~6A

Rear wiper motor

(445)V

B10 FA17

Back lamp LH

Monitor (2-19)

Monitor (1-20) Monitor (1-29) Monitor (1-30)

70W 70W

(965-f) [R5]

(PB)(448)

B9 (519) WB

Back lamp RH

(226)

Head lamp (RH)(Hi)

Monitor (2-12) C3

(RW)(447)

Monitor (GL) (1-34) (225)

75W

70W

Opt power (ACC2)

F1 F2 B8

Head lamp (RH)(Lo)

20A

Lo (441)W F2 M (442)O Hi (444)Y F1

70W

20A CAN1

Brake lamp (LH)

Front wiper motor

(blown at 19.5A)

S1H S1L S1S

Brake lamp (RH)

12W

Air suspension seat 5.6A

E (813) WL

25W 25W

Seat heater SW (opt) Seat heater

Dome light (B pillar)

Opt power (ACC1) To rear view camera

Brake lamp switch

(503) (WR)

12W

(965-k) R3

+ -

(206) (BrW)

(15A)

S1H

(414)(LY) 10 L

Flasher (Revolving light) (091) (opt) (965-k) FB9 L1.25 R3 Flasher SW

10A

(965-e) R2

Monitor (2-13)

(808) (WB)

(415) (PW)

10A

(538) W

Rear turn signal (L)

(412) (L)

11 R (413)(RW)

10A

+12V 0 5A

S1L

Rear view monitor (opt)

Cigar lighter (+24V)

75W S1H

Front turn signal (L)

10A

DC-DC converter (opt) +

25W

Turn signal SW

0.81A

(502) RL

(205) (Gr)

(408)(GW)

Rear turn signal (R)

25W

10Wx2

10W

Hazard SW (342) (GB)

Front turn signal (R)

Monitor (2-15)

(M)

Dome light

(ON2)

J-A

Parking relay

(ON2) ON1

(201) (Br)

25W

Coupler PULL

(341) (LR)

2.3A

ON1: Alternate (apply brake) (ON2): Momentary (release)

ON1

(501) LR

Monitor (2-14)

Cab wiring

Parking switch (021)(Y)

25W

Door switch

(Key SW M) FA13

J-A

E L

(411) BrY

Coupler SW (opt)

S1L

Flasher unit (Hazard)

MC(C-4)/Dual auto leveler lower kickout (opt) Lift arm lower kickout detent (float) Both to be replaced with dual auto leveler (opt)

(433)(LY)

6 7 Lever safety lock SW (opt) S1L CAN1 Lever safety lock SW (opt) S1S (631) (630) A/C unit BR (LB) (BrY) internal wiring F/R shift select SW (opt) (965-l) (085) BM MB [R2] FB10 LR Fan reverse SW (AUTO) 4 2 Blower motor 3 1 M 20A Fan reverse SW (MANUAL) PTR (965-j) (084) CR [R3] FB6 ECC Secondary steering Gr (601)G check SW (opt) Compressor clutch 10A Power mode SW BR 1.5A Ride control SW (AUTO)(opt) B Parking brake SW Radio (912-b) (802) Working lamp SW [W3] FA5 P2 Optional power (+)10 R Working lamp SW supply (battery) (-)6 (001) (15A) Hazard SW (GR) (KEY SW ACC) 8 (+)9 FB1 E (912-a) (017) L (-)5

Monitor (1-25)

(014) YR

Height kickout (proximity SW)

(536)(LY)

S1H

(912-d) [W3] FA7

Horn (Low) Horn SW Horn SW (Side)

(211)(GB)

10A

Blow-off thermistor

THF

(615) (Y)

MC(C-3)/Dual auto leveler height kickout (opt)

Horn (High)

2.2A

Bucket leveler (proximity SW)

(432)(BrY)

THI

2.2A

(527)WB

(535)(BrY)

Inside air thermistor

(015) A9 P

10A

Tail lamp (L) Tail lamp (R)

(912-d) [W3] FA6

Bucket detent

Solar insolation sensor

10W

MAM

(611) (WG)

(616)(GR) A/C unit (619) internal wiring 16 (PB)

Width lamp (R)

(625)(WB)

Width lamp (L) 5W

10A

Blow-off servo motor

(621)(GR)

3 (623)(O) (624)(BL) 2 12

E Lock valve SW

(965-f) (081) [R5] FA16 YG

High beam relay

(425)(YR)

(464) (PB)

(629) (GW)

Working lamp SW

5 (628) (Lg)

Air conditioner unit

A/C unit internal wiring

Lighting SW

Hi Lo

OFF SM H

[W3]

C 13 14

16 15 C

(021) (Y)

(Dimmer)

(532) RB

Rear washer motor

M E

Cab rear working lamp (LH) Cab rear working lamp (RH)(opt) Cab rear working lamp (LH)(opt) E

09708-07621

-3-

90Z6 Fuses and Relays Fuse Box-A 20A

ECM2

A10

10A

Fuse Box-A Fuse Box-B F-A F-B

Fuse Box-B 5A

20A

A20

Secondary steering (opt)

10A

A19

High beam

15A

Air conditioner 2

B10

20A

Revolving lamp (opt)

10A

15A

965l

Voltage Relay VR

10A

OPEN

B20

OPEN

B19

Relay Box-C R-C

965c ECM1

10A

912c

Data link E/G

965k MC, ICF, Monitor GPS, GSM, Load dump

10A

Flasher unit

10A

965f

A18

Parking brake

Seat heater (opt)

15A

OPEN

B18

20A

A17

Rear working lamp DC/DC converter (opt)

10A

OPEN

B17

Relay Box-B R-B

9 10

965j

912d Horn

10A

A16

Loader control

OPT1 (Battery)

802

OPEN

10A

A15

MC PPV solenoid

Lighting

10A

A14

Neutral relay Alternate droop

Air conditioner 1

10A

OPEN

B16

Rear wiper

10A

OPEN

B15

Front working lamp

20A

OPEN

813 B14

OPT4 (Acc)

OPEN

812 B13

OPT3 (Acc)

905

10A

B12

Starter key SW

912a

B11

Radio Room lamp

Relay Box-A R-A

965d

965b

912b

965a Head lamp

10A

923

10A

A13

Front wiper

Power ON

15A

965h Turn signal Brake lamp

Backup alarm Backup lamp

965g

965e

OPEN

808 A12

OPT2 (Acc)

24V cigar lighter

10A

514

10A

515 A11

Position (tail lamp)

Radio power ON

9001

MPDr. Dr. FRONT

Relay Box-A 458

Relay Box-B 425

21 CAB front working lamp

ECM1 9

426

406

215

409

451

882

206

225

Lift arm height kickout

208

A10

11 Load dump 2

461

B10

232

471

455

C10

Secondary steering (opt)

Wiper Relay

520

Rear washer

457

75 83

Load dump 1

CAB rear working lamp (opt)

0 432

Fuse Box & Relay Box

426

231

446 503

462

519

Rear wiper

527

Brake lamp

425 CAB front working lamp (opt)

531 83

505

405

Front washer

502

445 0

Pilot shut-off (Loading lever lock)(opt)

Backup lamp

411

721

Horn 431

222

Engine alternate droop

211

Bucket leveler

416

718

305

Turn (L)

501 15

ECM2 13

Parking (2)

411 511

408

415

705 907

518

Turn (R)

458

711

High beam 73

451 Neutral

75 512

406 21

Head light

421

517

Rear working lamp 72

202

Parking (1)

74 713

422

Relay Box-C

68 525

532

CAN1 (J1939) Power Train Monitor 2-30 2-29

ICF S1H S1L

C-5 C-11

MC S1H S1L

D2 D3

A/C

447

S1H S1L

8 9

S1H S1L

C D

444

Rear view monitor

INSITE

OPT CAN

443

ECM

S1H

S1L

46 37 36

S1H

S1L Front wiper motor (Hi)

S1ᾢ

448 441

443

S1H

-4-

Front wiper motor (Lo)

442

S1L Terminator 09708-07621

90Z6 Front Chassis Wiring Diagram

CN: Connector, JN: Junction From Wire No.

Front axle

Axle temperature sensor

Horn

Front lamp (LH)

GND

Front lamp (RH)

Front chassis harness

Lift arm kickout sensor

Front chassis

Center harness (between front - rear chassis)

ᴾ

Rear chassis 03256-01240 33194-47450A (front) 33194-47460 (center) 33194-48010 (kickout)

CN.004 502-01 R-L

WKL 1 CB001

Center Harness CN.041

CN.043 To rear main CN.211 1

000-01

Center harness 2

GND

1.25

000-02

CN.015

GND

CN.018

Quick coupler (opt)

1.25

000-03

CN.006

Front combination lamp (L)(GND)

CN.015

GND

1.25

000-04

CN.007

Head light (L)

CN.015

GND

1.25

000-05

JN.A05

CN.015

GND

1.25

000-06

CN.017

Head light (R)

CN.015

1.25

000-07

CN.021

Front combination lamp (R)(GND)

CN.015

GND GND

1.25

000-08

CN.022

Bucket leveler proximity SW

CN.015

GND

1.25

000-09

JN.A05

CN.010

Horn (low)

1.25

000-10

CN.012

Horn (high)

1.25

YAZAKI SWP 7222-7484-40

YAZAKI SWP 7123-7484-40

CN.044 To rear main CN.216

YAZAKI SWP 7222-7544-40

R-L 5

000-11

CN.008

Lift arm kickout proximity SW

CN.015

GND

1.25

121-01

CN.016

Lift arm raise pilot pressure sensor

CN.001

Center harness 1

1.25

122-01

CN.016

Lift arm raise pilot pressure sensor

CN.001

Center harness 1

1.25

123-01

CN.008

Lift arm kickout proximity SW

CN.001

Center harness 1

1.25

124-01

JN.A06

CN.002

Center harness 2

1.25

G-B

124-02

CN.008

Lift arm kickout proximity SW

JN.A06

1.25

G-B

124-03

CN.014

Axle oil temperature sensor

JN.A06

1.25

G-B

131-01

CN.016

Lift arm raise pilot pressure sensor

CN.001

Center harness 1

1.25

R-L

135-01

CN.001

Center harness 1

CN.008

Lift arm kickout proximity SW

1.25

141-01

CN.014

Axle oil temperature sensor

CN.002

Center harness 2

1.25

208-01

CN.008

Lift arm kickout proximity SW

CN.002

Center harness 2

1.25

R-G

215-01

CN.022

Bucket leveler proximity SW

CN.002

Center harness 2

1.25

L-R

331-01

CN.003

Ride control solenoid

CN.002

Center harness 2

1.25

Y-B

332-01

CN.003

Ride control solenoid

CN.002

Center harness 2

1.25

W-B

341-01

CN.001

Center harness 1

CN.018

Quick coupler (opt)

1.25

L-R

342-01

CN.001

Center harness 1

CN.018

Quick coupler (opt)

1.25

G-B

501-01

CN.019

Front combination lamp (turn R)

CN.002

Center harness 2

1.25

L-R

502-01

CN.004

Front combination lamp (turn L)

CN.002

1.25

R-L

511-01

JN.A01

CN.002

Center harness 2 Center harness 2

1.25

G-Y

511-02

JN.A01

CN.007

Head light (L)

1.25

G-Y

511-03

JN.A01

CN.017

Head light (R)

1.25

G-Y

512-01

JN.A03

CN.002

Center harness 2

1.25

Y-B

512-02

CN.007

1.25

Y-B

512-03

JN.A03

CN.017

Head light (R)

1.25

Y-B

515-01

JN.A02

CN.002

Center harness 2

1.25

515-02

JN.A02

CN.020

Front combination lamp (width R)

1.25

515-03

JN.A02

CN.005

Front combination lamp (width L)

1.25

527-01

JN.A04

CN.002

Center harness 2

1.25

W-B

527-02

CN.011

1.25

W-B

527-03

JN.A04

1.25

W-B

Front combination lamp (Turn signal (L))

HLL white tape

JN.A06 JN.A03

527-01 511-01 512-01 502-01 W-B G-Y Y-B R-L

14 YAZAKI SWP 7123-7544-40

LPS

JN.A01

Y-B 4

W-B

501-01 208-01 8 L-R R-G

11 11

YAZAKI SWP 7222-7544-40

CN.031 000-11 208-01 B R-G

LPS

Gray

CN.017 Head light RH

CN.019 1

1 B

G-Y

CN.021

124-03 141-01 G-B Br

YAZAKI SWP 7123-1424-40

YAZAKI 090-2 7283-7027-40

B SL01510

000-01 000-02 000-03 000-04 000-05 000-06 000-07 000-08 000-11

CB001

1 332-01 331-01 W-B Y-B

SUMITOMO MT090 6189-0031

Gray

CN.012

Ride control solenoid

(YA-7120-3011)

SUMITOMOMT090 6180-2405

YAZAKI SWP 7123-7434-40

YAZAKI SWP 7222-7434-40

Horn (high)

7116-2270

527-03 W-B

Horn (high)

CN.010

Lift arm (boom) raise pilot pressure sensor

121-01 131-01 122-01 P R-L V

000-10 B

(YA-7120-3011)

CN.016 3

7116-2270

CN.013

JN.A05 JN.A04

Front combination lamp (width lamp RH)

YAZAKI SWP 7222-7434-40

CN.015 GND

Front combination lamp RH GND

CN.003 2

000-08 215-01 B L-R

BPS

515-02 P

WLR

341-01 000-02 342-01 L-R B G-B YAZAKI SWP 7123-7434-40

Front combination lamp (Turn signal (R))

CA001

CN.020 1

CN.022 Bucket leveler proximity SW

000-07 B

FCR 1

COUP

CB001

Y-B

CN.018 Coupler (Opt)

501-01 L-R

WKR

000-06 511-03 512-03

HLR

Head light LH

Lift arm kickout proximity SW

YAZAKI SWP 7123-1424-40

white tape

CN.014 Axle oil temperature sensor

208-01 000-11 R-G B

BPS

YAZAKI SWP 7222-7464-40

YAZAKI SWP 7123-7434-40

CN.033

white tape

Horn (high)

Front combination lamp (width lamp L)

215-01 124-01 141-01 000-01 L-R G-B Br B

CN.013

YAZAKI SWP 7123-7464-40

502-01 512-01 511-01 527-01 R-L Y-B G-Y W-B

JN.A04

123-01 135-01 124-02 W Y G-B

331-01 332-01 515-01

208-01 501-01 8 R-G L-R

000-01 141-01 124-01 215-01 B Br G-B L-R

000-04 511-02 512-02 G-Y Y-B B

Horn (low)

JN.A03

F2 white tape

Front combination lamp LH GND

208-01 000-11 R-G B

YAZAKI SWP 7123-7434-40

JN.A02

CN.002

515-01 332-01 331-01 P W-B Y-B

Head light (L)

CN.008

3 8

JN.A05

CN.007

YAZAKI SWP 7222-7484-40

CN.042 3

1 2 3 331-01 332-01 515-01 Y-B W-B P 1.25 1.25 1.25 7 6 5 4 502-01 512-01 511-01 527-01 W-B G-Y Y-B R-L 1.25 1.25 1.25 1.25 8 9 10 501-01 208-01 L-R R-G 1.25 1.25 11 12 13 14 215-01 124-01 141-01 000-01 L-R G-B Br B 1.25 1.25 1.25 1.25

6 515-03 P

1 CB001

3 000-03 B

CA001

WLL

131-01 123-01135-01

135-01 123-01 131-01 Y W R-L

Wire Color

CN.005

341-01 342-01 122-01 121-01 L-R P G-B V

131-01 123-01 135-01 R-L W Y 5

121-01 122-01 342-01 341-01 P V G-B L-R

341-01 342-01 122-01 121-01 L-R G-B V P

FCL

Front Chassis Harness CN.001

Wire Dia.

CN/JN No. CN.015

CN.006

To rear chassis main (p.8)

CN/JN No. CN.002

(YA-7120-3011)

7116-2270

000-09 B

Horn (low)

CN.011 (YA-7120-3011)

7116-2270

527-02 W-B

Horn (low)

-5-

90Z6 Rear Chassis Cable Layout (1/2)

Pressure sensor (secondary pilot, pilot accumulator)

Pressure sensor primary pilot, brake accumulator)

Center harness (between front and rear chassis)

Pump swash angle solenoid

Floor GND

Parking brake solenoid Floorboard Washer tank Combination valve

Arrow View A-A Floor harness Pressure sensor (main pump accessory) Floor harness Floorboard

Hydraulic oil tank

Hydraulic main pump Hydraulic oil temperature sensor T/C oil temperature sensor Air heater

Air heater GND

Starter motor To Engine

Air cleaner

Fuel level sensor

B Fusible link

Arrow View B-B

ECM Air cleaner clogging sensor A/C compressor

Battery box Battery box

Fuel tank

Combination lamp Combination lamp Rear working lamp

Buzzer

Rear working lamp 03257-02910

Fan motor

-6-

90Z6 Rear Chassis Cable Layout (2/2) Rear chassis main harness To battery relay

Rear chassis main harness

S Rear chassis main harness

Red&Green

White&Blue

15 Red

8 White

8 Red x4

70A white tape

20 Red

To fusible link

Green&White

20 Red

100A

100A yellow tape

To starter

100A

100

20 Black

To GND

100 Red 8 White

100 Red

yellow tape

To engine body

15 Black

Green&White

Battery relay 20 Red

To engine GND

100 Red

Black

100 Black

Heater relay

Black&White

15 Black

Black& Blue

Starter Motor Wiring

To air heater

Alternator Wiring

2 poles

Buzzer

+ To alternator

Rear working lamp

To battery (+)

Rear working lamp

Engine Relay Wiring < Rear Grille Harness > CN: Connector, JN: Junction From Wire No.

CN/JN No.

000-01

CN.311

000-02

JN.C01

CN.303

000-03

JN.C01

CN.309

000-04

JN.C01

CN.304

000-05

CN.310

000-06

CN.305

325-01

CN.311

326-01

CN.311

501-01

CN.311

502-01

CN.311

503-01

CN.311

Rear chassis main harness

Rear combination lamp (L) Rear working lamp (L) Rear chassis main harness Rear chassis main harness Rear chassis main harness Rear chassis main harness Rear chassis main harness Rear combination lamp (R)

CN/JN No.

0.85

B B W-B

CN.306

CN.309

CN.310

JN.C04

CN.309

505-01

CN.311

Rear chassis main harness

Rear combination lamp (R)

CN.309

0.85

JN.C04

JN.C02

0.85

JN.C01

503-02

505-02

0.85 2

JN.C01

503-03

505-03

Buzzer Rear combination lamp (R) Rear working lamp (R)

Wire Color

JN.C01

Wire Dia.

Hydraulic fan solenoid Hydraulic fan solenoid

0.85

B-R

Rear combination lamp (R) Rear combination lamp (L)

0.85

L-R

JN.C04

Rear combination lamp (L)

CN.310

JN.C02 JN.C02

Rear combination lamp (L) Buzzer

CN.310

0.85

R-L

0.85

W-R

0.85

W-R

0.85

W-R

0.85

Br-W

0.85

Br-W

0.85

Br-W

0.85

W-G

506-01

CN.311

CN.303

515-01

CN.311

Rear chassis main harness Rear chassis main harness

JN.C03

0.85

515-02

CN.309

Rear combination lamp (R)

JN.C03

0.85

515-03

JN.C03

518-01

CN.311

Rear chassis main harness

Rear working lamp (R)

518-02

CN.304

518-03

JN.C05

Rear combination lamp (L)

CN.310

JN.C05 JN.C05

Rear working lamp (L)

CN.305

0.85

G-W

0.85

G-W

0.85

G-W

Fan motor

Combination lamp

Rear Grille Wiring

CN.310

To rear main (p.8)

CN.311 1

CLL

325-01 326-01 W-B B-R

Rear combination lamp (L) 4

506-01 000-01 501-01 505-01 W-G B L-R Br-W

515-03 503-03 000-05 P W-R B

502-01 503-01 515-01 518-01 R-L W-R P G-W

CN.304

1 502-01 505-03 R-L Br-W

518-02 000-04

WLR

CN.305 1

G-W

Rear working lamp (R)

Rear working lamp (L) CN.306

SUMITOMO TS 6189-0239

YAZAKI SWP 7123-7464-40

1 518-03 000-06 G-W B

WLL

SUMITOMO TS 6189-0239

Black

F JN.C03 JN.C04

JN.C02

white tape

JN.C01

CN.309 3

JN.C05

CLR 6

4 YAZAKI SWP 7123-7464-40

W-B

Hydraulic fan solenoid

515-02 503-02 000-03 P W-R B

B-R

DEUTSCH DT DT06-2S-CE05

CN.303

Rear combination lamp (R)

326-01 325-01

white tape

1 501-01 505-02 L-R Br-W

YAZAKI SWP 7222-7923-40

Black

000-02 506-01 B W-G

Back Buzzer

DEUTSCH DT DT06-2S-CE05

03257-02910 33194-47760 33194-47790

-7-

90Z6 Rear Chassis Wiring Diagram (1/2)(S/N 0101~0102) To rear console (p.18)

341-01 342-01 122-01 121-01 L-R

G-B

For rear console option (not used)

841-01 842-01 843-01 R W L

RRO

328-01 331-01 332-01 525-01 G-Y Y-B W-B L-R 13

CN.208 To steering pressure switch (opt)

RRB

AMP EJC2 174357-2

YAZAKI SWP 7222-7564-40

To center harness (p.5)

121-01 122-01 342-01 341-01 P V G-B L-R

R1 8

R-L

CN.218 To Air cleaner clogging SW CN.337

CN.230 Fuel level sensor

YAZAKI SWP 7123-7464-40

YAZAKI SWP 7222-7464-40

Black

124-03 139-01 123-03 G-B Gr W

527-01 511-01 512-01 502-02 W-B G-Y Y-B R-L 208-01 501-02 R-G L-R

YAZAKI SWP 7123-1424-40

Gray

154-01 153-01 Gr Y-B

FLS

CN.225 Alternator R-terminal

AMP EJC2 174352-2

JN.C11

CN.237 Diode unit (parking brake)

YAZAKI SWP 7222-1424-40

YAZAKI SWP 7123-1424-40

Gray

B-W

061-02 407-02 B-W P

YAZAKI SWP 7123-1424-40

YAZAKI SWP 7322-9623-40

CN.226 Alternator I-terminal

000-02 000-03 000-04 000-05 000-06

SL00105

1 601-03 000-12 G B

CN.234 Fusible link (100A-Floor)

white tape

DAC

CN.240 A/C compressor (GND)

YAZAKI SWP 7123-1424-40

YAZAKI SWP 7322-9623-40

Gray

R 965a-01 965b-01 SL03006 965c-01 965d-01

JN.C16

707-01 G-W

ALI

CN.241 Diode unit (A/C) 2

100

YAZAKI 62Z 7123-8521-80

Gray

YAZAKI SWP 7123-7544-40

SL00506

CA001

CN.221 Parking solenoid

1 061-03 407-03

000-15 141-01 124-02 215-01 B Br G-B L-R

GND

YAZAKI 62Z 7123-8520-40

799-01 W-L

ALR

white tape

CN.242 To ECM GND

JN.C10

1 000-es 525-01 B L-R

1 322-01 321-01 L-Y R-Y

PSS

CN.227 To secondary steering motor

515-02 332-01 331-01 P W-B Y-B

AMP EJC2 174359-2

000-10 151-01 B R-L

CN.222 Pump swash plate tilt solenoid

AMP EJC2 174357-2

ACS

YAZAKI 91-RV 7223-6536-30

124-07 136-01 123-07 G-B L-W W

ESP

328-01 327-01 G-Y Y-R

FRS

123-06 127-02 124-08 R-L G-B W

CN.235 Secondary steering pressure sensor

CN.216 To Center Harness CN.044

YAZAKI SWP 7123-7923-40

red tape

YAZAKI SWP 7123-7484-40

326-01 325-01 B-R W-B

JN.C30 JN.C29 JN.C28

135-01 123-02 131-01 Y

CN.224 Fan reversing solenoid (opt)

YAZAKI SWP 7222-7434-40

CN.211 To Center Harness CN.043

518-01 515-03 503-01 502-03 G-W P W-R R-L

CN.203 Parking brake pressure sensor

505-01 501-03 000-11 506-01 Br-W L-R B W-G

YAZAKI SWP 7123-7464-40

124-05 126-01 123-05 G-B Y-B W

YAZAKI SWP 7123-7434-40

843-01 000-opt R B

YAZAKI SWP 7222-7464-40

CN.238 Service brake primary pressure sensor

137-01 000-sps 021-02 Br-Y B Y

SPS

840-01 841-01 842-01 Y-G W L

OPT 6

127-01 126-01 142-01 327-01 Y-R R-L Y-B W-L

For rear grille option (not used)

YAZAKI SWP 7123-7434-40

YAZAKI SWP 7222-7434-40

CN.210 To rear grille CN.311

131-01 123-01 135-01 139-01 R-L W Y Gr

CN.251

CN.202 To Rear Console CN.706 1

To rear grille (p.7)

CN.252

CN.239 A/C compressor (+)

000-13 B

ACG SL00205

JN.C13

1 601-02 G

AC+

JN.C14 JN.C12

JN.C21 JN.C09 JN.C08

JN.C18

JN.C19 JN.C20

CN.228 GND (front) -F SL00510

CN.212 Diode unit (washer-F) 2

B 000-15 000-es 000-sps 000-wmf 000-wmr

DWF

000-07 000-wmf B

WMR

To rear console (p.18) 5

-8-

30 511-01 718-01 840-01 141-01 721-01 124-01 Br G-B G-Y Y-G W-B Lg-R 40 407-01 061-01 322-01 321-01 532-02 531-02 592-01 591-01 136-01 724-01 L-W B-W L-Y R-Y R-B W-L V G-Y Y-B P

RRC 2

W-L 50

G-W

R-G

G 47

Y-B

CN.204 To rear console CN.708

000-04 000-05 021-03 S1L-b S1S-b B B Y W Gr 47

S1H-b L

CN.268 To Battery relay CN269 2

1 701-01 000-09 W-B B

S1H-a S1L-a L W

1 965d-01 965c-01 R R YAZAKI 58Y 7123-4220-40

Gray

712-01 W-R

DEUTSCH DT DT06-3S-CE05

DEUTSCH DT DT04-3P-P006

10 710-01 G-W

11 708-01 B-L

CN.233 Fusible link (70A-Floor)

8 592-01 V

70 SL00806

912-01 W 8.0

1 G-W

GRC

white tape

CN.223 Fusible link (70A-Battery relay)

YAZAKI SWP 7123-1424-40

Gray

718-01 Lg-R 41

31 30

19 896-01 B-Y 18 7 895-01 B-R 17

6 896-01 5 B-Y 16 895-01 B-R 15

CN.217 To Heater relay CN.333

B-L

ECM2

Gray

708-01 710-01

716-01 W

YAZAKI 58Y 7123-4220-30

Black

965b-01 965a-01 R

769-01

YAZAKI SWP 7123-1424-40

770-01 13 R-Y

CN.207 ECM (31-pole)

RGT

912-01 W

CN.229 CAN resistor

YAZAKI SWP 7182-5055-40

DEUTSCH DRC DRC26-50S01

SL00808

Gray

RRE

RRD

R-W

YAZAKI 58Y 7123-4210-40

20 1

RRA

000-03 000-02 711-03

724-01 556-01 Y-B W-R 15

711-02 713-04 554-03 R-W L-W Br

000-06 717-01 715-01 B R B 50

CN.232 Battery relay (SW)

CN.209 Battery power

208-01 527-01 799-01 707-01 704-01 601-01 154-01 153-01 W-B

Gray

554-01 556-01 Br W-R

R-G

911-01 R

W-L

CN.205 To rear console CN.709

716-01 715-01 W R

721-03 721-02 713-03 713-02 554-02 W-B W-B L-W L-W Br

STC SL00105

15 10 S1S-c1 S1L-c S1H-c 021-01 713-01 711-01 137-01 326-01 325-01 518-01 Gr W L Y L-W R-W Br-Y B-R W-B G-W

G-B

TOKAIRIKA 090-2 4F0178-0001

CN.206 ECM (50-pole)

ECM

Blue

515-01 503-01 502-01 501-01 505-01 506-01 151-01 701-01 P W-R R-L L-R Br-W W-G R-L W-B

JN.C23 JN.C24 JN.C25

704-01 R-G

YAZAKI CN 7123-2228-90

769-01 770-01 712-01 717-01 R R-Y W-R B

532-01 532-02 R-B

CN.201 To rear console CN.705

215-01 512-01 L-R Y-B 25

000-08 000-wmr

JN.C22

JN.C15

124-06 142-01

CN.219 Starter (C)

CN.214 Washer motor (R)

YAZAKI SWP 7123-1424-40

JN.C31

YAZAKI SWP 7123-1424-40

White

Gray

OTS

YAZAKI CN 7123-2228

DWR

white tape

CN.220 Hydraulic oil temperature sensor CN.331

1 532-01 000-08 R-B B

white tape

B 000-09 000-10 000-11 000-14 000-opt

WMF

CN.215 Diode unit (washer-R)

SL00510

531-01 531-02 W-L

Gray

-R

CN.213 Washer motor (F)

YAZAKI SWP 7123-1424-40

YAZAKI SWP 7322-9623-40

CN.236 GND (rear)

1 531-01 000-07 W-L B

YAZAKI SWP 7322-9623-40

white tape

SL00806

911-01 R 8.0

27 591-01 G-Y

DEUTSCH HD HD36-24-31ST

33194-47740

90Z6 Rear Chassis Wiring Diagram (2/2)(S/N 0101~0102) CN: Connector, JN: Junction

CN: Connector, JN: Junction From

To Pin

Wire Dia.

Wire Color

Wire No. Pin CN/JN No.

CN/JN No.

From

To Pin

Wire Dia.

Wire Color

Wire No. CN/JN No.

Pin CN/JN No.

000-02

CN.206

ECM (50-pole)

CN.242

ECM (GND)

0.85

502-01

JN.C19

CN.201

Rear console CN705

0.85

R-L

000-03

CN.206

ECM (50-pole)

CN.242

ECM (GND)

0.85

502-02

JN.C19

CN.216

Center harness (2)

0.85

R-L

000-04

CN.206

ECM (50-pole)

CN.242

ECM (GND)

0.85

502-03

CN.210

Rear grille

JN.C19

000-05

CN.206

ECM (50-pole)

CN.242

ECM (GND)

0.85

503-01

CN.210

Rear grille

CN.201

Rear console CN705

000-06

CN.206

ECM (50-pole)

CN.242

ECM (GND)

0.85

505-01

CN.210

Rear grille

CN.201

000-07

CN.213

Washer motor (F)

CN.212

Diode unit (washer-F)

0.85

506-01

CN.210

Rear grille

CN.201

000-08

CN.215

Diode unit (washer-R)

CN.214

Washer motor (R)

0.85

511-01

CN.216

Center harness (2)

000-09

CN.231

Battery relay (coil)

CN.236

GND (rear)

0.85

512-01

CN.201

Rear console CN705

000-10

CN.218

Air cleaner clogging SW

CN.236

GND (rear)

0.85

515-01

000-11

CN.210

Rear grille

CN.236

GND (rear)

0.85

000-12

JN.C13

CN.241

Diode unit (A/C)

1.25

000-13

JN.C13

CN.240

A/C compressor (GND)

1.25

000-14

JN.C13

CN.236

GND (rear)

000-15

CN.228

GND (front)

CN.216

Center harness (2)

000-es

CN.227

Secondary steering motor (opt)

CN.228

GND (front)

000-opt

CN.251

For rear grille option

CN.236

GND (rear)

000-sps

CN.228

GND (front)

CN.208

000-wmf

CN.213

Washer motor (F)

000-wmr

CN.214

Washer motor (R)

021-01

CN.201

Rear console CN705

021-02

JN.C21

CN.208

Steering pressure SW (opt)

021-03

JN.C21

CN.206

061-01

JN.C10

061-02

JN.C10

061-03

JN.C10

121-01

CN.211

Center harness (1)

122-01

CN.211

Center harness (1)

123-01

123-02

123-03

CN.224

123-04

JN.C30

123-05

CN.238

123-06

123-07

124-01

JN.C09

CN.201

Rear console CN705

124-02

JN.C09

CN.216

Center harness (2)

124-03

CN.224

124-04

0.85

R-L

0.85

W-R

Rear console CN705

0.85

Br-W

Rear console CN705

0.85

W-G

CN.201

Rear console CN705

0.85

G-Y

CN.216

Center harness (2)

0.85

Y-B

JN.C20

CN.201

Rear console CN705

0.85

515-02

JN.C20

CN.216

Center harness (2)

0.85

515-03

CN.210

Rear grille

JN.C20

518-01

CN.210

Rear grille

CN.201

Rear console CN705

1.25

525-01

CN.202

Rear console CN706

CN.227

0.85

527-01

CN.216

Center harness (2)

CN.201

0.85

531-01

CN.212

Diode unit (washer-F)

CN.213

0.85

531-02

CN.213

Washer motor (F)

CN.201

Steering pressure SW (opt)

0.85

532-01

CN.215

Diode unit (washer-R)

CN.228

GND (front)

0.85

532-02

CN.201

Rear console CN705

CN.228

GND (front)

0.85

554-01

JN.C21

0.85

ECM (50-pole)

0.85

CN.201

Rear console CN705

0.85

B-W

591-01

CN.201

Rear console CN705

CN.221

Parking brake solenoid

0.85

B-W

592-01

CN.201

Rear console CN705

CN.237

Diode unit (parking brake)

0.85

B-W

601-01

JN.C12

CN.201

CN.202

Rear console CN706

0.85

601-02

CN.239

CN.202

Rear console CN706

0.85

100

601-03

JN.C12

JN.C08

CN.202

Rear console CN706

0.85

101

701-01

CN.231

Battery relay (coil)

CN.201

JN.C08

CN.211

Center harness (1)

0.85

102

704-01

CN.219

Starter SW C-terminal

CN.201

103

707-01

CN.226

Alternator I-terminal

CN.201

0.85

G-W

Secondary steering motor (opt)

0.85

L-R

Rear console CN705

0.85

W-B

Washer motor (F)

0.85

W-L

Rear console CN705

0.85

W-L

CN.214

Washer motor (R)

0.85

R-B

CN.214

Washer motor (R)

0.85

R-B

JN.C31

CN.201

Rear console CN705

0.85

554-02

JN.C31

CN.206

ECM (50-pole)

0.85

554-03

JN.C31

CN.206

ECM (50-pole)

0.85

556-01

CN.201

CN.206

ECM (50-pole)

0.85

W-R

CN.207

ECM (31-pole)

0.85

G-Y

CN.207

ECM (31-pole)

0.85

Rear console CN705

1.25

Diode unit (A/C)

1.25

Rear console CN705

0.85

W-B

Rear console CN705

1.25

R-G

Rear console CN705

0.85

G-W

Rear console CN705

A/C compressor (+)

JN.C12 CN.241

Fan reversing solenoid (opt)

JN.C08

0.85

JN.C08

0.85

104

708-01

CN.217

Heater relay

CN.207

ECM (31-pole)

0.85

B-L

Service brake primary pressure sensor

JN.C08

0.85

105

710-01

CN.217

Heater relay

CN.207

ECM (31-pole)

0.85

G-W

CN.203

Parking brake pressure sensor

JN.C30

0.5

106

711-01

CN.201

Rear console CN705

JN.C16

0.85

R-W

CN.235

Secondary steering pressure sensor (opt)

JN.C08

0.85

107

711-02

CN.206

ECM (50-pole)

JN.C16

0.85

R-W

0.85

G-B

108

711-03

CN.206

ECM (50-pole)

JN.C16

0.85

R-W

0.85

G-B

109

712-01

CN.201

Rear console CN705

CN.206

0.85

W-R

JN.C09

0.85

G-B

110

713-01

CN.201

Rear console CN705

JN.C14

0.85

L-W

JN.C09

JN.C28

0.85

G-B

111

713-02

CN.206

ECM (50-pole)

JN.C14

0.85

L-W

124-05

JN.C09

CN.238

Service brake primary pressure sensor

0.85

G-B

112

713-03

CN.206

ECM (50-pole)

JN.C14

0.85

L-W

124-06

JN.C09

CN.220

Hydraulic oil temperature sensor

0.85

G-B

113

713-04

JN.C14

L-W

124-07

CN.235

Secondary steering pressure sensor (opt)

JN.C09

0.85

G-B

114

715-01

CN.201

Rear console CN705

124-08

CN.203

Parking brake pressure sensor

JN.C28

0.5

G-B

115

716-01

CN.201

126-01

CN.238

Service brake primary pressure sensor

CN.202

0.85

Y-B

116

717-01

127-01

CN.202

Rear console CN706

JN.C29

0.85

R-L

117

718-01

127-02

CN.203

Parking brake pressure sensor

JN.C29

0.5

R-L

118

131-01

CN.211

Center harness (1)

CN.202

Rear console CN706

0.85

R-L

119

135-01

CN.211

Center harness (1)

CN.202

Rear console CN706

0.85

136-01

CN.235

Secondary steering pressure sensor (opt)

CN.201

Rear console CN705

0.85

137-01

CN.201

Rear console CN705

CN.208

Steering pressure SW (opt)

139-01

CN.224

Fan reversing solenoid (opt)

CN.202

Rear console CN706

141-01

CN.216

Center harness (2)

CN.201

142-01

CN.220

Hydraulic oil temperature sensor

CN.202

151-01

CN.218

Air cleaner clogging SW

153-01

CN.230

Fuel level sensor

154-01

CN.230

Fuel level sensor

208-01

CN.216

215-01

CN.216

321-01

322-01

Fan reversing solenoid (opt)

ECM (50-pole)

CN.206

ECM (50-pole)

0.85

CN.206

ECM (50-pole)

0.85

Rear console CN705

CN.206

ECM (50-pole)

0.85

CN.201

Rear console CN705

CN.206

ECM (50-pole)

0.85

CN.201

Rear console CN705

CN.206

ECM (50-pole)

0.85

Lg-R

721-01

CN.201

Rear console CN705

0.85

W-B

721-02

JN.C15

ECM (50-pole)

0.85

W-B

120

721-03

CN.206

ECM (50-pole)

JN.C15

0.85

W-B

L-W

121

724-01

CN.206

ECM (50-pole)

CN.201

Rear console CN705

0.85

Y-B

0.85

Br-Y

122

769-01

CN.201

Rear console CN705

CN.206

ECM (50-pole)

0.85

123

770-01

CN.201

Rear console CN705

CN.206

ECM (50-pole)

0.85

R-Y

Rear console CN705

0.85

124

799-01

CN.225

Alternator R-terminal

CN.201

Rear console CN705

0.85

W-L

Rear console CN706

0.85

W-L

125

840-01

CN.251

For rear grille option

CN.201

Rear console CN705

0.85

Y-G

CN.201

Rear console CN705

0.85

R-L

126

841-01

CN.252

For rear console option

CN.251

For rear grille option

0.85

CN.201

Rear console CN705

0.85

Y-B

127

842-01

CN.252

For rear console option

CN.251

For rear grille option

0.85

CN.201

Rear console CN705

0.85

128

843-01

CN.252

For rear console option

CN.251

For rear grille option

0.85

Center harness (2)

CN.201

Rear console CN705

0.85

R-G

129

895-01

CN.207

ECM (31-pole)

CN.207

ECM (31-pole)

0.85

B-R

Center harness (2)

CN.201

Rear console CN705

0.85

L-R

130

896-01

CN.207

ECM (31-pole)

CN.207

ECM (31-pole)

0.85

B-Y

CN.222

Pump swash plate tilt solenoid

CN.201

Rear console CN705

0.85

R-Y

131

911-01

CN.223

Fusible link (70A-Battery relay)

CN.232

Battery relay (SW)

8.0

CN.222

Pump swash plate tilt solenoid

CN.201

Rear console CN705

0.85

L-Y

132

912-01

CN.233

Fusible link (70A-Floor)

CN.209

Battery power

8.0

Rear console CN706

JN.C15 CN.206

325-01

CN.210

Rear grille

CN.201

Rear console CN705

0.85

W-B

133

965a-01

CN.234

Fusible link (100A-Floor)

CN.205

Rear console CN709

8.0

326-01

CN.210

Rear grille

CN.201

Rear console CN705

0.85

B-R

134

965b-01

CN.205

Rear console CN709

CN.234

Fusible link (100A-Floor)

8.0

327-01

CN.224

Fan reversing solenoid (opt)

CN.202

Rear console CN706

0.85

Y-R

135

965c-01

CN.204

Rear console CN708

CN.234

Fusible link (100A-Floor)

8.0

328-01

CN.224

Fan reversing solenoid (opt)

CN.202

Rear console CN706

0.85

G-Y

136

965d-01

CN.204

Rear console CN708

CN.234

Fusible link (100A-Floor)

8.0

331-01

CN.216

Center harness (2)

CN.202

Rear console CN706

0.85

Y-B

137

S1H-a

JN.C23

CN.229

CAN terminator

0.5

332-01

CN.216

Center harness (2)

CN.202

Rear console CN706

0.85

W-B

138

S1H-b

CN.206

ECM (50-pole)

JN.C23

0.5

341-01

CN.211

Center harness (1)

CN.202

Rear console CN706

0.85

L-R

139

S1H-c

CN.201

Rear console CN705

JN.C23

0.5

342-01

CN.211

Center harness (1)

CN.202

Rear console CN706

0.85

G-B

140

S1L-a

JN.C24

0.5

407-01

JN.C11

CN.201

Rear console CN705

0.85

141

S1L-b

CN.206

ECM (50-pole)

JN.C24

0.5

407-02

JN.C11

CN.221

Parking brake solenoid

0.85

142

S1L-c

CN.201

Rear console CN705

JN.C24

0.5

407-03

JN.C11

CN.237

Diode unit (parking brake)

0.85

143

S1S-b

JN.C25

0.5

501-01

JN.C18

CN.201

Rear console CN705

0.85

L-R

144

S1S-c

JN.C22

JN.C25

501-02

JN.C18

CN.216

Center harness (2)

0.85

L-R

145

S1S-c1

JN.C22

CN.201

501-03

CN.210

0.85

L-R

Rear grille

JN.C18

CN.229

CN.206

CAN terminator

ECM (50-pole)

Rear console CN705

0.5

-933194-47740

90Z6 Rear Chassis Wiring Diagram (1/2)(S/N 0103~/9001~)

To rear grille (p.7) CN.251

CN.243 To secondary steering (opt) 3

136-01 000-es 525-01 L-R L-W B

124-07 123-07 137-01 Br-Y G-B W

YAZAKI SWP 7222-7464-40

CN.252 For rear console option (not used) 1

For rear grille option (not used) 6

YAZAKI SWP 7123-7434-40

121-01 122-01 342-01 341-01 P V G-B L-R

R1 8

R-L

1 5

RRB 5 9

G-B

131-01 123-01 135-01 139-01 R-L W Y Gr 127-01 126-01 142-01 327-01 Y-R R-L Y-B W-L

YAZAKI 91-RV 7223-6536-30

YAZAKI SWP 7222-7464-40

Black

527-01 511-01 512-01 502-02 W-B G-Y Y-B R-L 208-01 501-02 R-G L-R

2 12

JN.C11

JN.C10

CN.237 Diode unit (parking brake) 2

B-W

YAZAKI SWP 7123-1424-40

YAZAKI SWP 7322-9623-40

799-01 W-L

ALR CA001

white tape

CN.226 Alternator I-terminal

000-02 000-03 000-04 000-05 000-06

SL00105

1 601-03 000-12 G B

CN.234 Fusible link (100A-Floor)

white tape

DAC

CN.240 A/C compressor (GND)

YAZAKI SWP 7123-1424-40

YAZAKI SWP 7322-9623-40

Gray

R 965a-01 965b-01 SL03006 965c-01 965d-01

JN.C16

707-01 G-W

ALI

CN.241 Diode unit (A/C) 2

100

YAZAKI 62Z 7123-8521-80

Gray

CN.225 Alternator R-terminal

SL00506

061-02 407-02 B-W P

Gray

154-01 153-01 Gr Y-B AMP EJC2 174352-2

GND

YAZAKI SWP 7123-1424-40

FLS

CN.221 Parking solenoid

000-10 151-01 B R-L

ACS

CN.230 Fuel level sensor

YAZAKI SWP 7123-7464-40

CN.242 To ECM GND

YAZAKI 62Z 7123-8520-40

YAZAKI SWP 7123-7544-40

124-03 139-01 123-03 G-B Gr W

1 322-01 321-01 L-Y R-Y

PSS

YAZAKI SWP 7222-7564-40

CN.222 Pump swash plate tilt solenoid

061-03 407-03

000-15 141-01 124-02 215-01 B Br G-B L-R

CN.218 To Air cleaner clogging SW CN.337

YAZAKI SWP 7123-7923-40

FRS

515-02 332-01 331-01 P W-B Y-B

123-06 127-02 124-08 R-L G-B W

328-01 327-01 G-Y Y-R

328-01 331-01 332-01 525-01 G-Y Y-B W-B L-R

CN.216 To Center Harness CN.044

341-01 342-01 122-01 121-01 L-R

YAZAKI SWP 7123-7484-40

3 3

326-01 325-01 B-R W-B

red tape

JN.C30 JN.C29 JN.C28

135-01 123-02 131-01 Y

CN.224 Fan reversing solenoid (opt)

CN.203 Parking brake pressure sensor

CN.202 To Rear Console CN.706 1

518-01 515-03 503-01 502-03 G-W P W-R R-L

AMP EJC2 174357-2

To rear console (p.18)

CN.211 To Center Harness CN.043

YAZAKI SWP 7123-7464-40

505-01 501-03 000-11 506-01 Br-W L-R B W-G

124-05 126-01 123-05 G-B Y-B W

To center harness (p.5)

YAZAKI SWP 7123-7464-40

843-01 000-opt R B

YAZAKI SWP 7222-7464-40

CN.238 Service brake primary pressure sensor

YAZAKI SWP 7222-7434-40

840-01 841-01 842-01 Y-G W L

OPT

3 841-01 842-01 843-01 R W L

RRO

CN.210 To rear grille CN.311

CN.239 A/C compressor (+)

000-13 B

ACG SL00205

1 601-02 G

AC+

JN.C14 JN.C12

JN.C21 JN.C09 JN.C08

JN.C18

JN.C19 JN.C20

CN.228 GND (front) -F SL00510

CN.212 Diode unit (washer-F) 2

DWF

000-07 000-wmf B

WMR

To rear console (p.18)

- 10 -

30 511-01 718-01 840-01 141-01 721-01 124-01 Br G-B G-Y Y-G W-B Lg-R 40 407-01 061-01 322-01 321-01 532-02 531-02 592-01 591-01 136-01 724-01 L-W B-W L-Y R-Y R-B W-L V G-Y Y-B P

RRC 2

RRE

CN.204 To rear console CN.708

27 2

1 965d-01 965c-01 R R

208-01 527-01 799-01 707-01 704-01 601-01 154-01 153-01 R-G

W-B

W-L 50

G-W

R-G

G 47

CN.268 To Battery relay CN269 2

Y-B

YAZAKI SWP 7182-5055-40

1 701-01 000-09 W-B B

S1H-a S1L-a L W

S1H-b L

YAZAKI 58Y 7123-4220-40

Gray

DEUTSCH DT DT06-3S-CE05

DEUTSCH DT DT04-3P-P006

CN.233 Fusible link (70A-Floor) 70 SL00806

912-01 W 8.0

1 B-L

G-W

GRC

white tape

CN.223 Fusible link (70A-Battery relay)

YAZAKI SWP 7123-1424-40

Gray

35 712-01 W-R

10 710-01 G-W

11 708-01 B-L

8 592-01 V

718-01 Lg-R 41

31 30

19 896-01 B-Y 18 7 895-01 B-R 17

6 896-01 5 B-Y 16 895-01 B-R 15

CN.217 To Heater relay CN.333 708-01 710-01

716-01 W

YAZAKI 58Y 7123-4220-30

Black

ECM2

965b-01 965a-01 R

769-01

Gray

770-01 13 R-Y

CN.207 ECM (31-pole)

YAZAKI SWP 7123-1424-40

RRD

000-04 000-05 021-03 S1L-b S1S-b B B Y W Gr

CN.229 CAN resistor A

Gray

RGT

912-01 W

YAZAKI 58Y 7123-4210-40

RRA

DEUTSCH DRC DRC26-50S01

SL00808

554-01 556-01 Br W-R

R-W

CN.205 To rear console CN.709

716-01 715-01 W R

000-06 717-01 715-01 B R B 50

CN.232 Battery relay (SW)

CN.209 Battery power

15 10 S1S-c1 S1L-c S1H-c 021-01 713-01 711-01 137-01 326-01 325-01 518-01 Gr W L Y L-W R-W Br-Y B-R W-B G-W

Gray

Blue

515-01 503-01 502-01 501-01 505-01 506-01 151-01 701-01 P W-R R-L L-R Br-W W-G R-L W-B

769-01 770-01 712-01 717-01 R R-Y W-R B

911-01 R

YAZAKI CN 7123-2228-90

000-03 000-02 711-03

724-01 556-01 Y-B W-R 15

711-02 713-04 554-03 R-W L-W Br

STC SL00105

W-L

704-01 R-G

ECM

721-03 721-02 713-03 713-02 554-02 W-B W-B L-W L-W Br

1 G-B

TOKAIRIKA 090-2 4F0178-0001

CN.206 ECM (50-pole)

124-06 142-01

CN.219 Starter (C)

000-08 000-wmr

JN.C22

CN.201 To rear console CN.705 5

532-01 532-02 R-B

JN.C13 JN.C23 JN.C24 JN.C25

JN.C15

YAZAKI SWP 7123-1424-40

CN.214 Washer motor (R)

Gray

215-01 512-01 L-R Y-B 25

OTS

White

YAZAKI SWP 7123-1424-40

white tape JN.C31

CN.220 Hydraulic oil temperature sensor CN.331

YAZAKI CN 7123-2228

DWR

white tape

B 000-09 000-10 000-11 000-14 000-opt

1 532-01 000-08 R-B B

SL00510

WMF

CN.215 Diode unit (washer-R)

-R

531-01 531-02 W-L

Gray

B 000-15 000-es 000-sps 000-wmf 000-wmr

CN.213 Washer motor (F)

YAZAKI SWP 7123-1424-40

YAZAKI SWP 7322-9623-40

CN.236 GND (rear)

1 531-01 000-07 W-L B

YAZAKI SWP 7322-9623-40

white tape

SL00806

911-01 R 8.0

27 591-01 G-Y

DEUTSCH HD HD36-24-31ST

33194-49880

90Z6 Rear Chassis Wiring Diagram (2/2)(S/N 0103~/9001~) CN: Connector, JN: Junction

CN: Connector, JN: Junction From

To Pin

Wire Dia.

Wire Color

Wire No. Pin CN/JN No.

CN/JN No.

From

To Pin

Wire Dia.

Wire Color

Wire No. CN/JN No.

Pin CN/JN No.

000-02

CN.206

ECM (50-pole)

CN.242

ECM (GND)

0.85

502-01

JN.C19

CN.201

Rear console CN705

0.85

R-L

000-03

CN.206

ECM (50-pole)

CN.242

ECM (GND)

0.85

502-02

JN.C19

CN.216

Center harness (2)

0.85

R-L

000-04

CN.206

ECM (50-pole)

CN.242

ECM (GND)

0.85

502-03

CN.210

Rear grille

JN.C19

000-05

CN.206

ECM (50-pole)

CN.242

ECM (GND)

0.85

503-01

CN.210

Rear grille

CN.201

Rear console CN705

000-06

CN.206

ECM (50-pole)

CN.242

ECM (GND)

0.85

505-01

CN.210

Rear grille

CN.201

000-07

CN.213

Washer motor (F)

CN.212

Diode unit (washer-F)

0.85

506-01

CN.210

Rear grille

CN.201

000-08

CN.215

Diode unit (washer-R)

CN.214

Washer motor (R)

0.85

511-01

CN.216

Center harness (2)

000-09

CN.268

Battery relay (coil)

CN.236

GND (rear)

0.85

512-01

CN.201

Rear console CN705

000-10

CN.218

Air cleaner clogging SW

CN.236

GND (rear)

0.85

515-01

000-11

CN.210

Rear grille

CN.236

GND (rear)

0.85

000-12

JN.C13

CN.241

Diode unit (A/C)

1.25

000-13

JN.C13

CN.240

A/C compressor (GND)

1.25

000-14

JN.C13

CN.236

GND (rear)

000-15

CN.228

GND (front)

CN.216

Center harness (2)

000-es

CN.228

GND (front)

CN.243

Secondary Steering (opt)

000-opt

CN.251

For rear grille option

CN.236

GND (rear)

000-wmf

CN.213

Washer motor (F)

CN.228

000-wmr

CN.214

Washer motor (R)

CN.228

021-01

CN.201

Rear console CN705

061-01

0.85

R-L

0.85

W-R

Rear console CN705

0.85

Br-W

Rear console CN705

0.85

W-G

CN.201

Rear console CN705

0.85

G-Y

CN.216

Center harness (2)

0.85

Y-B

JN.C20

CN.201

Rear console CN705

0.85

515-02

JN.C20

CN.216

Center harness (2)

0.85

515-03

CN.210

Rear grille

JN.C20

518-01

CN.210

Rear grille

CN.201

1.25

525-01

CN.202

Rear console CN706

CN.243

0.85

527-01

CN.216

Center harness (2)

CN.201

0.85

531-01

CN.212

Diode unit (washer-F)

CN.213

0.85

531-02

CN.213

Washer motor (F)

CN.201

GND (front)

0.85

532-01

CN.215

Diode unit (washer-R)

0.85

532-02

CN.201

Rear console CN705

CN.206

GND (front) ECM (50-pole)

0.85

554-01

JN.C10

CN.201

Rear console CN705

0.85

B-W

061-02

JN.C10

CN.221

Parking brake solenoid

0.85

B-W

061-03

JN.C10

CN.237

Diode unit (parking brake)

0.85

G-W

Secondary steering (opt)

0.85

L-R

Rear console CN705

0.85

W-B

Washer motor (F)

0.85

W-L

Rear console CN705

0.85

W-L

CN.214

Washer motor (R)

0.85

R-B

CN.214

Washer motor (R)

0.85

R-B

JN.C31

CN.201

Rear console CN705

0.85

554-02

JN.C31

CN.206

ECM (50-pole)

0.85

554-03

JN.C31

CN.206

ECM (50-pole)

0.85

B-W

556-01

CN.201

Rear console CN705

CN.206

ECM (50-pole)

0.85

W-R G-Y

Rear console CN705

121-01

CN.211

Center harness (1)

CN.202

Rear console CN706

0.85

591-01

CN.201

Rear console CN705

CN.207

ECM (31-pole)

0.85

122-01

CN.211

Center harness (1)

CN.202

Rear console CN706

0.85

592-01

CN.201

Rear console CN705

CN.207

ECM (31-pole)

0.85

123-01

JN.C08

CN.202

Rear console CN706

0.85

601-01

JN.C12

CN.201

Rear console CN705

1.25

CN.211

Center harness (1)

1.25

CN.241

Diode unit (A/C)

1.25

G W-B

0.85

601-02

CN.239

JN.C08

0.85

601-03

JN.C12

JN.C08

0.85

701-01

CN.268

Battery relay (coil)

CN.201

Rear console CN705

0.85

JN.C08

0.85

704-01

CN.219

Starter SW C-terminal

CN.201

Rear console CN705

1.25

R-G

JN.C30

0.5

100

707-01

CN.226

Alternator I-terminal

CN.201

Rear console CN705

0.85

G-W

0.85

101

708-01

CN.217

Heater relay

CN.207

ECM (31-pole)

0.85

B-L

0.85

G-B

102

710-01

CN.217

Heater relay

CN.207

ECM (31-pole)

0.85

G-W

123-02

JN.C08

123-03

CN.224

123-04

JN.C30

123-05

CN.238

Service brake primary pressure sensor

123-06

CN.203

Parking brake pressure sensor

123-07

JN.C08

CN.243

Secondary Steering (opt)

124-01

JN.C09

CN.201

Rear console CN705

CN.216

Center harness (2)

Fan reversing solenoid (opt)

A/C compressor (+)

JN.C12

0.85

G-B

103

711-01

CN.201

Rear console CN705

JN.C16

0.85

R-W

JN.C09

0.85

G-B

104

711-02

CN.206

ECM (50-pole)

JN.C16

0.85

R-W

JN.C09

JN.C28

0.85

G-B

105

711-03

CN.206

ECM (50-pole)

JN.C16

0.85

R-W

124-05

JN.C09

CN.238

Service brake primary pressure sensor

0.85

G-B

106

712-01

CN.201

Rear console CN705

CN.206

0.85

W-R

124-06

JN.C09

CN.220

Hydraulic oil temperature sensor

0.85

G-B

107

713-01

CN.201

Rear console CN705

JN.C14

0.85

L-W

124-07

JN.C09

CN.243

Secondary Steering (opt)

0.85

G-B

108

713-02

CN.206

ECM (50-pole)

JN.C14

0.85

L-W

124-08

CN.203

Parking brake pressure sensor

JN.C28

0.5

G-B

109

713-03

CN.206

ECM (50-pole)

JN.C14

0.85

L-W

126-01

CN.238

Service brake primary pressure sensor

CN.202

0.85

Y-B

110

713-04

JN.C14

L-W

127-01

CN.202

Rear console CN706

JN.C29

0.85

R-L

111

715-01

CN.201

Rear console CN705

127-02

CN.203

Parking brake pressure sensor

JN.C29

0.5

R-L

112

716-01

CN.201

124-02

JN.C09

124-03

CN.224

124-04

Fan reversing solenoid (opt)

Rear console CN706

ECM (50-pole)

CN.206

ECM (50-pole)

0.85

CN.206

ECM (50-pole)

0.85

Rear console CN705

CN.206

ECM (50-pole)

0.85

131-01

CN.211

Center harness (1)

CN.202

Rear console CN706

0.85

R-L

113

717-01

CN.201

Rear console CN705

CN.206

ECM (50-pole)

0.85

135-01

CN.211

Center harness (1)

CN.202

Rear console CN706

0.85

114

718-01

CN.201

Rear console CN705

CN.206

ECM (50-pole)

0.85

Lg-R

136-01

CN.201

Rear console CN705

CN.243

Secondary Steering (opt)

0.85

L-W

115

721-01

CN.201

Rear console CN705

0.85

W-B

137-01

CN.201

Rear console CN705

CN.243

Secondary Steering (opt)

0.85

Br-Y

116

721-02

JN.C15

ECM (50-pole)

0.85

W-B

139-01

CN.224

Fan reversing solenoid (opt)

CN.202

Rear console CN706

0.85

117

721-03

CN.206

ECM (50-pole)

JN.C15

0.85

W-B

141-01

CN.216

Center harness (2)

CN.201

Rear console CN705

0.85

118

724-01

CN.206

ECM (50-pole)

CN.201

Rear console CN705

0.85

Y-B

142-01

CN.220

Hydraulic oil temperature sensor

CN.202

Rear console CN706

0.85

W-L

119

769-01

CN.201

Rear console CN705

CN.206

ECM (50-pole)

0.85

151-01

CN.218

Air cleaner clogging SW

CN.201

Rear console CN705

0.85

R-L

120

770-01

CN.201

Rear console CN705

CN.206

ECM (50-pole)

0.85

R-Y

JN.C15 CN.206

153-01

CN.230

Fuel level sensor

CN.201

Rear console CN705

0.85

Y-B

121

799-01

CN.225

Alternator R-terminal

CN.201

Rear console CN705

0.85

W-L

154-01

CN.230

Fuel level sensor

CN.201

Rear console CN705

0.85

122

840-01

CN.251

For rear grille option

CN.201

Rear console CN705

0.85

Y-G

208-01

CN.216

Center harness (2)

CN.201

Rear console CN705

0.85

R-G

123

841-01

CN.252

For rear console option

CN.251

For rear grille option

0.85

215-01

CN.216

Center harness (2)

CN.201

Rear console CN705

0.85

L-R

124

842-01

CN.252

For rear console option

CN.251

For rear grille option

0.85

321-01

CN.222

Pump swash plate tilt solenoid

CN.201

Rear console CN705

0.85

R-Y

125

843-01

CN.252

For rear console option

CN.251

For rear grille option

0.85

322-01

CN.222

Pump swash plate tilt solenoid

CN.201

Rear console CN705

0.85

L-Y

126

895-01

CN.207

ECM (31-pole)

CN.207

ECM (31-pole)

0.85

B-R

325-01

CN.210

Rear grille

CN.201

Rear console CN705

0.85

W-B

127

896-01

CN.207

ECM (31-pole)

CN.207

ECM (31-pole)

0.85

B-Y

326-01

CN.210

Rear grille

CN.201

Rear console CN705

0.85

B-R

128

911-01

CN.223

Fusible link (70A-Battery relay)

CN.232

Battery relay (SW)

8.0

327-01

CN.224

Fan reversing solenoid (opt)

CN.202

Rear console CN706

0.85

Y-R

129

912-01

CN.233

Fusible link (70A-Floor)

CN.209

Battery power

8.0

328-01

CN.224

Fan reversing solenoid (opt)

CN.202

Rear console CN706

0.85

G-Y

130

965a-01

CN.234

Fusible link (100A-Floor)

CN.205

Rear console CN709

8.0

331-01

CN.216

Center harness (2)

CN.202

Rear console CN706

0.85

Y-B

131

965b-01

CN.205

Rear console CN709

CN.234

Fusible link (100A-Floor)

8.0

332-01

CN.216

Center harness (2)

CN.202

Rear console CN706

0.85

W-B

132

965c-01

CN.204

Rear console CN708

CN.234

Fusible link (100A-Floor)

8.0

341-01

CN.211

Center harness (1)

CN.202

Rear console CN706

0.85

L-R

133

965d-01

CN.204

Rear console CN708

CN.234

Fusible link (100A-Floor)

8.0

342-01

CN.211

Center harness (1)

CN.202

Rear console CN706

0.85

G-B

134

S1H-a

JN.C23

CN.229

CAN terminator

0.5

407-01

JN.C11

CN.201

Rear console CN705

0.85

135

S1H-b

CN.206

ECM (50-pole)

JN.C23

0.5

407-02

JN.C11

CN.221

Parking brake solenoid

0.85

136

S1H-c

CN.201

Rear console CN705

JN.C23

0.5

407-03

JN.C11

CN.237

Diode unit (parking brake)

0.85

137

S1L-a

JN.C24

0.5

W W

CN.229

CAN terminator

501-01

JN.C18

CN.201

Rear console CN705

0.85

L-R

138

S1L-b

CN.206

ECM (50-pole)

JN.C24

0.5

501-02

JN.C18

CN.216

Center harness (2)

0.85

L-R

139

S1L-c

CN.201

Rear console CN705

JN.C24

0.5

501-03

CN.210

0.85

L-R

140

S1S-b

JN.C25

141

S1S-c

JN.C22

JN.C25

142

S1S-c1

JN.C22

CN.201

Rear grille

JN.C18

CN.206

ECM (50-pole)

0.5 0.5

Rear console CN705

0.5

- 11 33194-49880

90Z6 Rear Chassis Wiring Diagram (Transmission) To rear console (p.18) CN.114 T/C input revolution sensor (E/G speed)

CN.101 To rear console CN.703 4

1 101-01 182-01 L W-Y 5

103-01 L

102-01 186-01 L W-Y

188-01 105-01 W-Y L

CN.103 T/M 4th speed clutch solenoid 1

362-01 361-01 B-W R

W-Y

SUMITOMO MT090 6189-0031

YAZAKI SWP 7123-1424-40

Gray 9

356-01 355-01 G-B L-W

13 360-01 B-Y

358-01 357-01 B-Y R-G

359-01 362-01 R-W B-W

352-01 351-01 17

B-W

361-01 16 R

G-B

113-01 B-W

TCT SL00104

white tape

SUMITOMO DL040 6188-0494

CN.110 T/C output revolution sensor TO

1 360-01 359-01 R-W B-Y

1 356-01 355-01 G-B L-W

SUMITOMO MT090 6189-0031

CN.108 T/M forward clutch solenoid

YAZAKI SWP 7123-1424-40

white tape

1 354-01 353-01 G-B L

SUMITOMO MT090 6189-0031

186-01 102-01 W-Y L

CN.107 T/M reverse clutch solenoid

CN.105 T/M 1st speed clutch solenoid

CN.106 T/M 3rd speed clutch solenoid

CN.112 T/C oil temperature sensor

RTM1

354-01 353-01

W-Y

1 358-01 357-01 B-Y R-G

182-01 101-01

184-01 W-Y

CN.104 T/M 2nd speed clutch solenoid

Gray

CN.102 To rear console CN.704

1 352-01 351-01 B-W W-Y

F 3

white tape

122-01 125-01 121-01 B-Y G-B R-W

white tape

CN.111 RTM2

113-01 B-W

CN.113

184-01 105-01

W-Y

YAZAKI SWP 7222-7464-40

T/M output revolution sensor (Machine speed sensor)

POP

SUMITOMO MT090 6189-0031

1 122-01 125-01 121-01 B-Y

G-B

R-W

Main pump delivery pressure sensor

AMP EJC2 174357-2

YAZAKI SWP 7123-1424-40

Gray

Rear chassis main harness

CN.109 2

TM 03257-02910 33194-47750

T/M intermediate shaft revolution sensor (machine speed backup)

188-01 103-01 W-Y L

E/G speed sensor (T/C input revolution sensor)

YAZAKI SWP 7123-1424-40

Gray

CN: Connector, JN: Junction

CN.101 From

Wire No.

CN/JN No.

Wire Dia.

Wire Color

CN/JN No.

101-01

CN.114

T/C input rev. sensor (E/G speed)

CN.101

Rear console CN.703

0.85

102-01

CN.110

T/C output rev. sensor

CN.101

Rear console CN.703

0.85

103-01

CN.109

T/M intermediate shaft rev. sensor (machine speed backup)

CN.101

Rear console CN.703

0.85

105-01

CN.111

T/M output rev. sensor (machine speed)

CN.101

Rear console CN.703

0.85

113-01

CN.112

T/C oil temperature sensor

CN.102

Rear console CN.704

0.75

B-W

121-01

CN.113

Main pump delivery pressure sensor

CN.102

Rear console CN.704

0.75

R-W

122-01

CN.113

Main pump delivery pressure sensor

CN.102

Rear console CN.704

0.75

B-Y

125-01

CN.113

Main pump delivery pressure sensor

CN.102

Rear console CN.704

0.85

G-B

182-01

CN.114

T/C input rev. sensor (E/G speed)

CN.101

Rear console CN.703

0.85

W-Y

184-01

CN.111

T/M output rev. sensor (machine speed)

CN.101

Rear console CN.703

0.85

W-Y

186-01

CN.110

T/C output rev. sensor

CN.101

Rear console CN.703

0.85

W-Y

188-01

CN.109

T/M intermediate shaft rev. sensor (machine speed backup)

CN.101

Rear console CN.703

0.85

W-Y

351-01

CN.108

T/M forward clutch solenoid

CN.101

Rear console CN.703

0.85

W-Y

352-01

CN.108

T/M forward clutch solenoid

CN.101

Rear console CN.703

0.75

B-W

353-01

CN.107

T/M reverse clutch solenoid

CN.101

Rear console CN.703

0.85

354-01

CN.107

T/M reverse clutch solenoid

CN.101

Rear console CN.703

0.85

G-B

355-01

CN.105

T/M 1st speed clutch solenoid

CN.101

Rear console CN.703

0.85

L-W

356-01

CN.105

T/M 1st speed clutch solenoid

CN.101

Rear console CN.703

0.85

G-B

357-01

CN.104

T/M 2nd speed clutch solenoid

CN.101

Rear console CN.703

0.85

R-G

358-01

CN.104

T/M 2nd speed clutch solenoid

CN.101

Rear console CN.703

0.75

B-Y

359-01

CN.106

T/M 3rd speed clutch solenoid

CN.101

Rear console CN.703

0.75

R-W B-Y

360-01

CN.106

T/M 3rd speed clutch solenoid

CN.101

Rear console CN.703

0.75

361-01

CN.103

T/M 4th speed clutch solenoid

CN.101

Rear console CN.703

0.85

362-01

CN.103

T/M 4th speed clutch solenoid

CN.101

Rear console CN.703

0.75

B-W

Rear console harness T/M control valve

CN.102

Solenoid valves T/C oil temperature sensor To main pump delivery pressure sensor

T/C output revolution sensor

Machine speed sensor backup (T/M intermediate shaft revolution sensor) Machine speed sensor (T/M output revolution sensor)

- 12 -

90Z6 Front Console Cable Layout Monitor 1-A (CN.411) (20-pole)

Solar isolation sensor (CN.433) SS

Monitor 1-B (CN.412) (16-pole)

Monitor

Monitor 2-B (CN.415) (16-pole) Monitor 2-A (CN.416) (20-pole)

Switch assy

P Parking brake SW (CN.408) Auto/manual SW CN.417 AM Cap

Buzzer Declutch SW CN.419 CLU

Working lamp SW (CN.407) WL

BZ (CN.425)

Hazard SW (CN.406) HAZ Shift up delay SW (opt) CN.418 SUP

Starter key SW (CN.413) KEY

CL Cigar lighter (+24V) (CN.426/427)

Front wiper motor (CN.414) WIP

ICF-A (CN.410)31P ICF-C (CN.409)17P

Monitor Backside Wiring

Monitor Starter key SW ICF controller Workig lamp SW

Auto/manual SW

Parking brake SW Declutch SW

Hazard SW

Front wiper relay (HI)(CN.431) WRH

Front wiper relay (LO)(CN.432) WRL To CN713 (CN.404) FFD 20P

To CN711 (CN.402) FFB 20P

X Cigar lighter (24V)

To CN712 (CN.403) FFC 16P

Cab GND

To CN710 (CN.401) FFA 16P Cab GND

Enlarged X

Floor board

Floor harness (Rear console)

- 13 03030-40081

CN.411 Monitor 1-A

90Z6 Front Console Wiring Diagram (1/2) 10

CN.432 Front wiper relay (Lo) 3

447-01 R-W 0.5

444-01 Y 0.85

000-28 B 0.85

443-01 V 0.85

082-02 G 0.5

448-01 P-B 0.5

441-01 W 0.85

442-01 O 0.85

443-01 V 0.85

082-03 G 0.5

CN.406 Hazard SW 1

4 515-02 3 P 0.5 000-08 9 B 10 0.5

WRH

CN.407 Working light SW

501-01 000-07 1 L-R B 0.5 0.5 205-01 014-01 412-01 205-01 Gr L Y-R Gr 0.5 5 0.5 0.5 0.5

JN.D11

JN.D09

JN.D10 JN.D13

YAZAKI SDL-2 7183-4000

CN.412 Monitor 1-B

426-01 000-10 1 P R-W B 0.5 0.5 0.5 000-11 425-03 464-03 464-02 425-02 515-05 B Y-R P-B P-B Y-R P 10 0.5 0.5 0.5 0.5 0.5 0.5 5

8 000-mt 7 B 0.5 15

M-1B

YAZAKI SDL-2 7183-4000

514-01 543-01 542-01 554-01 556-01 1 Y-R Y-R V Br W-R 0.5 0.5 0.5 0.5 0.5 13 11 226-01 553-01 229-01 228-01 G-L O Br-Y P-B 0.5 0.5 0.5 0.5 9

CN.433 Solar isolation sensor CN.408 Parking brake SW CN.423 Diode (Front wiper SW)

B 000-01 000-20 000-25 000-26 000-27 000-28 000-29 000-fc 000-mt

YAZAKI 090 7321-9822

JN.D08

CN.420 GND

543-01 Y-R 0.5

YAZAKI 090 7321-9822

CN.401 To Rear Console CN.710

451-01 P-B 0.5

595-01 1 G-R 0.5 270-01 021-07 G-R Y 0.5 0.5 5 2

000-06 7 B 0.5

021-06 529-01 Y L-R 0.5 0.5

YAZAKI 090 7123-7729-40

YAZAKI SDL-2 7183-4000

CN.418 Shift up delay SW

DNR

000-04 267-01 021-02 000-03 268-01 217-01 W-G Y B G-Y L-Y B 0.5 0.5 0.5 0.5 0.5 5 0.5

JN.D12

218-01 000-02 1 Br-Y B 0.5 0.5

4 218-01 217-01 Br-Y L-Y 0.5 0.5

CLU

CN.425 Buzzer

CN.419 Declutch SW

YAZAKI 050 7283-7623

YAZAKI SDL-2 7183-4000

YAZAKI 090 7123-7729-40

CN.424 Diode (Column FNR SW)

SL00810

000-13 1 B 0.5

000-14 B 0.5 9 201-01 202-01 000-15 515-03 Br G-O B P 0.5 0.5 0.5 0.5 5

JN.D03

DFW

AMP 040 175966-2

2 612-01 611-01 1 P W-G 0.5 0.5

224-01 1 Br-W 0.5

2 226-01 G-L 0.5

WRL

000-25 272-01 021-05 011-05 1 B W-L Y R 0.5 0.5 0.5 0.5 14 13 592-01 591-01 V G-Y 0.5 0.5 11

AMP 040 175967-2

4 515-04 3

HAZ

SUMITOMO MICRO-ISO-RELAY 6098-1493

555-01 5 W-R 0.5 16 15 227-01 552-01 151-01 000-26 B-Y R-B R-L B 0.5 0.5 0.5 0.5 20

M-1A

CN.431 Front wiper relay (Hi)

CN.426 Cigar lighter (+24V)

YAZAKI SDL-2 7183-4000

SUMITOMO MTW 6030-2981

SUP

CB001

To rear console (p.18) 1

912-01 901-01 923-01 905-01 W O L-Y Y-G 1.25 0.5 0.85 0.85 426-01 425-01 014-01 907-01 R-W Y-R Y-R L-B 0.5 0.5 0.5 0.85 032-01 000-fc 515-01 202-01 W-L B P G-O 0.85 2.0 0.5 0.5 464-01 412-01 409-01 501-02 P-B L R-W L-R 0.5 0.5 0.5 0.5

CN.402 To Rear Console CN.711 1 S1S-00 556-01 Gr W-R 0.5 0.5 5

451-01 P-B 0.5

517-01 511-01 12 G-Y L-W 0.5 0.5

FFA 12

red tape

- 14 -

JCC 11

SUMITOMO HM090 6400-0081

555-01 W-R 0.5 11

SUMITOMO HM090 6409-0255

255-01 254-01 Br-W V 0.5 20 0.5

SUMITOMO DL040 6188-0494

AM JPA

021-04 032-01 907-01 011-04 Y W-L L-B R 0.5 0.5 0.85 0.85

CN.415 Monitor 2-B 6

G-W 0.5 154-01 153-01 14 Y-B Gr 0.5 0.5 16

402-01 Y

441-01 442-01 W O 0.85 0.85

WIP

M-2B

011-02 011-03 3 R R 0.5 0.5

021-03 707-03 000-23 10 Y G-W B 0.5 0.5 0.5

577-01 S1H-03 Y-R L 0.5 0.5

HMS

CN.421 Hour meter stop SW

S1L-03 W 0.5

CA001

S1S-02 S 0.5

000-27 B

CN.422 Hour meter stop SW CB001

272-01 W-L

CN.435 Disconnect (ICF)

JN.D01

S1S-03 S 0.5

I-C 12

JN.D02

CN.410 (Information controller) ICF-A

I-A

White

AMP 040-3 353027-1 White

YAZAKI CN 7123-2262

000-22 000-21 B B 0.5 0.5

CN.434 Disconnect (Monitor)

912-01 W 1.25 4

White

YAZAKI CN 7123-2262

S1H-02S1L-02 L W 0.5 0.5 9

905-01 Y-G 0.85

082-04 444-01 G Y 0.85 0.85 4

CN.409 (Information controller) ICF-C

M-2A

901-01 O 0.5

923-01 L-Y 6 0.85

CN.414 Front wiper motor

CN.413 Starter key SW

4 3

AMP 040 175966-2

FFD

000-24 254-01 255-01 B Br-W V 0.5 0.5 0.5

906-01 G

AMP 040 175967-2

8 707-02 7

SUMITOMO MTW 6040-6111

SUMITOMO DL090 6195-0054

3 2 529-01 4 L-R 0.5 447-01 448-01 461-01 462-01 501-03 502-01 511-01 517-01 R-W P-B L V L-R R-L G-Y L-W 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 9

(YA-7120-3011)

000-30 B

SUMITOMO DL090 6195-0051

CN.416 Monitor 2-A

591-01 8 G-Y 0.5

595-01 16 G-R 0.5

201-01 409-01 211-01 000-01 Br R-W G-B B 0.5 0.5 0.5 0.5

SUMITOMO DL090 6188-0495

552-01 12 R-B 0.5

7116-2270 0.85

KEY

JN.D21

611-01 612-01 4 W-G P 0.5 0.5

270-01 15 G-R 0.5

267-01 268-01 W-G G-Y 0.5 0.5

582-01 584-01 581-01 578-01 4 P L-R Y-G Br 0.5 0.5 0.5 0.5 5 579-01 593-01 583-01 594-01 8 Gr B-Y R-L W-G 0.5 0.5 0.5 0.5 FFC 598-01 597-01 585-01 596-01 R-W Y-R W-B Gr 12 0.5 0.5 0.5 0.5 9 577-01 011-01 021-01 082-01 Y-R R Y G 0.5 0.85 0.85 1.25 16 13

CN.404 To Rear Console CN.713

CN.417 Auto/manual SW

CN.428 Joint option (A)

021-07 021-06 021-05 021-04 021-03 021-02 021-01 Y Y Y Y Y Y Y 0.5 0.5 0.5 0.5 0.5 0.5 0.85 17 16 011-05 011-04 011-03 011-02 011-01 R R R R R 0.5 0.5 0.85 0.5 0.5

13 227-01 B-Y 0.5

white tape

CN.430 Joint connector (C)

CN.403 To Rear Console CN.712

SUMITOMO DL040 6188-0494

9 592-01 151-01 V R-L 0.5 0.5

white tape

FFB

S1L-01 S1H-01 W L 0.5 0.5 20

1 087-01 000-sw W-R B 0.85 1.25 6 5 211-01 G-B 0.5

JN.D22 JN.D23 JN.D24

CN.429 Joint option (B)

707-01 16 G-W 0.5

462-01 461-01 V L 0.5 0.5

153-01 154-01 Y-B Gr 0.5 17 0.5

JN.D07 JN.D06 JN.D05 JN.D04

229-01 8 Br-Y 0.5

514-01 228-01 Y-R P-B 0.5 0.5

502-01 R-L 0.5

white tape

YAZAKI SWP 7222-7564-40

554-01 542-01 4 Br V 0.5 0.5

9 553-01 224-01 O Br-W 0.5 0.5 13

CN.427 Cigar lighter (GND)

087-01 W-R 0.85

10 593-01 11 B-Y 0.5 22

582-01 P 0.5

578-01 Br 0.5

579-01 9 Gr 0.5

583-01 594-01 000-17 598-01 R-W B W-G R-L 0.5 0.5 0.5 0.5

597-01 21 Y-R 0.5

585-01 W-B 0.5

596-01 Gr 0.5 31

AMP 040-3 353031-1 White

584-01 L-R 0.5

581-01 Y-G 0.5

000-18 000-19 B B 0.5 0.5

33194-50210

90Z6 Front Console Wiring Diagram (2/2) CN: Connector, JN: Junction

CN: Connector, JN: Junction From

Wire Color

0.5

412-01

CN.406

0.5

425-01

JN.D10

0.5

425-02

CN.407

0.5

425-03

JN.D10

Wire No. Pin CN/JN No.

CN/JN No.

From

Wire Dia.

To Pin

Wire Dia.

Wire No. Pin CN/JN No.

CN/JN No.

CN.401

Rear console CN.710

0.5

CN.401

Rear console CN.710

0.5

Y-R

0.5

Y-R

CN.407

Working light SW

0.5

Y-R

CN.401

Rear console CN.710

0.5

R-W

Front wiper motor

CN.431

Front wiper relay (HI)

0.85

Front wiper motor

CN.431

Front wiper relay (HI)

0.85

CN.431

Front wiper relay (HI)

CN.432

Front wiper relay (LO)

0.85

444-01

CN.414

Front wiper motor

CN.432

Front wiper relay (LO)

0.85

447-01

CN.416

Monitor 2-A

CN.432

Front wiper relay (LO)

0.5

R-W

448-01

CN.416

Monitor 2-A

CN.431

Front wiper relay (HI)

0.5

P-B

451-01

CN.402

Rear console CN.711

CN.424

Diode (FNR SW)

0.5

P-B

0.5

461-01

CN.402

Rear console CN.711

CN.416

Monitor 2-A

0.5

462-01

CN.402

Rear console CN.711

CN.416

Monitor 2-A

0.5

464-01

JN.D13

CN.401

Rear console CN.710

0.5

P-B

0.5

464-02

CN.407

Working light SW

0.5

P-B

0.5

464-03

JN.D13

CN.407

Working light SW

0.5

P-B

JN.D01

0.5

501-01

JN.D07

CN.406

Hazard SW

0.5

L-R

JN.D01

0.5

501-02

JN.D07

CN.401

Rear console CN.710

0.5

L-R

0.5

501-03

JN.D07

CN.416

Monitor 2-A

0.5

L-R

0.5

502-01

CN.402

Rear console CN.711

CN.416

Monitor 2-A

0.5

R-L

0.5

511-01

CN.402

Rear console CN.711

CN.416

Monitor 2-A

0.5

G-Y

ICF-C

0.5

514-01

CN.402

Rear console CN.711

CN.412

Monitor 1-B

0.5

Y-R

Auto/manual SW

0.5

515-01

JN.D05

CN.401

Rear console CN.710

0.5

CN.420

GND

0.5

515-02

CN.406

Hazard SW

JN.D05

0.5

CN.420

GND

0.5

100

515-03

CN.408

Parking brake SW

JN.D05

0.5

Hour meter stop SW

CN.420

GND

0.5

101

515-04

CN.407

Working light SW

JN.D05

0.5

Front wiper relay (LO)

CN.420

GND

0.85

102

515-05

CN.407

Working light SW

JN.D05

0.5

CN.420

GND

0.5

103

517-01

CN.402

Rear console CN.711

CN.416

Monitor 2-A

0.5

L-W

0.85

104

529-01

CN.416

Monitor 2-A

CN.425

Buzzer

0.5

L-R

CN.401

Rear console CN.710

2.0

105

542-01

CN.402

Rear console CN.711

CN.412

Monitor 1-B

0.5

CN.420

GND

0.5

106

543-01

CN.412

Monitor 1-B

CN.424

Diode (FNR SW)

0.5

Y-R

CN.404

Rear console CN.713

1.25

107

552-01

CN.404

Rear console CN.713

CN.411

Monitor 1-A

0.5

R-B

Joint connector (C)

CN.403

Rear console CN.712

0.85

108

553-01

CN.402

Rear console CN.711

CN.412

Monitor 1-B

0.5

CN.430

Joint connector (C)

CN.409

ICF-C

0.5

109

554-01

CN.402

Rear console CN.711

CN.412

Monitor 1-B

0.5

011-03

CN.430

Joint connector (C)

CN.409

ICF-C

0.5

110

555-01

CN.404

Rear console CN.713

CN.411

Monitor 1-A

0.5

W-R

011-04

CN.430

Joint connector (C)

CN.428

Joint option (A)

0.5

111

556-01

CN.402

Rear console CN.711

CN.412

Monitor 1-B

0.5

W-R

011-05

CN.430

Joint connector (C)

CN.411

Monitor 1-A

0.5

112

577-01

CN.409

ICF-C

CN.403

Rear console CN.712

0.5

Y-R

014-01

CN.406

Hazard SW

CN.401

Rear console CN.710

0.5

Y-R

113

578-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

021-01

CN.430

Joint connector (C)

CN.403

Rear console CN.712

0.85

114

579-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

021-02

CN.419

Declutch SW

CN.430

Joint connector (C)

0.5

115

581-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

Y-G

021-03

CN.430

Joint connector (C)

CN.409

ICF-C

0.5

116

582-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

021-04

CN.430

Joint connector (C)

CN.428

Joint option (A)

0.5

117

583-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

R-L

021-05

CN.430

Joint connector (C)

CN.411

Monitor 1-A

0.5

118

584-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

L-R

021-06

CN.430

Joint connector (C)

CN.425

Buzzer

0.5

119

585-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

W-B

021-07

CN.418

Shift up delay SW

CN.430

Joint connector (C)

0.5

120

591-01

CN.404

Rear console CN.713

CN.411

Monitor 1-A

0.5

G-Y

032-01

CN.428

Joint option (A)

CN.401

Rear console CN.710

0.85

W-L

121

592-01

CN.404

Rear console CN.713

CN.411

Monitor 1-A

0.5

082-01

JN.D08

CN.403

Rear console CN.712

1.25

122

593-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

B-Y

082-02

CN.432

0.5

123

594-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

W-G

082-03

JN.D08

Front wiper relay (HI)

0.5

124

595-01

CN.418

Shift up delay SW

CN.404

Rear console CN.713

0.5

G-R

082-04

CN.414

Front wiper motor

JN.D08

0.85

125

596-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

087-01

CN.426

Cigar lighter (+24V)

CN.404

Rear console CN.713

0.85

W-R

126

597-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

Y-R

151-01

CN.404

Rear console CN.713

CN.411

Monitor 1-A

0.5

R-L

127

598-01

CN.410

ICF-A

CN.403

Rear console CN.712

0.5

R-W

153-01

CN.402

Rear console CN.711

CN.415

Monitor 2-B

0.5

Y-B

128

611-01

CN.433

Solar isolation sensor

CN.404

Rear console CN.713

0.5

W-G

154-01

CN.402

Rear console CN.711

CN.415

Monitor 2-B

0.5

129

612-01

CN.433

Solar isolation sensor

CN.404

Rear console CN.713

0.5

201-01

CN.408

Parking brake SW

CN.428

Joint option (A)

0.5

130

707-01

JN.D06

CN.402

Rear console CN.711

0.5

G-W

202-01

CN.408

Parking brake SW

CN.401

Rear console CN.710

0.5

G-O

131

707-02

CN.415

0.5

G-W

205-01

CN.406

Hazard SW

CN.406

Hazard SW

0.5

132

707-03

JN.D06

CN.409

ICF-C

0.5

G-W

211-01

CN.428

Joint option (A)

CN.404

Rear console CN.713

0.5

G-B

133

901-01

CN.413

Starter key SW

CN.401

Rear console CN.710

0.5

217-01

CN.419

Declutch SW

CN.419

Declutch SW

0.5

L-Y

134

905-01

CN.413

Starter key SW

CN.401

Rear console CN.710

0.85

Y-G

218-01

CN.419

Declutch SW

CN.419

Declutch SW

0.5

Br-Y

135

906-01

CN.429

Joint option (B)

CN.429

Joint option (B)

0.85

224-01

CN.402

Rear console CN.711

CN.423

Diode (Front wiper SW)

0.5

Br-W

136

907-01

CN.428

Joint option (A)

CN.401

Rear console CN.710

0.85

L-B

226-01

CN.412

Monitor 1-B

CN.423

Diode (Front wiper SW)

0.5

G-L

137

912-01

CN.413

Starter key SW

CN.401

Rear console CN.710

1.25

227-01

CN.404

Rear console CN.713

CN.411

Monitor 1-A

0.5

B-Y

138

923-01

CN.413

Starter key SW

CN.401

Rear console CN.710

0.85

L-Y

228-01

CN.402

Rear console CN.711

CN.412

Monitor 1-B

0.5

P-B

139

S1H-01

JN.D22

CN.402

Rear console CN.711

0.5

229-01

CN.402

Rear console CN.711

CN.412

Monitor 1-B

0.5

Br-Y

140

S1H-02

CN.415

0.5

254-01

CN.404

Rear console CN.713

CN.417

Auto/manual SW

0.5

Br-W

141

S1H-03

JN.D22

CN.409

ICF-C

0.5

255-01

CN.404

Rear console CN.713

CN.417

Auto/manual SW

0.5

142

S1L-01

JN.D23

CN.402

Rear console CN.711

0.5

267-01

CN.419

Declutch SW

CN.404

Rear console CN.713

0.5

W-G

143

S1L-02

CN.415

Monitor 2-B

JN.D23

0.5

268-01

CN.419

Declutch SW

CN.404

Rear console CN.713

0.5

G-Y

144

S1L-03

CN.409

ICF-C

JN.D23

0.5

270-01

CN.418

Shift up delay SW

CN.404

Rear console CN.713

0.5

G-R

145

S1S-00

CN.402

Rear console CN.711

JN.D21

0.5

272-01

CN.411

Monitor 1-A

CN.422

Hour meter stop SW

0.5

W-L

146

S1S-01

JN.D21

JN.D24

0.5

402-01

CN.429

Joint option (B)

CN.429

Joint option (B)

0.5

147

S1S-02

JN.D24

CN.434

Disconnect (Monitor)

0.5

409-01

CN.428

Joint option (A)

CN.401

Rear console CN.710

0.5

R-W

148

S1S-03

JN.D24

CN.435

Disconnect (ICF)

0.5

000-01

CN.428

Joint option (A)

CN.420

000-02

CN.419

Declutch SW

JN.D12

000-03

CN.419

Declutch SW

000-04

JN.D12

CN.419

000-05

JN.D12

JN.D04

0.5

426-01

CN.407

Working light SW

000-06

CN.418

Shift up delay SW

JN.D04

0.5

441-01

CN.414

000-07

CN.406

Hazard SW

JN.D09

0.5

442-01

CN.414

000-08

CN.406

Hazard SW

JN.D09

0.5

443-01

000-09

JN.D09

JN.D04

0.5

000-10

CN.407

JN.D11

0.5

000-11

JN.D11

CN.407

0.5

000-12

JN.D11

JN.D04

0.5

000-13

CN.408

Parking brake SW

JN.D03

000-14

CN.408

Parking brake SW

JN.D03

000-15

JN.D03

CN.408

000-16

JN.D03

JN.D04

000-17

JN.D01

CN.410

000-18

CN.410

ICF-A

000-19

CN.410

ICF-A

000-20

JN.D01

000-21

CN.409

000-22

JN.D02

CN.409

ICF-C

000-23

JN.D02

CN.409

000-24

JN.D04

CN.417

000-25

CN.411

Monitor 1-A

000-26

CN.411

Monitor 1-A

000-27

CN.421

000-28

CN.432

000-29

JN.D02

000-30

CN.427

Cigar lighter (GND)

JN.D04

000-fc

CN.420

GND

000-mt

CN.412

Monitor 1-B

000-sw

JN.D04

011-01

CN.430

011-02

36 37

Working light SW

JN.D12

CN.420 ICF-C

Front wiper relay (LO)

GND

Hazard SW

Declutch SW

Working light SW

Parking brake SW ICF-A

GND

6 19

JN.D02

JN.D08 CN.431

Working light SW

Monitor 2-B

Wire Color

JN.D10

JN.D13

JN.D06

JN.D22

- 15 33194-50210

90Z6 Floor Cable Layout (Rear and Side Console) (1/2) Side Console 2 Cable Assy RS3 16P

Side Console 1 Cable Assy Wiper SW (CN.900) WS 10P

Steering column

Turn (CN.781) TRN 4P

A/C panel-B (CN.753) ACB

RS1 20P

Lighting (CN.782) LT 6P

A/C panel-A (CN.756) ACA

T/M (CN.780) TM 8P Steering column

Wiper&horn (CN.731) WHS Throttle pedal

GND (floor~chassis)

Brake lamp SW (CN.767) Floor GND

Floor board

Brake secondary pressure sensor (for declutch) (CN.701)

GND SBC Brake secondary pressure sensor (for declutch) (CN.701)

Rear Console Fuse & Relay (See p.4)

Brake lamp SW (CN.767) BLS Rear chassis

Front Console (See p.13)

Seat power supply (Opt)(CN.790) DC-DC converter (Opt)(CN.730)

Main controller (MC)

Main controller (MC) MC(F)(CN.797) 26P

Air conditioner CN.751 AC3 32P

Socket (CN.761) ST

Air conditioner connectors 32P

MC(E)(CN.795) 24P MC(D)(CN.793) 30P MC(C)(CN.799) 17P MC(B)(CN.755) 24P MC(A)(CN.798) 31P

Cab harness

4P Air conditioner (CN.743 AC1 4P, CN.744 AC2 10P)

10P

Flasher unit (CN.754) FL 4P

Cab harness CAB-A 6P CAB-B 4P

Rear view monitor (CN.729) BM 8P CAN (opt)(CN.725) CAN 8P

R B

L W R Y W R

WR B LW

LW RG WR

CAB-B

CAB-A

R W

CAB-F 1P CAB-R 1P GMS controller (CN.750) GSM 16P

View Y

ACC1 ACC2 ACC3 BT GND1 GND2 GND3

V GR

OPT

W B

CAB-R

CAB-F

Rear console harness

Connection between Floor and Cab

RRE Black 2P RRD Gray 2P

View Z

Rear (70A fusible link) (CN.747) RRC Gray 1P FRONT Rear chassis connector (CN.706) RRB 16P

Rear chassis connector (CN.705) RRA 52P

- 16 03255-03071

90Z6 Floor Cable Layout (Rear and Side Console) (2/2) Floor GND

Brake valve

Wiper SW (CN.900) WS 10P

Horn SW (CN.899) HS

Air conditioner lines

To transmission (p.12) CN.704 RTM2 6P

CN.703 RTM1 20P

A/C gas Hi/Lo pressure SW (CN.789) ACP 2P

Lever cable

To rear chassis main (p.8) Rear chassis connector (CN.705) RRA 52P

T/M harness

Rear chassis connector (CN.706) RRB 16P

A/C gas pressure sensor (CN.794) ACG 3P

Wiper&horn (CN.731) WHS

View A Thermistor assy (atmosperic temperature) (CN.746) TS

Safety device Rear chassis harness

A RTM1,2

Throttle pedal (CN.728) ACL 6P

View from Floor Board Bottom Side

Floor board

Hold SW (CN.611)

RRA,RRB

Lift Arm (Boom) lever Bucket lever

Emergency throttle (CN.788) EMG 6P

Power mode SW (CN.512)

Side Console 2 Cable Assy

FR shift SW (CN.511)

Floor GND

View B Hold SW (CN.611)

FNR SW (CN.616)

FRONT RS4 RS3 16P

Switch arrangement Side Console 1 Cable Assy

FRONT Primary pilot pressure sensor (for control lever) PS 3P Bucket detent (CN.613) BL (blue) FRONT Boom height kickout detent (CN.614) BKO (yellow)

Side Console Wiring

Boom lower kickout detent (float) (CN.612) FL (red)

03255-03071

- 17 -

90Z6 Floor Wiring Diagram (Rear Console) (1/5) CN.754 Flasher unit 2 CN.735 000-fls B Optional power supply (ACC1) 0.85 1

CN.738 Optional power supply (ACC2)

CN.803 Optional power supply (ACC3) 1

802-01 P 2.0

YAZAKI CN 7123-2215-80

GND1

RS1 Blue

CN.741

YAZAKI CN 7122-2115-30

Option GND (ACC2)

Black

ACC3

YAZAKI CN 7123-2215-90

Brown

000-op1 B 2.0

813-01 W-L 0.85

4 295-01 294-01 L-B W-G 0.5 0.5

CN.762 Option GND (ACC3)

1 000-op2 B 1.25

GND2

CN.763

Black 1

1 000-op3 B 0.85

000-bt B 2.0

Option GND (Bt)

GND3

GNDB

YAZAKI CN 7122-2115-30

Black

3 083-06 446-01 017-01 1 W-R R-G L-W 0.85 0.85 0.85 6 001-01 445-01 G-R V 0.5 0.85 4

CN.768 CAB-B 2

1 517-02 L-W 0.85 000-cab 091-01 CAB-B B L 3.0 1.25 3 4 YAZAKI CN 7123-2446

YAZAKI CN 7123-2262

JN.G48 JN.G49

519-01 W-B 0.85

CAB-F

CAB-R

7123-2215

CN.749 Axle oil cooler relay (opt) 1

OAX

CN.750 GPS/GSM unit

YAZAKI SWP 7222-7444-40

ACG

CN.789 A/C gas Hi/Lo pressure SW ACP

000-acp 605-01 B L-W 0.5 0.5

YAZAKI CN 7123-2215

YAZAKI CN 7122-2215

White

RTM2 red tape

7123-7960 YAZAKI 62C

707-02 021-09 011-03 1 G-W Y R 0.5 0.5 0.5 10 9 000-gps B 0.5 8

GSM

Disconnect (rear view monitor) CN.729 Rear view monitor 5

Disconnect (opt CAN)

DEUTSCH DT DT04-8PA-CE01

S1S-02 S 0.5

S1L-04 000-bm B W 2 0.5 0.5 8 808-03 W-R 0.5 1

CN.708 To rear CN.204 1

CN.725 CAN (Opt)

DEUTSCH DT DT06-8SA-CE05

S1L-02 W 0.5 YAZAKI 62Z 7222-7780-40

YAZAKI 62Z 7123-7780-40

965c-01 965d-01 R R 8.0 8.0

Gray

CAN 7

RRC

RRB

YAZAKI 91-RV 7223-6536-30

JN.G26

Gray

3 SUMITOMO TS 6189-0094

121-03 125-01 122-03 P G V 0.5 0.5 0.5 6 5 113-01 B-W 0.5

4 186-01 102-01 Y-B L-W 0.5 0.5

8 184-01 G-B 0.5

SBC

16 361-01 R 0.5

Black 4

353-01 354-01 L G-B 20 0.5 0.5

121-04 122-02 342-01 341-01 1 P V G-B L-R 0.5 0.5 0.5 0.5 139-01 135-01 123-03 131-01 5 Gr Y W R-L 0.5 0.5 0.5 0.5 327-01 142-01 126-01 127-01 Y-R W-L Y-B R-L 9 0.5 0.5 0.5 0.5 525-01 332-01 331-01 328-01 L-R W-B Y-B G-Y 0.5 0.5 0.5 0.5 13 9

JN.H01 27

2 35

To rear chassis main (p.8, 10)

FFA

360-01 13 B-L 0.5

351-01 352-01 W B-W 17 0.5 0.5

SUMITOMO DL040 6189-0714

716-01 W 0.5 717-01 B 0.5 715-01 R 0.5

202-01 515-03 000-fc 032-01 G-O P B W-L 0.5 0.5 2.0 0.85 501-02 409-02 412-01 514-04 Y-R L R-W L-R 0.5 0.5 0.5 0.5

229-01 Br-Y 0.5

JN.H20

red tape 16

707-03 G-W 0.5

C 20

556-01 S1S-99 W-R Gr 0.5 0.5

228-01 514-03 P-B Y-R 0.5 0.5

511-03 517-03 G-Y L-W 0.5 0.5

FFB

DEUTSCH DT DT06-3S-CE05

224-01 553-01 Br-W O 0.5 0.5

461-01 462-01 L V 0.5 0.5

S1H-13 S1L-13 L W 0.5 0.5

451-05 P-B 0.5

502-02 R-L 0.5 13

154-01 153-01 Gr Y-B 0.5 0.5

SUMITOMO DL040 6189-0714

MAT

1 616-03 615-01 G-R Y 0.5 0.5 YAZAKI 090-2 7283-7028-30

CN.764 CN.765 MAINTENANCE (E/G fault lamp) (short-circuit)

DEUTSCH DT DT04-6P-CE03

CN.726 Themistor assy (atmospheric temperature MC) 124-05 143-01 G-B L-R 0.5 0.5

YAZAKI CN 7123-2228

YAZAKI CN 7122-2228

White

SL00810

CN.778 GND (D) SL00810

612-04 611-01 000-sw 087-01 P W-G B W-R 0.5 0.5 1.25 0.85 8 591-01 555-01 6 211-03 G-Y W-R G-B 0.5 0.5 0.5 552-01 11 151-01 592-01 9 R-B R-L V 12 0.5 0.5 0.5 16 595-01 15 270-01 227-01 G-R G-R B-Y 0.5 0.5 0.5 254-01 255-01 268-01 267-01 Br-W V G-Y W-G 20 0.5 0.5 0.5 0.5 4

CN.713 To front console CN.404

SL00810

CN.787 GND (C)

CN.712 To front console CN.403

472-01 B 0.5

FFD

SUMITOMO DL040 6189-0714

578-01 581-01 584-01 582-01 Br Y-G L-R P 0.5 0.5 0.5 0.5 594-01 583-01 593-01 579-01 W-G R-L B-Y Gr 0.5 0.5 0.5 0.5

596-01 585-01 597-01 598-01 Gr W-B Y-R R-W 9 0.5 0.5 0.5 0.5

082-02 021-02 011-04 577-01 G Y R Y-R 1.25 0.85 0.85 0.5 13

FFC

CN.786 GND (B)

724-01 Y-B 0.5

YAZAKI 090-2 7283-7028-30

CN.785 GND (A) 18

554-03 Br 0.5

red tape

CN.705 To rear chassis CN.201

542-01 554-02 V Br 0.5 0.5

A 062-02 206-01 B L-B Br-W 0.5 0.5

CN.746 Themistor assy (atmospheric temperature A/C)

1 701-01 151-01 506-01 505-01 501-03 502-03 503-01 515-02 8 W-B R-L W-G Br-W L-R R-L W-R P 0.5 0.5 0.5 0.5 0.85 0.85 0.5 0.5 518-01 325-01 326-01 137-01 711-03 713-01 021-08 S1H-01 S1L-01 S1S-01 G-W W-B B-R Br-Y R-W L-W Y L W Gr 0.85 0.5 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5 715-01 716-01 717-01 712-01 770-01 769-02 512-01 215-01 25 21 Y-B L-R R W B W-R R-Y R 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 124-03 721-01 141-01 840-01 718-01 511-01 556-01 554-01 33 29 G-B Br G-Y Lg-R W-B Y-G W-R Br 0.5 0.5 0.85 0.5 0.5 0.5 0.5 0.5 724-01 136-01 591-01 592-01 531-01 532-01 321-01 322-01 061-01 407-01 L-W Y-B G-Y V W-L R-B R-Y L-Y B-W P 0.5 0.5 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5 153-01 154-01 601-01 704-01 707-01 799-01 527-01 208-01 W-B R-G Y-B Gr G R-G G-W W-L 0.85 0.5 52 0.5 0.5 1.25 0.85 0.85 0.5 45

000-bls B 0.5

TSM

YAZAKI SWP 7283-5055-40

907-01 014-02 425-01 426-01 L-B Y-R Y-R R-W 0.85 0.5 0.5 0.5

CN.711 To front console CN.402

DEUTSCH DT DT06-6S-CE05

905-01 923-01 901-01 912-02 Y-G L-Y O W 0.85 0.85 0.5 1.25

YAZAKI SWP 7123-7564-40

BLS

103-01 5 W-R 0.5

CN.767 Brake lamp SW

CN.788 Emergency throttle

EMG

355-01 356-01 9 L-W G-W 0.5 0.5

362-01 359-01 B-R R-W 0.5 0.5

YAZAKI 91-RV 7223-6536-30

182-01 101-01 1 W-B Y-L 0.5 0.5

105-01 188-01 L-Y L-B 0.5 0.5

CN.710 To front console CN.401

123-02 138-01 124-02 W G-Y G-B 0.5 0.5 0.5

YAZAKI 58Y 7222-4220-30

Black

121-02 P 0.5

CN.703 To T/M CN.101

RRA

RRE

122-04 V 0.5

DEUTSCH DT DT06-6S-CE05

965a-01 965b-01 R R 8.0 8.0

134-01 P-B 0.5

3 1

JN.G20 CN.701 Service brake secondary pressure sensor (CC)

JN.G11

CN.728

SUMITOMO TS 6189-0099

RRD

JN.H02 JN.H03 JN.H04

JN.G23

YAZAKI SWP 7123-7564-40

CN.709 To rear CN.205

JN.G35

S1L-12 S1H-12 000-ap W L B 0.5 0.5 0.5

To front console (p.14)

JN.H17 JN.H18 JN.H19

white tape

Throttle pedal

12 357-01 358-01 R-L B-Y 0.5 0.5

TRN

631-01 630-01 629-01 628-01 Br-Y L-B G-W Lg 0.5 0.5 0.5 0.5

YAZAKI SWP 7123-7923-40

CN.781 Column shift lever (turn) 062-05 413-01 L-B R-W 0.5 0.5 414-01 3 L-Y 0.5

YAZAKI SWP 7123-7464-40

627-01 626-01 625-01 624-01 B-R W-R W-B B-L 0.5 0.5 0.5 0.5

ACB

YAZAKI SWP 7123-7444-40

ACL

YAZAKI 58Y 7222-4220-40

1 S1H-02 L 0.5

8 912-04 W 8.0

YAZAKI 58Y 7222-4210-40

- 18 -

422-01 421-01 514-02 Gr R-Y Y-R 0.5 0.5 0.5 5 4 016-01 Br 0.85

CN.706 To rear chassis CN.202 4

RTM1

CN.747 To rear (70A fusible link)

L 0.5

CN.719

S1H-04

JN.G09 JN.H05 JN.H06 JN.H07

S1S-04 S 0.5

121-01 128-01 122-06 P Y V 0.5 0.5 0.5

S1S-12 S 0.5

CN.782 Column shift lever (lighting)

432-01 000-sc5 Y-G Br-Y B 0.5 0.5 0.5 235-01 000-sc3 211-04 5 G-R B G-B 0.5 0.5 0.5 236-01 536-01 244-01 535-01 P-W L-Y W-L Br-Y 9 0.5 0.5 0.5 0.5 431-01 258-01 14 246-01 W-R R-Y Y-B 0.5 0.5 0.5 13

CN.753 A/C operation panel (B)

YAZAKI SWP 7123-7484-40

124-04 129-01 123-04 G-B P W 0.5 0.5 0.5

YAZAKI SWP 7123-7464-40

CN.718

CN.704 To T/M CN.102

To transmission (p.12)

456-01 Br 0.5

JN.G61

JN.G22 3

1 241-01 242-01 243-01 000-cs2 W-R L-Y G-W B 0.5 0.5 0.5 0.5 247-01 248-01 000-cs3 5 L-Y Br-Y B 0.5 0.5 0.5

JN.G19

CN.702 Control lever pilot primary pressure sensor

CN.794 A/C gas pressure sensor

4 7 579-01 578-01 593-01 577-01 Gr Br B-Y Y-R 0.5 0.5 0.5 0.5 12 597-01 598-01 596-01 13 Y-R R-W Gr 0.5 0.5 0.5 16

RS4

YAZAKI SWP 7123-7444-40

JN.G18 JN.G29 JN.G41 JN.G08

White

1 520-01 G 0.85 YAZAKI CN

White

222-01 515-05 G-R P 0.5 0.5

623-01 622-01 621-01 620-01 O Gr G-R Y-R 9 0.5 0.5 0.5 0.5 SUMITOMO DL090 6195-0149

CN.716 Disconnect (A/C panel)

DTL

YAZAKI 090 7123-9135-50

081-02 3

ACA

CN.780 Column shift lever (T/M)

414-01 L-Y 0.5

YAZAKI SWP 7123-7564-40

white tape

CN.766 CAB-F YAZAKI CN 7123-2215

Black

JN. G38

JN.G46

White

CN.732 CAB-R

White

CAB-A JN. G53

612-01 611-01 605-01 021-13 1 P W-G L-W Y 0.5 0.5 0.5 0.5 5 619-01 618-01 616-01 615-01 P-B B-Y G-R Y 0.5 0.5 0.5 0.5

CN.717 To side console 2 CN.601

CN.727 To side console 4 000-sc4 305-01 B R-Y 0.5 0.5

416-01 W-R 0.5

YAZAKI 62Z 7123-7780-40

To side console2 (p.24)

RS3

JN.H10 JN.H11 JN.H12

YAZAKI 090 7321-9834-30

JN.G62

CN.734 CAB-A

CAB Connectors

293-01 000-sc1 1 Gr-L B 0.5 0.85

224-03 000-wip 231-01 232-01 Br-W B R-W L-Y 0.5 0.5 0.5 0.5

1 412-03 L 0.5

HWS 8

SUMITOMO DL040 6189-0714

white tape

YAZAKI CN 7122-2115-30

DTR

CN.756 A/C operation panel (A)

211-02 227-01 229-01 228-01 G-B B-Y Br-Y P-B 0.5 0.5 0.5 0.5

CN.784 Diode unit (hazard2)

259-01 249-01 252-01 296-01 5 P-W Br W-L W-Y 0.5 0.5 0.5 0.5 12 342-01 081-03 506-01 505-03 9 G-B Y-G W-G Br-W 0.5 0.5 0.5 0.5 14 13 515-04 257-01 341-01 P L-Y L-R 0.5 0.5 0.5 19 18 17 251-01 253-01 L-B Gr 0.5 0.5

white tape

To side console1 (p.23)

White

415-01 412-02 P-W L 0.5 0.5

YAZAKI 090 7123-9135-50

CN.715 To side console 1 CN.501

JN.G31 JN.G32 JN.G33

CN.740 Option GND (ACC1)

CB001

Blue

CN.736 Optional power supply (Bt)

Blue

YAZAKI 090 7321-9834-30

840-01 Y-G 0.5

OPS

1 413-01 R-W 0.5

YAZAKI CN 7123-2446

YAZAKI CN 7123-2215-90

ACC2

YAZAKI CN 7123-2215-90

ACC1

JN.G34

812-01 W-B 1.25

014-03 411-01 Y-R Br-Y 0.85 3 4 0.85

CN.804 For option SW (not used)

white tape

808-02 W-R 2.0

CN.783 Diode unit (hazard1)

To floor rear console (2/5) (p.19)

To A/C panel cable (p.24)

CN.731 To wiper/horn SW

SUMITOMO DL090 6189-0715

33194-48790B 17

90Z6 Floor Wiring Diagram (Rear Console) (2/5)

CN.795 MCZ(E)

CN.797 MCZ(F) 1

065-02 R-L 0.85 7

065-03 R-L 0.85

065-04 R-L 0.85

000-mc2 B 0.85

000-mc3 B 0.85

000-mc4 B 0.85

252-01 259-01 137-01 251-01 258-01 12 W-L P-W Br-Y Gr R-Y 0.5 0.5 0.5 0.5 0.5 20 295-01 296-01 257-01 L-B W-Y L-Y 0.5 0.5 0.5

293-01 294-01 15 Gr-L W-G 0.5 0.5 255-01 254-01 24 V Br-W 0.5 0.5

JN.G06

M-F

122-01 124-01 V G-B 0.5 0.5 17 121-06 123-01 P W 0.5 0.5 26

JN.G07

S1S-06 S 0.5

CN.793 MCZ(D)

0.5 0.5 182-01 184-01 186-01 188-01 268-01 299-01 262-01 261-01 263-01 247-01 W-B G-B Y-B L-B G-Y P-B Y-G R-L W-L L-Y 16 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 M-E 12 101-01 105-01 102-01 103-01 11 248-01 235-01 236-01 298-01 Y-L L-Y L-W W-R Br-Y G-R P-W G-W 0.5 0.5 0.5 0.5 20 0.5 0.5 0.5 0.5 17 21 24 AMP 025/090 1318756-1

White

CN.767 3

DCF

141-01 143-01 552-01 555-01 455-01 456-01 12 Br L-R R-B W-R R-W Br 0.5 0.5 0.5 0.5 0.5 0.5 16

M-D

DCN 30

AMP 025/090 1318758-1

M-C

542-01 18 V 0.5

355-01 L-W 0.5

361-01 R 0.5

Diode unit (column-N) YAZAKI 090 7321-9822

326-01 325-01 B-R W-B 16 0.5 0.5 23

Diode unit (column-R) YAZAKI 090 7321-9834-30

357-01 358-01 9 R-L B-Y 0.5 0.5

DMR

451-04 P-B 0.5

246-01 279-01 Y-B Br-W 0.5 0.5

Diode unit (opt-R) YAZAKI 090 7321-9834-30

YAZAKI 090 7123-9135-50

M-A

CN.771 31 3

DMF

451-03 P-B 0.5

244-01 278-01 W-L O 0.5 0.5

YAZAKI 090 7123-9135-50

Diode unit (opt-F) YAZAKI 090 7321-9834-30

To floor rear console (3/5) (p.20)

CN.721 Joint connector (A)

M-B 2

CN.730 To DC-DC converter (opt)

CN.723 Diode unit (key ON power)

616-04 1 G-R 0.5 5

YAZAKI 58M 7123-6040

YAZAKI 090-2 7283-1100

SEAT

089-01 L-R 2.0

SUMITOMO TS 6098-0514

DBR2 JCA

AMP 250 180907-5

AMP 250 180908-5

Black

YAZAKI 090 7321-9822

701-05 W-B 0.5

AC3

AMP 025 1473799-1

CN.761 539-01 G-L 0.85 1

Socket

CN.724 Joint connector (B)

DBR3

6 10

021-14 Y 17 0.5

SUMITOMO HM090 6400-0015

SUMITOMO HM090 6409-0074

YAZAKI 090 7123-7729-40

JN.G10

3 2 630-01 631-01 612-02 619-01 618-01 4 B-Y P-B P L-B Br-Y 0.5 0.5 0.5 0.5 0.5 23 22 21 000-ac3 616-02 24 622-01 625-01 18 B G-R Gr W-B 0.5 0.5 0.5 0.5

1 707-04 G-W 0.5

JCB

121-04 121-03 121-02 121-05 011-04 011-03 011-02 011-05 P P P P R R R R 0.5 0.5 0.5 0.5 0.85 0.5 0.85 0.85 122-04 122-03 122-02 122-05 707-04 707-03 707-02 707-01 V V V V G-W G-W G-W G-W 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85

CN.745 Diode unit (alternator)

20 623-01 624-01 626-01 627-01 12 W-R B-R O B-L 0.5 0.5 0.5 0.5 621-01 620-01 629-01 628-01 28 G-R Y-R G-W Lg 0.5 0.5 0.5 0.5 32

YAZAKI 58M 7122-6040

CN.751 Air conditioner (3) 16

000-sh B 2.0 2

AC1

701-02 W-B 0.5

YAZAKI 090 7123-7729-40

YAZAKI 090 7321-9822

CN.790 Air suspension seat power (opt)

AC2

1 021-06 Y 0.5

2 088-01 000-dc 1 W-B B 0.85 0.85 DC 538-01 539-01 W G-L 0.85 3 4 0.85

CN.744 Air conditioner (2) 4 612-03 3 P 0.5 10 601-01 8 G 1.25

243-01 263-01 G-W W-L 0.5 0.5

White

2 000-ac2 085-01 1 B L-R 2.0 2.0 084-01 021-15 Gr Y 4 1.25 3 0.5

360-01 359-01 351-01 352-01 354-01 353-01 321-01 322-01 328-01 327-01 20 B-L R-W W B-W G-B L R-Y L-Y G-Y Y-R 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 15 22 23 27 28 29 30 332-01 331-01 26 W-B Y-B 0.5 0.5

AMP 040-3 353029-1

CN.743 Air conditioner (1)

362-01 B-R 0.5

White

CN.772

AMP 040-3 353031-1

242-01 L-Y 0.5

YAZAKI 090 7123-9135-50

4 356-01 G-W 0.5

CN.755 MCZ(B)

Diode unit (column-F)

JN.G52 JN.G54

451-02 P-B 0.5

CN.798 MCZ(A)

White

262-01 Y-G 0.5

white tape

405-01 L-B 0.5 17

YAZAKI 090 7321-9834-30

YAZAKI 090 7123-7729-40

White

DCR

AMP 040-3 353027-1

261-01 R-L 0.5

CN.779 22

125-01 131-01 15 G R-L 0.5 0.5 13

241-01 W-R 0.5

CN.770

142-01 113-01 535-01 536-01 595-01 553-01 6 W-L B-W Br-Y L-Y G-R O 0.5 0.5 0.5 0.5 0.5 0.5

451-01 P-B 0.5

011-08 R 0.85

YAZAKI 090 7123-9135-50

10 8 9 5 6 7 S1H-06S1L-06 4 135-01 139-01 L W Y Gr 0.5 0.5 0.5 0.5 11 249-01 278-01 279-01 134-01 127-01 126-01 138-01 129-01 136-01 20 21 Br O Br-W P-B R-L Y-B G-Y P L-W 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 26 27 253-01 270-01 25 128-01 29 L-B G-R Y 0.5 0.5 0.5

CN.799 MCZ(C)

000-mc6 011-07 267-01 021-10 B R W-G Y 0.85 0.85

CN.714 Disconnect (MCZ1)

White

AMP 025/090 1318757-1

000-mc5 B 0.85

538-01 W YAZAKI POSITIVE-LOCK 2 0.85 7123-8322

To floor rear console (1/5) (p.18)

JN.H14 JN.H15 JN.H16

021-10 021-09 021-08 021-07 021-06 021-05 021-04 021-03 021-02 021-01 Y Y Y Y Y Y Y Y Y Y 0.5 0.5 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5 081-05 081-04 081-03 081-02 081-01 515-05 515-04 515-03 515-02 515-01 Y-G Y-G Y-G Y-G Y-G P P P P P 0.5 0.5 0.5 0.5 0.85 0.5 0.5 0.5 0.5 0.85 17

SUMITOMO HM090 6440-0129

JN.G36

- 19 -

SUMITOMO HM090 6440-0128

33194-48790B

90Z6 Floor Wiring Diagram (Rear Console) (3/5)

CN.733 Fuse box (A)

1 063-01 062-01 072-01 016-01 802-01 015-01 014-01 011-01 009-01 013-01 10 V L-B R Br P P Y-R R Y-B Gr 0.5 0.5 0.85 0.85 2.0 0.85 0.85 0.85 0.85 0.85 21 28 965a-02 23 912-08 25 912-05 27 912-06 30 R W W W 3.0 3.0 3.0 5.0 36 965b-02 38 965b-03 40 514-01 965a-03 923-01 965a-04 35 Y-R R L-Y R R R 31 0.85 2.0 0.85 2.0 5.0 2.0 515-01 808-01 021-01 033-01 065-01 081-01 075-01 061-01 073-01 068-01 P W-R Y O R-L Y-G W B-W P Br 11 0.85 2.0 0.85 0.5 2.0 0.85 2.0 0.5 0.85 0.5 20 14 17

To floor rear console (2/5) (p.19) F-A

CN.757 Diode unit (voltage relay) 2

YAZAKI 090 7321-9822

DVR

YAZAKI 090 7123-7729-40

000-vr2 704-01 B R-G 0.5 0.85

JN.G01

F-B

Diode unit (ECM2)

461-01 L 0.5

B4: Brake lamp 16

011-10 R 0.5

206-01 Br-W 0.5

471-01 R-W 0.5

503-01 W-R 0.5 19

011-09 011-10 R 0.5 25

062-03 062-04 L-B 0.5 20

062-04 L-B 0.5

11 033-01 033-02 O 0.5

B2: Parking (2) 8 409-01 R-W 0.5

721-03 W-B 0.5

718-01 Lg-R 0.5

408-01 G-W 0.5 10

701-04 W-B 0.5

YAZAKI 090 7123-9025-30

YAZAKI 090 7321-9823-30

48 232-01 L-Y 0.5

DBT

083-05 W-R 0.5

231-01 R-W 0.5

445-01 V 0.85

083-03 W-R 0.5

225-01 L-W 0.5

36 37

B1: Parking (1)

406-01 Gr 0.5

202-01 G-O 0.5

- 20 -

000-rb1 000-rb2 B 0.5

A2: Head lamp

421-01 R-Y 0.5

000-r02 000-r03 B 0.5

431-01 W-R 0.5

073-01 P 15 0.85

072-01 R 10 0.85

A1: ECM1

422-01 Gr 0.5

000-r01 000-r02 B 0.5

512-01 Y-B 0.85

511-02 G-Y 14 0.85

011-12 R 0.5

211-01 G-B 0.5

457-01 P 0.5

527-01 W-B 0.85

015-01 015-02 P 0.5 0.85

015-02 P 0.5

000-r09 B 0.5

A9: Horn

406-01 Gr 0.5 4

458-03 O 0.5

713-01 L-W 0.85

009-01 Y-B 0.85

416-01 W-R 0.5

451-07 P-B 0.5

C4: CAB rear working lamp (opt)

C5: Secondary steering (opt) 23

033-02 O 0.5

068-02 Br 0.5

000-rc3 B 0.5

455-01 R-W 0.5

021-07 021-16 Y 0.5

705-01 Y-B 0.85

501-01 L-R 0.85

411-02 Br-Y 0.85

415-01 P-W 0.5

33 000-r08 000-r09 B 0.5

518-01 G-W 0.85

075-02 W 0.85

426-02 R-W 0.5

000-r07 000-r08 B 0.5

A7: Rear working lamp

26 27

517-01 L-W 0.85

074-02 P 0.85

A6: CAB front working lamp

525-01 L-R 0.5

068-01 068-02 Br 0.5

16 17

520-01 G 0.85

075-03 W 0.85

426-03 R-W 0.5

C3: CAB front working lamp (opt) 13 000-rc2 000-rc3 B 0.5

425-03 Y-R 0.5

405-01 L-B 0.5

519-01 W-B 0.85

074-03 P 0.85

C1: ECM2

C2: Back lamp

6 7

505-02 Br-W 0.5

063-01 V 0.5

021-03 Y 0.5

3 000-rc1 000-rc2 B 0.5

1 2

711-01 R-W 0.85

013-01 Gr 0.85

222-01 G-R 0.5

305-01 R-Y 0.5

531-01 W-L 0.85

502-01 R-L 0.85 34

083-04 083-05 W-R 0.5 50 0.85

446-01 R-G 0.85 45

082-03 082-04 G 0.5 40 0.85

411-03 Br-Y 0.85 35

907-01 L-B 0.85 30

B9: Rear wiper

B8: Front washer

B7: Turn signal (L)

B6: Neutral relay

081-05 081-09 Y-G 0.5

B10: Rear washer

R-C 10

C10: (open)

C9: (open)

C8: (open)

33194-48790B YAZAKI 361897-0553

C7: (open)

458-04 O 0.5

083-02 083-03 W-R 0.5 44 0.85

425-02 Y-R 0.5

CN.775 Relay box (C)

021-16 Y 0.5

36 37

A8: Turn signal (R)

000-rb2 B 0.5

081-04 081-06 Y-G 0.5

000-r03 000-r04 B 0.5

532-01 R-B 0.85

YAZAKI 361897-0553

JN.G12

082-04 G 0.5

000-r04 B 19 0.5

A10: Load dump 2

B3: Engine alternate droop 13 451-06 451-07 P-B 0.5

A3: High beam

YAZAKI 361897-0553

R-B

471-01 R-W 0.5

215-01 L-R 0.5

011-06 011-12 R 0.5 50

YAZAKI 090 7321-9823-30

10A

YAZAKI CN 7323-2064

Diode unit (ECM1)

462-01 V 0.5

B5: Load dump 1

10A

JN.G37 JN.G40

081-06 Y-G 0.5

432-01 Br-Y 0.5

CN.774 Relay box (B)

CN.739 Diode unit (Load dump 1)

A4: Bucket leveler 18

R-A

YAZAKI 090 7321-9823-30

10A

YAZAKI 090 7123-9025-30

DE2

JN.G04

YAZAKI 090 7123-9025-30

458-02 1 O 0.5

3 2 1 581-01 584-01 585-01 Y-G L-R W-B 0.5 0.5 0.5 6 5 4 582-01 594-01 583-01 P W-G R-L 0.5 0.5 0.5

YAZAKI 090 7321-9834-30

Dr.

457-01 P 0.5

10A

000-r06 000-r07 B 0.5

CN.791 Maintenance Pro Dr.

CN.748

20A

DE1

10A

DEUTSCH HD HDC16-9

208-01 R-G 0.5

CN.742

10A

A5: Lift arm height kickout DEUTSCH HD HD10-9-1939P

021-04 458-01 Y O 0.5 0.5

10A

CN.773 Relay box (A)

YAZAKI 361897-0533

YAZAKI 090 7321-9822

YAZAKI 090 7123-9135-50

10A

409-03 R-W 0.5

OPEN

408-01 G-W 0.5

YAZAKI 361897-0533

10A

OPEN

407-01 P 0.5

20A

10A

15A

OPEN

15A

S1L-10 W C 0.5 S1H-10 L A 0.5 000-is 711-02 B R-W 0.85 0.85 J

CN.776 Diode unit (parking brake) DP

10A

Top view

15A

10A

S1S-98 B 0.5

YAZAKI SWP 7222-7444-40

YAZAKI 090 7123-7729-40

20A

10A

Top view

10A

20A

15A

10A

224-02 Br-W 0.5

20A

225-01 L-W 0.5

Fuse box (A)

CN.777 Diode unit (front wiper SW) 2

YAZAKI SWP 7222-7464-40

YAZAKI SWP 7123-7464-40

E/G

DFW

Fuse box (B)

CN.792 Data link for DIAG (INSITE)

YAZAKI SWP 7123-7444-40

JN.H21

000-st1 B 0.5 4

YAZAKI other 361897-0533

R 2.0 40

OPEN

CN.759 DIAG INC/DEC SW

769-02 770-01 R R-Y 0.5 0.5

299-01 298-01 P-B G-W 0.5 0.5

R 3.0 38

10A

JN.G02

R 3.0 36

10A

DIAG

IDC

Blue

721-02 712-01 W-B W-R 0.5 0.5

JN.G03

CN.720 Arm angle, T/M learning SW

O R R 0.5 3.0 5.0 912-07 905-01 965d-04 34 35 W Y-G R 31 0.85 0.85 3.0 017-01 032-01 812-01 813-01 15 L-W W-L W-B W-L 11 0.85 0.85 1.25 0.85

YAZAKI CN 7123-2446-90

JN.G14

1 001-01 087-01 082-01 074-01 083-01 084-01 088-01 089-01 091-01 085-01 10 G-R W-R G P W-R Gr W-B L-R L L-R 0.5 0.85 1.25 2.0 0.85 1.25 0.85 2.0 1.25 2.0 21 901-01 965c-02 23 965c-03 25 965c-04 27 965d-02 29 965d-03 30

799-02 705-01 W-L Y-B 0.5 0.85 3 4

JN.G59 JN.G28 JN.G30 JN.G24 JN.G17 JN.G16 JN.G05 JN.G39 JN.G44 JN.G47 JN.G60

CN.752 Voltage relay

000-vr3 799-03 B W-L 0.5 0.5

CN.737 Fuse box (B)

081-09 Y-G 0.5

C6: Loading lever lock valve (opt)

90Z6 Floor Wiring Diagram (Rear Console) (4/5)

CN: Connector, JN: Junction Wire No.

From CN/JN No.

To Pin

000-ac1

JN.G52

000-ac2

CN.743

000-ac3

JN.G52

000-acp

CN.789

A/C gas Hi/Lo pressure SW

000-ap

CN.753

000-bls

CN.787

000-bm

CN/JN No. CN.785

Air conditioner 1

GND(A)

Wire Pin Dia. 1

JN.G52

Wire Color

2.0

CN.751

Air conditioner 3

0.5

CN.785

GND(A)

0.5

A/C operation panel (B)

CN.785

GND(A)

0.5

GND(C)

CN.767

Brake lamp SW

0.5

CN.778

GND(D)

CN.729

Rear view monitor

0.5

000-bt

CN.763

Option GND (Bt)

CN.786

GND(B)

2.0

000-cab

CN.768

CAB-B

CN.787

GND(C)

3.0

000-cs1

JN.G61

CN.778

GND(D)

0.5

Column shift lever (T/M)

000-cs2

CN.780

000-cs3

JN.G61

000-dc

CN.730

DC/DC converter

000-fc

CN.710

Front console CN.401

000-fls

CN.754

Flasher unit

000-gps

CN.750

GPS or GSM

000-is

CN.792

Data link for DIAG (INSITE)

000-mc1

JN.G54

000-mc2

CN.797

MCZ(F)

000-mc3

CN.797

MCZ(F)

000-mc4

JN.G54

CN.797

MCZ(F)

000-mc5

JN.G54

CN.795

000-mc6

CN.795

MCZ(E)

JN.G54

000-op1

CN.740

Option GND (ACC1)

000-op2

CN.741

Option GND (ACC2)

000-op3

CN.762

000-r01

000-r02

000-r03

JN.G61

0.5

CN: Connector, JN: Junction From

CN/JN No.

To Pin

CN/JN No.

021-10

CN.724

Joint connector (B)

CN.795

021-13

CN.756

A/C operation panel (A)

JN.G18

021-14

JN.G18

021-15

JN.G18

021-16

CN.774

Relay box (B)

032-01

CN.737

Fuse box (B)

MCZ(E)

166

134-01

CN.728

Throttle pedal

CN.793

MCZ(D)

0.5

167

135-01

CN.793

MCZ(D)

CN.706

Rear chassis CN.202

0.5

CN.710

Front console CN.401

0.85

W-L

168

136-01

CN.705

Rear chassis CN.201

CN.793

MCZ(D)

0.5

L-W

033-01

CN.774

Relay box (B)

CN.733

Fuse box (A)

0.5

169

137-01

CN.797

MCZ(F)

CN.705

Rear chassis CN.201

0.5

Br-Y

033-02

CN.774

Relay box (B)

CN.774

Relay box (B)

0.5

170

138-01

CN.701

Service brake secondary pressure sensor (CC)

CN.793

MCZ(D)

0.5

G-Y

061-01

CN.733

Fuse box (A)

CN.705

Rear chassis

0.5

B-W

171

139-01

CN.793

MCZ(D)

CN.706

Rear chassis CN.202

0.5

062-01

CN.733

Fuse box (A)

JN.G30

0.5

L-B

172

141-01

CN.705

Rear chassis CN.201

CN.799

MCZ(C)

0.5

062-02

JN.G30

173

142-01

CN.799

MCZ(C)

CN.706

Rear chassis CN.202

0.5

W-L L-R

CN.767

Brake lamp SW

0.5

L-B

062-03

JN.G30

CN.774

Relay box (B)

0.5

L-B

174

143-01

CN.799

MCZ(C)

CN.726

Themistor assy (outside temp. MC)

0.5

062-04

CN.774

Relay box (B)

CN.774

Relay box (B)

0.5

L-B

175

151-01

CN.705

Rear chassis CN.201

CN.713

Front console CN.404

0.5

R-L

062-05

CN.781

Column shift lever (turn)

JN.G30

0.5

L-B

176

153-01

CN.711

Front console CN.402

CN.705

Rear chassis CN.201

0.5

Y-B

0.5

177

154-01

CN.711

Front console CN.402

CN.705

Rear chassis CN.201

0.5

2.0

R-L

178

182-01

CN.703

Transmission CN.101

CN.795

MCZ(E)

0.5

W-B

0.85

R-L

179

184-01

CN.703

Transmission CN.101

CN.795

MCZ(E)

0.5

G-B

0.85

R-L

180

186-01

CN.703

Transmission CN.101

CN.795

MCZ(E)

0.5

Y-B

063-01

CN.733

Fuse box (A)

CN.775

065-01

CN.733

Fuse box (A)

JN.G07

CN.787

GND(C)

0.85

065-02

JN.G07

CN.785

GND(A)

0.5

065-03

CN.797

MCZ(F)

CN.786

GND(B)

0.85

100

065-04

JN.G07

CN.778

GND(D)

1 1

2.0

101

068-01

CN.733

Fuse box (A)

JN.G54

0.85

102

068-02

CN.775

JN.G54

0.85

103

072-01

CN.733

0.85

104

073-01

MCZ(E)

0.85

105

074-01

0.85

106

074-02

JN.G40

CN.773

Relay box (A)

CN.785

GND(A)

2.0

107

074-03

JN.G40

CN.775

Relay box (C)

CN.786

GND(B)

1.25

108

075-01

CN.733

Fuse box (A)

Option GND (ACC3)

CN.786

GND(B)

0.85

109

075-02

CN.773

Relay box (A)

CN.786

GND(B)

CN.773

Relay box (A)

0.5

110

075-03

JN.G37

CN.773

Relay box (A)

CN.773

Relay box (A)

0.5

111

081-01

CN.733

CN.773

Relay box (A)

CN.773

Relay box (A)

0.5

112

081-02

113 114

000-r07

CN.773

Relay box (A)

CN.773

Relay box (A)

0.5

000-r08

CN.773

Relay box (A)

CN.773

Relay box (A)

0.5

000-r09

CN.773

Relay box (A)

CN.773

Relay box (A)

0.5

000-rb1

CN.774

Relay box (B)

CN.786

GND(B)

0.5

CN.774

Relay box (B)

0.5

CN.775

Relay box (C)

0.5

000-rb2

CN.774

Relay box (B)

000-rc1

CN.786

GND(B)

P-B

0.5

R-L

0.5

Relay box (B)

0.5

Air conditioner 1

0.5

CN.774

2.0

2 18

CN.743

0.85

Relay box (A)

Control lever pilot primary pressure sensor

MCZ(D)

Relay box (A)

CN.793

MCZ(C)

CN.773

CN.702

CN.799

GND(D)

CN.773

A/C gas pressure sensor

GND(A)

MCZ(D)

Rear chassis CN.202

CN.785

CN.794

Wire Color

CN.706

CN.778

GND(B)

CN.793

129-01

Wire Dia.

131-01

Relay box (A)

128-01

164

165

CN.786

163

CN/JN No.

CN.773

0.5

To Pin

0.5

000-r06

0.5

CN/JN No.

000-r04

Wire No.

Air conditioner 3

Column shift lever (T/M)

Wire Color

CN.751

CN.780

From

Wire Dia.

CN.797

Relay box (C)

MCZ(F)

JN.G07 CN.797

MCZ(F)

0.85

R-L

181

188-01

CN.703

Transmission CN.101

CN.795

MCZ(E)

0.5

L-B

CN.775

Relay box (C)

0.5

182

202-01

CN.774

Relay box (B)

CN.710

Front console CN.401

0.5

G-O

Relay box (C)

CN.775

Relay box (C)

0.5

183

206-01

CN.774

Relay box (B)

CN.767

Brake lamp SW

0.5

Br-W

Fuse box (A)

CN.773

Relay box (A)

0.85

184

208-01

CN.773

Relay box (A)

CN.705

Rear chassis CN.201

0.5

R-G

CN.733

Fuse box (A)

CN.773

Relay box (A)

0.85

185

211-01

CN.773

Relay box (A)

JN.G26

CN.737

Fuse box (B)

JN.G40

2.0

186

211-02

JN.G26

CN.731

Wiper, horn SW

0.85

187

211-03

JN.G26

CN.713

0.85

188

211-04

JN.G26

CN.717

JN.G37

2.0

189

215-01

CN.705

Rear chassis CN.201

JN.G37

0.85

190

222-01

CN.727

Side console 4

CN.775

Relay box (C)

0.85

191

224-01

JN.G23

Fuse box (A)

CN.724

Joint connector (B)

0.85

Y-G

192

224-02

CN.777

Diode unit (F wiper SW)

CN.717

Side console 2 CN.601

CN.724

Joint connector (B)

0.5

Y-G

193

224-03

JN.G23

081-03

CN.724

Joint connector (B)

CN.715

Side console 1 CN.501

0.5

Y-G

194

225-01

CN.777

Diode unit (F wiper SW)

081-04

CN.724

Joint connector (B)

CN.773

Relay box (A)

0.5

Y-G

195

227-01

CN.731

Wiper, horn SW

115

081-05

CN.724

Joint connector (B)

CN.775

Relay box (C)

0.5

Y-G

196

228-01

CN.711

Front console CN.402

116

081-06

CN.773

Relay box (A)

CN.773

Relay box (A)

0.5

Y-G

197

229-01

CN.711

Front console CN.402

117

081-09

CN.775

Relay box (C)

CN.775

Relay box (C)

0.5

Y-G

198

231-01

CN.774

Relay box (B)

118

082-01

CN.737

Fuse box (B)

JN.G24

1.25

199

232-01

CN.774

Relay box (B)

119

082-02

JN.G24

120

082-03

JN.G24

121

082-04

CN.774

122

083-01

123

083-02

0.5

G-B

0.5

G-B

Front console CN.404

0.5

G-B

Side console 2 CN.601

0.5

G-B

CN.773

Relay box (A)

0.5

L-R

CN.775

Relay box (C)

0.5

G-R

CN.711

Front console CN.402

0.5

Br-W

JN.G23

0.5

Br-W

CN.731

Wiper, horn SW

0.5

Br-W

CN.774

Relay box (B)

0.5

L-W

CN.713

Front console CN.404

0.5

B-Y

CN.731

Wiper, horn SW

0.5

P-B

CN.731

Wiper, horn SW

0.5

Br-Y

CN.731

Wiper, horn SW

0.5

R-W

CN.731

Wiper, horn SW

0.5

L-Y

0.5

G-R

CN.712

Front console CN.403

1.25

200

235-01

CN.795

MCZ(E)

CN.717

Side console 2 CN.601

CN.774

Relay box (B)

0.85

201

236-01

CN.795

MCZ(E)

CN.717

Side console 2 CN.601

0.5

P-W

CN.774

Relay box (B)

0.5

202

241-01

CN.780

Column shift lever (T/M)

CN.769

Diode unit (Column F)

0.5

W-R

JN.G39

CN.737

Fuse box (B)

0.85

W-R

203

242-01

CN.780

Column shift lever (T/M)

CN.779

Diode unit (Column N)

0.5

L-Y

JN.G39

CN.774

Relay box (B)

0.85

W-R

204

243-01

CN.780

Column shift lever (T/M)

CN.770

Diode unit (Column R)

0.5

G-W

CN.774

Relay box (B)

0.5

W-R

205

244-01

CN.771

Diode unit (opt-F)

CN.717

Side console 2 CN.601

0.5

W-L

CN.774

Relay box (B)

0.85

W-R

206

246-01

CN.772

Diode unit (opt-R)

CN.717

Side console 2 CN.601

0.5

Y-B

CN.774

Relay box (B)

0.5

W-R

207

247-01

CN.795

MCZ(E)

CN.780

Column shift lever (T/M)

0.5

L-Y

CAB-A

JN.G39

0.85

W-R

208

248-01

CN.795

MCZ(E)

CN.780

Column shift lever (T/M)

0.5

Br-Y

000-rc2

CN.775

Relay box (C)

CN.775

Relay box (C)

0.5

000-rc3

CN.775

Relay box (C)

CN.775

Relay box (C)

0.5

000-sc1

CN.715

Side console 1 CN.501

CN.778

GND(D)

0.85

000-sc2

JN.G62

CN.778

GND(D)

0.5

124

083-03

CN.774

Side console 4

0.5

125

083-04

JN.G39

0.5

126

083-05

CN.774

Relay box (B)

2.0

127

083-06

CN.734

Relay box (B)

000-sc3

CN.717

Side console 2 CN.601

JN.G62

000-sc4

CN.787

GND(C)

CN.727

000-sc5

CN.717

Side console 2 CN.601

JN.G62

000-sh

CN.790

Air suspension seat power (opt)

CN.785

GND(A)

000-st1

CN.720

Arm angle, T/M learning SW

CN.787

GND(C)

0.5

128

084-01

CN.743

Air conditioner 1

CN.737

Fuse box (B)

1.25

209

249-01

CN.793

MCZ(D)

CN.715

Side console 1 CN.501

0.5

000-sw

CN.713

Front console CN.404

CN.778

GND(D)

1.25

129

085-01

CN.743

Air conditioner 1

CN.737

Fuse box (B)

2.0

L-R

210

251-01

CN.797

MCZ(F)

CN.715

Side console 1 CN.501

0.5

CN.787

GND(C)

0.85

130

087-01

CN.737

Fuse box (B)

CN.713

Front console CN.404

0.85

W-R

211

252-01

CN.797

MCZ(F)

CN.715

Side console 1 CN.501

0.5

W-L

Voltage relay

0.5

131

088-01

CN.737

Fuse box (B)

CN.730

DC/DC converter

0.85

W-B

212

253-01

CN.793

MCZ(D)

CN.715

Side console 1 CN.501

0.5

L-B

132

089-01

CN.790

Air suspension seat power (opt)

CN.737

Fuse box (B)

2.0

L-R

213

254-01

CN.797

MCZ(F)

CN.713

Front console CN.404

0.5

Br-W

000-vr

JN.G59

000-vr2

CN.752

000-vr3

JN.G59

000-wip

CN.731

Wiper, horn SW

001-01

CN.734

CAB-A

009-01

CN.733

011-01

CN.733

011-02

011-03

JN.G59 CN.757

Diode unit (voltage relay)

0.5

CN.787

GND(C)

0.5

133

091-01

CN.768

CAB-B

CN.737

Fuse box (B)

1.25

214

255-01

CN.797

MCZ(F)

CN.713

Front console CN.404

0.5

CN.737

Fuse box (B)

0.5

G-R

134

101-01

CN.703

Transmission CN.101

CN.795

MCZ(E)

0.5

Y-L

215

257-01

CN.797

MCZ(F)

CN.715

Side console 1 CN.501

0.5

L-Y

Fuse box (A)

CN.773

Relay box (A)

0.85

Y-B

135

102-01

CN.703

Transmission CN.101

CN.795

MCZ(E)

0.5

L-W

216

258-01

CN.797

MCZ(F)

CN.717

Side console 2 CN.601

0.5

R-Y

Fuse box (A)

JN.G05

0.85

136

103-01

CN.703

Transmission CN.101

CN.795

MCZ(E)

0.5

W-R

217

259-01

CN.797

MCZ(F)

CN.715

Side console 1 CN.501

0.5

P-W

CN.721

Joint connector (A)

JN.G06

0.85

137

105-01

CN.703

Transmission CN.101

CN.795

MCZ(E)

0.5

L-Y

218

261-01

CN.769

Diode unit (Column F)

CN.795

MCZ(E)

0.5

R-L

CN.721

Joint connector (A)

CN.750

GPS or GSM

0.5

138

113-01

CN.799

MCZ(C)

CN.704

Transmission CN.102

0.5

B-W

219

262-01

CN.779

Diode unit (Column N)

CN.795

MCZ(E)

0.5

Y-G

Joint connector (A)

011-04

CN.721

011-05

JN.G05

CN.712

Front console CN.403

0.85

139

121-01

JN.G48

CN.702

0.5

220

263-01

CN.770

Diode unit (Column R)

CN.795

MCZ(E)

0.5

W-L

Joint connector (A)

Control lever pilot primary pressure sensor

CN.721

0.85

140

121-02

CN.721

Joint connector (A)

CN.728

Throttle pedal

0.5

221

267-01

CN.795

MCZ(E)

CN.713

Front console CN.404

0.5

W-G

141

121-03

CN.721

Joint connector (A)

CN.704

Transmission CN.102

0.5

222

268-01

CN.795

MCZ(E)

CN.713

Front console CN.404

0.5

G-Y

142

121-04

CN.706

Rear chassis CN.202

CN.721

Joint connector (A)

0.5

223

270-01

CN.793

MCZ(D)

CN.713

Front console CN.404

0.5

G-R

143

121-05

CN.721

Joint connector (A)

JN.G48

0.5

224

278-01

CN.771

Diode unit (opt-F)

CN.793

MCZ(D)

0.5

144

121-06

JN.G48

CN.797

MCZ(F)

0.5

225

279-01

CN.772

Diode unit (opt-R)

CN.793

MCZ(D)

0.5

Br-W

145

122-01

JN.G49

CN.797

MCZ(F)

0.5

226

293-01

CN.797

MCZ(F)

CN.715

Side console 1 CN.501

0.5

Gr-L

146

122-02

CN.706

Rear chassis CN.202

CN.721

Joint connector (A)

0.5

227

294-01

CN.797

MCZ(F)

CN.715

Side console 1 CN.501

0.5

W-G

147

122-03

CN.721

Joint connector (A)

CN.704

Transmission CN.102

0.5

228

295-01

CN.797

MCZ(F)

CN.715

Side console 1 CN.501

0.5

L-B

148

122-04

CN.721

Joint connector (A)

CN.728

Throttle pedal

0.5

229

296-01

CN.797

MCZ(F)

CN.715

Side console 1 CN.501

0.5

W-Y

Joint connector (A)

JN.G49

0.5

230

298-01

CN.795

MCZ(E)

CN.720

Arm angle, T/M learning SW

0.5

G-W

Control lever pilot primary pressure sensor

0.5

231

299-01

CN.795

MCZ(E)

CN.720

Arm angle, T/M learning SW

0.5

P-B

0.5

232

305-01

CN.727

Side console 4

CN.775

Relay box (C)

0.5

R-Y

0.5

233

321-01

CN.798

MCZ(A)

CN.705

Rear chassis CN.201

0.5

R-Y

0.5

234

322-01

CN.798

MCZ(A)

CN.705

Rear chassis CN.201

0.5

L-Y

0.5

235

325-01

CN.755

MCZ(B)

CN.705

Rear chassis CN.201

0.5

W-B B-R

011-06

JN.G05

CN.773

Relay box (A)

0.5

011-07

JN.G06

CN.795

MCZ(E)

0.85

011-08

JN.G06

CN.795

MCZ(E)

0.85

011-09

JN.G05

CN.774

Relay box (B)

0.5

011-10

CN.774

Relay box (B)

CN.774

Relay box (B)

0.5

011-12

CN.773

Relay box (A)

CN.773

Relay box (A)

0.5

CN.775

JN.G46

013-01

CN.733

Fuse box (A)

014-01

CN.733

Fuse box (A)

014-02

JN.G46

CN.710

Front console CN.401

014-03

JN.G46

CN.754

Flasher unit

Relay box (C)

0.85

Y-R

0.5

Y-R

0.85

Y-R

015-01

CN.733

Fuse box (A)

CN.773

Relay box (A)

0.85

015-02

CN.773

Relay box (A)

CN.773

Relay box (A)

0.5

016-01

CN.782

Column shift lever (lighting)

CN.733

Fuse box (A)

0.85

017-01

CN.734

CAB-A

CN.737

Fuse box (B)

0.85

L-W

021-01

CN.733

Fuse box (A)

CN.724

Joint connector (B)

0.85

149

122-05

CN.721

150

122-06

JN.G49

151

123-01

CN.797

152

123-02

JN.G08

153

123-03

CN.706

154

123-04

JN.G08

CN.702

MCZ(F)

Rear chassis CN.202

JN.G08 CN.701

Service brake secondary pressure sensor (CC)

JN.G08 CN.794

A/C gas pressure sensor

021-02

CN.724

Joint connector (B)

CN.712

Front console CN.403

0.85

155

124-01

CN.797

0.5

G-B

236

326-01

CN.755

MCZ(B)

CN.705

Rear chassis CN.201

0.5

021-03

CN.724

Joint connector (B)

CN.775

Relay box (C)

0.5

156

124-02

JN.G09

CN.701

Service brake secondary pressure sensor (CC)

0.5

G-B

237

327-01

CN.798

MCZ(A)

CN.706

Rear chassis CN.202

0.5

Y-R

021-04

CN.724

Joint connector (B)

CN.748

Diode unit (ECM1)

0.5

157

124-03

JN.G09

CN.705

Rear chassis CN.201

0.5

G-B

238

328-01

CN.798

MCZ(A)

CN.706

Rear chassis CN.202

0.5

G-Y

0.5

158

124-04

JN.G09

CN.794

A/C gas pressure sensor

0.5

G-B

239

331-01

CN.798

MCZ(A)

CN.706

Rear chassis CN.202

0.5

Y-B

0.5

159

124-05

JN.G09

CN.726

Themistor assy (outside temp. MC)

0.5

G-B

240

332-01

CN.798

MCZ(A)

CN.706

Rear chassis CN.202

0.5

W-B

MCZ(F)

JN.G09

021-05

CN.724

Joint connector (B)

JN.G18

021-06

CN.724

Joint connector (B)

CN.723

Diode unit (key ON power)

021-07

CN.724

Joint connector (B)

CN.774

Relay box (B)

0.5

160

125-01

CN.799

MCZ(C)

CN.704

Transmission CN.102

0.5

241

341-01

CN.706

Rear chassis CN.202

CN.715

Side console 1 CN.501

0.5

L-R

021-08

CN.724

Joint connector (B)

CN.705

Rear chassis CN.201

0.5

161

126-01

CN.793

MCZ(D)

CN.706

Rear chassis CN.202

0.5

Y-B

242

342-01

CN.706

Rear chassis CN.202

CN.715

Side console 1 CN.501

0.5

G-B

021-09

CN.724

Joint connector (B)

CN.750

GPS or GSM

0.5

162

127-01

CN.793

MCZ(D)

CN.706

Rear chassis CN.202

0.5

R-L

243

351-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

- 21 -

90Z6 Floor Wiring Diagram (Rear Console) (5/5)

CN: Connector, JN: Junction Wire No.

From CN/JN No.

Wire Pin Dia.

Wire Color B-W

CN/JN No.

244

352-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

245

353-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

246

354-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

G-B

247

355-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

L-W

248

356-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

G-W

249

357-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

R-L

250

358-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

B-Y

251

359-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

R-W

252

360-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

B-L

253

361-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

254

362-01

CN.703

Transmission CN.101

CN.798

MCZ(A)

0.5

255

405-01

CN.775

Relay box (C)

CN.799

MCZ(C)

CN: Connector, JN: Junction From

CN/JN No.

325

515-05

CN.724

326

517-01

JN.G38

327

517-02

CN.768

To Pin

Joint connector (B)

CN/JN No.

Wire Dia.

Wire Color

Wire No.

From CN/JN No.

To Pin

CN/JN No.

Wire Dia.

Wire Color W

CN.727

Side console 4

0.5

406

716-01

CN.705

Rear chassis CN.201

CN.788

Emergency throttle

0.5

CN.773

Relay box (A)

0.85

L-W

407

717-01

CN.705

Rear chassis CN.201

CN.788

Emergency throttle

0.5

0.85

L-W

408

718-01

CN.705

Rear chassis CN.201

CN.774

Relay box (B)

0.5

Lg-R

Rear chassis CN.201

JN.G34

0.5

W-B

DIAG INC/DEC SW

CAB-B

JN.G38

328

517-03

JN.G38

CN.711

Front console CN.402

0.5

L-W

409

721-01

CN.705

329

518-01

CN.773

Relay box (A)

CN.705

Rear chassis CN.201

0.85

G-W

410

721-02

JN.G34

330

519-01

CN.766

CAB-F

CN.775

Relay box (C)

0.85

W-B

411

721-03

CN.774

Relay box (B)

331

520-01

CN.732

CAB-R

CN.775

Relay box (C)

0.85

412

724-01

CN.765

MAINTENANCE (E/G fault lamp)

CN.705

Rear chassis CN.201

332

525-01

CN.706

Rear chassis CN.202

CN.775

Relay box (C)

0.5

L-R

413

769-02

CN.705

Rear chassis CN.201

CN.759

DIAG INC/DEC SW

333

527-01

CN.773

Relay box (A)

CN.705

Rear chassis CN.201

0.85

W-B

414

770-01

CN.705

Rear chassis CN.201

CN.759

334

531-01

CN.705

Rear chassis CN.201

CN.774

Relay box (B)

0.85

W-L

415

799-01

JN.G28

CN.705

335

532-01

CN.774

Relay box (B)

CN.705

Rear chassis CN.201

0.85

R-B

416

799-02

CN.752

Voltage relay

JN.G28

336

535-01

CN.799

MCZ(C)

CN.717

Side console 2 CN.601

0.5

Br-Y

417

799-03

JN.G28

B-R

337

536-01

CN.799

MCZ(C)

CN.717

Side console 2 CN.601

0.5

L-Y

418

802-01

CN.736

0.5

L-B

338

538-01

CN.730

DC/DC converter

CN.761

Socket

0.85

419

808-01

JN.G53

CN.759

Opt power supply (Bt)

0.5

W-B

0.5

W-B

0.5

Y-B

0.5

DIAG INC/DEC SW

0.5

R-Y

Rear chassis CN.201

0.5

W-L

0.5

W-L W-L

JN.G34

CN.757

Diode unit (voltage relay)

0.5

CN.733

Fuse box (A)

2.0

CN.733

Fuse box (A)

2.0

W-R

2.0

W-R

CN.729

Rear view monitor

0.5

W-R

256

406-01

CN.774

Relay box (B)

CN.774

Relay box (B)

0.5

339

539-01

CN.730

DC/DC converter

CN.761

Socket

0.85

G-L

420

808-02

CN.735

257

407-01

CN.776

Diode unit (parking brake)

CN.705

Rear chassis CN.201

0.5

340

542-01

CN.755

MCZ(B)

CN.711

Front console CN.402

0.5

421

808-03

JN.G53

258

408-01

CN.776

Diode unit (parking brake)

CN.774

Relay box (B)

0.5

G-W

341

552-01

CN.799

MCZ(C)

CN.713

Front console CN.404

0.5

R-B

422

812-01

CN.738

Opt power supply (ACC2)

CN.737

Fuse box (B)

1.25

W-B

259

409-01

JN.G44

CN.774

Relay box (B)

0.5

R-W

342

553-01

CN.799

MCZ(C)

CN.711

Front console CN.402

0.5

423

813-01

CN.803

Opt power supply (ACC3)

CN.737

Fuse box (B)

0.85

W-L

260

409-02

JN.G44

CN.710

Front console CN.401

0.5

R-W

343

554-01

JN.G35

CN.705

Rear chassis CN.201

0.5

424

840-01

CN.705

Rear chassis CN.201

CN.804

For option SW (not used)

0.5

Y-G

261

409-03

JN.G44

CN.776

Diode unit (parking brake)

0.5

R-W

344

554-02

CN.711

0.5

425

901-01

CN.737

Fuse box (B)

CN.710

Front console CN.401

0.5

262

411-01

CN.754

0.85

Br-Y

345

554-03

JN.G35

0.5

426

905-01

CN.737

Fuse box (B)

CN.710

Front console CN.401

0.85

Y-G

Relay box (B)

L-B

Flasher unit

JN.G47

Front console CN.402

JN.G35 CN.765

MAINTENANCE (E/G fault lamp)

Opt power supply (ACC1)

JN.G53

263

411-02

JN.G47

CN.773

Relay box (A)

0.85

Br-Y

346

555-01

CN.799

MCZ(C)

CN.713

Front console CN.404

0.5

W-R

427

907-01

CN.774

CN.710

Front console CN.401

0.85

264

411-03

JN.G47

CN.774

Relay box (B)

0.85

Br-Y

347

556-01

CN.711

Front console CN.402

CN.705

Rear chassis CN.201

0.5

W-R

428

912-02

JN.G29

CN.710

Front console CN.401

1.25

265

412-01

JN.G22

CN.710

Front console CN.401

0.5

348

577-01

CN.712

Front console CN.403

CN.750

GPS or GSM

0.5

Y-R

429

912-03

JN.G29

JN.G04

8.0

CN.783

Diode unit (Flasher1)

0.5

349

578-01

CN.712

Front console CN.403

CN.750

GPS or GSM

0.5

430

912-04

JN.G29

0.5

350

579-01

CN.712

Front console CN.403

CN.750

GPS or GSM

0.5

431

912-05

CN.733

351

581-01

CN.791

Maintenance Pro Dr.

CN.712

Front console CN.403

0.5

Y-G

432

912-06

JN.G04

352

582-01

CN.791

Maintenance Pro Dr.

CN.712

Front console CN.403

0.5

433

912-07

353

583-01

CN.791

Maintenance Pro Dr.

CN.712

Front console CN.403

0.5

R-L

434

354

584-01

CN.791

Maintenance Pro Dr.

CN.712

Front console CN.403

0.5

L-R

435

355

585-01

CN.791

Maintenance Pro Dr.

CN.712

Front console CN.403

0.5

W-B

356

591-01

CN.705

Rear chassis CN.201

CN.713

Front console CN.404

0.5

G-Y

357

592-01

CN.705

Rear chassis CN.201

CN.713

Front console CN.404

0.5

358

593-01

CN.712

Front console CN.403

CN.750

GPS or GSM

0.5

359

594-01

CN.791

Maintenance Pro Dr.

CN.712

Front console CN.403

0.5

360

595-01

CN.799

MCZ(C)

CN.713

Front console CN.404

0.5

361

596-01

CN.712

Front console CN.403

CN.750

GPS or GSM

362

597-01

CN.712

Front console CN.403

CN.750

GPS or GSM

363

598-01

CN.712

Front console CN.403

CN.750

GPS or GSM

266

412-02

JN.G22

267

412-03

CN.784

Diode unit (Flasher2)

JN.G22

268

413-01

CN.781

Column shift lever (turn)

CN.783

Diode unit (Flasher1)

0.5

R-W

269

414-01

CN.781

Column shift lever (turn)

CN.784

Diode unit (Flasher2)

0.5

L-Y

270

415-01

CN.783

Diode unit (Flasher1)

CN.773

Relay box (A)

0.5

P-W

271

416-01

CN.784

Diode unit (Flasher2)

CN.774

Relay box (B)

0.5

W-R

272

421-01

CN.782

Column shift lever (lighting)

CN.773

Relay box (A)

0.5

R-Y

273

422-01

CN.782

Column shift lever (lighting)

CN.773

Relay box (A)

0.5

274

425-01

JN.G16

CN.710

Front console CN.401

0.5

Y-R

275

425-02

CN.773

0.5

Y-R

Relay box (A)

JN.G16

276

425-03

JN.G16

CN.775

Relay box (C)

0.5

Y-R

277

426-01

JN.G17

CN.710

Front console CN.401

0.5

R-W

278

426-02

CN.773

279

426-03

JN.G17

280

431-01

CN.773

Relay box (A)

281

432-01

CN.717

282

445-01

283

446-01

284 285

Relay box (A)

0.5

R-W

CN.775

Relay box (C)

0.5

R-W

CN.717

Side console 2 CN.601

0.5

W-R

Side console 2 CN.601

CN.773

Relay box (A)

0.5

Br-Y

CN.734

CAB-A

CN.774

Relay box (B)

0.85

CN.734

CAB-A

CN.774

Relay box (B)

0.85

R-G

451-01

CN.769

Diode unit (Column F)

JN.G10

0.5

P-B

366

451-02

JN.G10

CN.770

Diode unit (column R)

0.5

P-B

367

286

451-03

JN.G10

CN.771

Diode unit (opt-F)

0.5

P-B

368

612-02

JN.G20

CN.751

Air conditioner 3

287

451-04

CN.772

0.5

P-B

369

612-03

JN.G20

CN.744

Air conditioner 2

288

451-05

JN.G10

CN.711

Front console CN.402

0.5

P-B

370

612-04

JN.G20

CN.713

289

451-06

JN.G10

CN.774

Relay box (B)

0.5

P-B

371

615-01

CN.756

CN.746

290

451-07

CN.774

Relay box (B)

CN.774

Relay box (B)

0.5

P-B

372

616-01

CN.756

A/C operation panel (A)

JN.G19

291

455-01

CN.775

Relay box (C)

CN.799

MCZ(C)

0.5

R-W

373

616-02

JN.G19

A/C operation panel (A)

CN.751

Air conditioner 3

292

456-01

CN.799

MCZ(C)

CN.749

Axle oil cooler relay (opt)

0.5

374

616-03

JN.G19

CN.746

293

457-01

CN.773

Relay box (A)

CN.742

Diode unit (ECM2)

0.5

375

616-04

JN.G19

294

458-01

CN.748

Diode unit (ECM1)

JN.G12

0.5

376

618-01

CN.756

A/C operation panel (A)

295

458-02

JN.G12

377

619-01

CN.756

296

458-03

CN.773

297

458-04

JN.G12

298

461-01

CN.774

Relay box (B)

299

462-01

CN.773

Relay box (A)

300

471-01

CN.739

301

472-01

CN.764

302

501-01

CN.773

303

501-02

JN.G41

304

501-03

JN.G41

305

502-01

CN.774

306

502-02

JN.G33

307

502-03

JN.G33

308

503-01

CN.705

309

505-01

JN.G31

Diode unit (opt-R)

JN.G17

JN.G10

CN.747

JN.G04

912-08

CN.733

Fuse box (A)

JN.G04

923-01

CN.733

Fuse box (A)

CN.710

436

965a-01

CN.709

Rear chassis CN.205

JN.G14

8.0

437

965a-02

CN.733

Fuse box (A)

JN.G14

3.0

438

965a-03

CN.733

Fuse box (A)

JN.G14

2.0

B-Y

439

965a-04

CN.733

Fuse box (A)

JN.G14

2.0

W-G

440

965b-01

CN.709

Rear chassis CN.205

JN.G03

8.0

G-R

441

965b-02

CN.733

Fuse box (A)

JN.G03

5.0

0.5

442

965b-03

CN.733

Fuse box (A)

JN.G03

2.0

0.5

Y-R

443

965c-01

CN.708

Rear chassis CN.204

JN.G01

8.0

0.5

R-W

444

965c-02

JN.G01

3.0

Air conditioner 2

1.25

445

965c-03

JN.G01

CN.789

A/C gas Hi/Lo pressure SW

0.5

L-W

446

965c-04

CN.737

Fuse box (B)

JN.G01

611-01

CN.756

A/C operation panel (A)

CN.713

Front console CN.404

0.5

W-G

447

965d-01

CN.708

Rear chassis CN.204

JN.G02

8.0

612-01

CN.756

A/C operation panel (A)

JN.G20

0.5

448

965d-02

JN.G02

CN.737

Fuse box (B)

3.0

0.5

449

965d-03

JN.G02

CN.737

Fuse box (B)

2.0

0.5

450

965d-04

JN.G02

CN.737

Fuse box (B)

3.0

Front console CN.404

0.5

451

S1H-01

CN.705

Rear chassis CN.201

JN.H02

0.5

Themistor assy (outside temp. A/C)

0.5

452

S1H-02

CN.725

Opt CAN

JN.H02

0.5

G-R

453

S1H-03

JN.H05

JN.H02

0.5

G-R

454

S1H-04

CN.729

JN.H05

0.5

Themistor assy (outside temp. A/C)

0.5

G-R

455

S1H-05

JN.H11

JN.H05

0.5

CN.744

Air conditioner 2

0.5

G-R

456

S1H-06

CN.793

JN.H11

0.5

CN.751

Air conditioner 3

0.5

B-Y

457

S1H-09

JN.H11

JN.H14

0.5

A/C operation panel (A)

CN.751

Air conditioner 3

0.5

P-B

458

S1H-10

JN.H14

CN.792

Rear view monitor

MCZ(D)

A/C operation panel (A)

CN.751

Air conditioner 3

0.5

Y-R

459

S1H-11

JN.H17

379

621-01

CN.756

A/C operation panel (A)

CN.751

Air conditioner 3

0.5

G-R

460

S1H-12

CN.753

A/C operation panel (B)

CN.711

Front console CN.402

0.5

380

622-01

CN.756

A/C operation panel (A)

CN.751

Air conditioner 3

0.5

461

S1H-13

CN.711

Front console CN.402

CN.711

Front console CN.402

0.5

381

623-01

CN.756

A/C operation panel (A)

CN.751

Air conditioner 3

0.5

462

S1L-01

CN.705

Diode unit (load dump 1)

CN.774

Relay box (B)

0.5

R-W

382

624-01

CN.753

A/C operation panel (B)

CN.751

Air conditioner 3

0.5

B-L

463

S1L-02

CN.725

MAINTENANCE (shortcircuit)

CN.764

MAINTENANCE (shortcircuit)

0.5

383

625-01

CN.753

A/C operation panel (B)

CN.751

Air conditioner 3

0.5

W-B

464

S1L-03

JN.H06

Relay box (A)

JN.G41

384

626-01

CN.753

A/C operation panel (B)

CN.751

Air conditioner 3

0.5

B-R

Front console CN.401

465

S1L-04

CN.729

385

627-01

CN.753

A/C operation panel (B)

CN.751

Air conditioner 3

0.5

W-R

466

S1L-05

JN.H12

386

628-01

CN.753

A/C operation panel (B)

CN.751

Air conditioner 3

0.5

467

S1L-06

CN.793

387

629-01

CN.753

A/C operation panel (B)

CN.751

Air conditioner 3

0.5

G-W

468

S1L-09

388

630-01

CN.753

A/C operation panel (B)

CN.751

Air conditioner 3

0.5

Br-Y

469

389

631-01

CN.753

A/C operation panel (B)

CN.751

Air conditioner 3

0.5

L-B

390

701-01

CN.705

Rear chassis CN.201

JN.G36

0.5

391

701-02

JN.G36

Diode unit (key ON power)

0.5

392

701-04

CN.739

0.5

CN.711

Rear chassis CN.201

Front console CN.402

0.85

L-R

0.85

R-L

0.5

R-L

Rear chassis CN.201

0.85

R-L

CN.774

Relay box (B)

0.5

W-R

CN.705

Rear chassis CN.201

0.5

Br-W

505-02

CN.775

311

505-03

JN.G31

312

506-01

CN.705

313

511-01

JN.G32

CN.705

314

511-02

JN.G32

315

511-03

JN.G32

316

512-01

CN.773

Relay box (A)

317

514-01

CN.733

318

514-02

CN.782

CN.705

310

Relay box (C)

Rear chassis CN.201

JN.G31

0.5

Br-W

0.5

Br-W

0.5

JN.H17

0.5

JN.H17

0.5

Rear chassis CN.201

JN.H03

0.5

Opt CAN

JN.H03

0.5

JN.H03

0.5

JN.H06

0.5

JN.H06

0.5

JN.H12

0.5

JN.H12

JN.H15

0.5

S1L-10

JN.H15

CN.792

470

S1L-11

JN.H18

W-B

471

S1L-12

CN.753

A/C operation panel (B)

W-B

472

S1L-13

CN.711

Front console CN.402

W-B

473

S1S-00

CN.705

Rear view monitor

MCZ(D)

0.5

JN.H15

0.5

JN.H18

0.5

JN.H18

0.5

Rear chassis CN.201

JN.H01

0.5

JN.H04

0.5

Disconnect (opt CAN)

JN.H04

0.5

JN.H04

0.5

JN.H07

0.5

CN.745

Diode unit (alternator)

0.5

W-B

474

S1S-01

JN.H01

Voltage relay

CN.705

Rear chassis CN.201

0.85

R-G

475

S1S-02

CN.719

705-01

CN.752

Voltage relay

CN.774

Relay box (B)

0.85

Y-B

476

S1S-03

JN.H07

396

707-01

CN.721

Joint connector (A)

CN.705

Rear chassis CN.201

0.85

G-W

477

S1S-04

CN.718

Y-B

397

707-02

CN.721

Joint connector (A)

CN.750

GPS or GSM

0.5

G-W

478

S1S-05

JN.H10

JN.H07

0.85

Y-R

398

707-03

CN.721

Joint connector (A)

CN.711

Front console CN.402

0.5

G-W

479

S1S-06

JN.H10

CN.714

0.5

Y-R

399

707-04

CN.721

Joint connector (A)

CN.745

Diode unit (alternator)

0.5

G-W

480

S1S-09

JN.H10

CN.715

Side console 1 CN.501

0.5

W-G

393

701-05

JN.G36

Rear chassis CN.201

0.85

G-Y

394

704-01

CN.773

Relay box (A)

0.85

G-Y

395

CN.711

Front console CN.402

0.5

G-Y

CN.705

Rear chassis CN.201

0.85

Fuse box (A)

JN.G11

Column shift lever (lighting)

JN.G11

JN.G36

Data link for DIAG (INSITE)

R R

JN.H14

CN.752

Data link for DIAG (INSITE)

5.0 3.0

0.5

Side console 1 CN.501

CN.723

Diode unit (load dump 1)

CN.715

Rear chassis CN.201

CN.744

CN.756

JN.G33

Fuse box (B)

A/C operation panel (A)

620-01

CN.705

CN.737

Rear chassis CN.201

378

W L-Y

CN.705

Relay box (B)

Fuse box (B)

3.0 0.85

CN.756

L-R

CN.737

W W

601-01

0.5

L-R

5.0 0.85

605-01

0.5

Front console CN.401

364

0.85

Fuse box (A)

365

Relay box (C)

CN.710

JN.G04 CN.733

CN.775

JN.G12

W W

Fuse box (B)

0.5

8.0 3.0

CN.737

Relay box (A)

Diode unit (ECM2)

CN.742

Rear chassis (70A fusible link)

Fuse box (A)

Disconnect (rear view monitor)

Disconnect (MCZ1)

0.5

JN.H16

0.5

319

514-03

JN.G11

CN.711

Front console CN.402

0.5

Y-R

400

711-01

CN.775

Relay box (C)

JN.G60

0.85

R-W

481

S1S-10

JN.H16

JN.H21

0.5

320

514-04

JN.G11

CN.710

Front console CN.401

0.5

Y-R

401

711-02

CN.792

Data link for DIAG (INSITE)

JN.G60

0.85

R-W

482

S1S-11

JN.H19

JN.H16

0.5

321

515-01

CN.733

Fuse box (A)

CN.724

Joint connector (B)

0.85

402

711-03

JN.G60

0.5

322

515-02

CN.724

Joint connector (B)

CN.705

Rear chassis CN.201

0.5

403

712-01

CN.705

Rear chassis CN.201

0.5

323

515-03

CN.724

Joint connector (B)

CN.710

Front console CN.401

0.5

404

713-01

CN.773

324

515-04

CN.724

Joint connector (B)

CN.715

Side console 1 CN.501

0.5

405

715-01

CN.705

- 22 -

Disconnect (A/C panel)

CN.705

Rear chassis CN.201

0.85

R-W

483

S1S-12

JN.H19

CN.716

CN.759

DIAG INC/DEC SW

0.5

W-R

484

S1S-13

JN.H19

JN.H20

Relay box (A)

CN.705

Rear chassis CN.201

0.85

L-W

485

S1S-98

JN.H21

CN.792

Data link for DIAG (INSITE)

0.5

Rear chassis CN.201

CN.788

Emergency throttle

0.5

486

S1S-99

JN.H20

CN.711

Front console CN.402

0.5

90Z6 Floor Wiring Diagram (Side Console 1) To rear console (p.18)

000-01 293-01 294-01 295-01 B Gr-L W-G L-B 0.85 0.5 0.5 0.5 5 296-01 259-01 252-01 249-01 P-W W-Y W-L Br 0.5 0.5 0.5 0.5 505-01 506-01 081-01 342-01 9 Br-W W-G Y-B G-B 12 0.5 0.5 0.5 0.5 515-01 341-01 257-01 14 P L-R L-Y 0.5 0.5 0.5 13 18 19 253-01 251-01 L-B Gr 0.5 0.5 17

506-01 W-G 0.5

CA001

505-01 Br-W 0.5

CB001

RC-A

CN.505 Secondary steering check switch (opt)

CN.501 To rear console 1 CN.715 1

CN.510 Ride control switch (Auto)

CN.508 CN.507 Back-up alarm 1 1

EMS 8

259-01 7 P-W 0.5

BBZ

CN.506 Joint connector (D) (waterproof)

16 12

J-D

341-01 L-R 0.5

Top View

From

Wire No.

000-03 294-01 293-01 6 B W-G Gr-L 0.5 0.5 0.5

CN.503 Lift arm auto leveler lower kickout SW 4

000-04 B 0.5

000-05 296-01 295-01 6 B W-Y L-B 0.5 0.5 0.5

YAZAKI SDL-2 7183-4000

000-13 7 B 0.5

000-14 1 B 0.5

249-01 515-06 Br P 0.5 0.5 5

000-10 7 B 0.5

000-11 1 B 0.5

251-01 515-05 Gr P 0.5 0.5 5

YAZAKI SDL-2 7183-4000

CN: Connector, JN: Junction

YAZAKI SDL-2 7183-4000

LKOS

CN.512 Power mode switch

CN.502 Lift arm auto leveler height kickout SW

000-17 1 B 0.5 252-01 253-01 000-18 515-03 P B L-B W-L 0.5 5 0.5 0.5 0.5 2

YAZAKI SDL-2 7183-4000

CARLING VC1/VC2 CARLING-VC

HKOS

SUMITOMO 040 6189-0900

000-02 B 0.5

000-08 515-02 B P 0.5 0.5 5

CN.511 FNR select switch

CN.504 Coupler switch (opt)

081-01 Y-B 0.5

000-09 1 B 0.5

YAZAKI SDL-2 7183-4000

COUP

white tape

000-12 000-11 000-10 000-09 000-08 000-07 000-06 000-05 000-04 000-03 000-02 000-01 B B B B B B B B B B B B 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.85 0.5 0.5 515-07 515-06 515-05 515-04 515-03 515-02 515-01 000-16 000-15 000-14 000-13 000-12 P P P P P P P B B B B B 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85

342-01 G-B 0.5

257-01 7 L-Y 0.5

B P 0.5 0.5 000-19 9 B 10 0.5

FAN

4 515-04 000-15

JN.E01

CN.509 Fan reverse switch (Auto/Manual)

000-07 515-07 B P 5 0.5 0.5

RS1

YAZAKI SDL-2 7183-4000

000-06 1 B 0.5

YAZAKI SDL-2 7183-4000

SUMITOMO DL040 6188-0494

Wire Dia.

Wire Color

000-01

CN/JN No. CN.501

Rear console CN.715

CN/JN Pin No. 1 CN.506

Joint connector (D) (waterproof)

0.85

000-02

CN.502

Lift arm auto leveler height kickout SW

CN.506

Joint connector (D) (waterproof)

0.5

000-03

CN.502

Lift arm auto leveler height kickout SW

CN.506

Joint connector (D) (waterproof)

0.5

000-04

CN.503

Lift arm auto leveler lower kickout SW

CN.506

Joint connector (D) (waterproof)

0.5

000-05

CN.503

Lift arm auto leveler lower kickout SW

CN.506

Joint connector (D) (waterproof)

0.5

000-06

CN.505

Secondary steering check switch (opt)

CN.506

Joint connector (D) (waterproof)

0.5

000-07

CN.505

Secondary steering check switch (opt)

CN.506

Joint connector (D) (waterproof)

0.5

000-08

CN.506

Joint connector (D) (waterproof)

CN.510

Ride control switch (Auto)

0.5

000-09

CN.510

Ride control switch (Auto)

CN.506

Joint connector (D) (waterproof)

0.5

000-10

CN.512

Power mode switch

CN.506

Joint connector (D) (waterproof)

0.5

000-11

CN.512

Power mode switch

CN.506

Joint connector (D) (waterproof)

0.5

000-12

CN.506

Joint connector (D) (waterproof)

CN.506

Joint connector (D) (waterproof)

0.85

000-13

CN.511

FNR select switch

CN.506

Joint connector (D) (waterproof)

0.5

000-14

CN.511

FNR select switch

CN.506

Joint connector (D) (waterproof)

0.5

000-15

CN.506

Joint connector (D) (waterproof)

CN.509

Fan reverse switch (Auto/Manual)

0.5

000-16

CN.506

Joint connector (D) (waterproof)

JN.E01

0.5

000-17

CN.509

Fan reverse switch (Auto/Manual)

JN.E01

0.5

000-18

JN.E01

CN.509

Fan reverse switch (Auto/Manual)

0.5

000-19

JN.E01

CN.509

Fan reverse switch (Auto/Manual)

0.5

081-01

CN.504

Coupler switch (opt)

CN.501

Rear console CN.715

0.5

Y-B

249-01

CN.501

Rear console CN.715

CN.511

FNR select switch

0.5

251-01

CN.512

Power mode switch

CN.501

Rear console CN.715

0.5

252-01

CN.509

Fan reverse switch (Auto/Manual)

CN.501

Rear console CN.715

0.5

W-L

253-01

CN.501

Rear console CN.715

CN.509

Fan reverse switch (Auto/Manual)

0.5

L-B

257-01

CN.501

Rear console CN.715

CN.510

Ride control switch (Auto)

0.5

L-Y

259-01

CN.501

Rear console CN.715

CN.505

Secondary steering check switch (opt)

0.5

P-W

293-01

CN.501

Rear console CN.715

CN.502

Lift arm auto leveler height kickout SW

0.5

Gr-L

294-01

CN.501

Rear console CN.715

CN.502

Lift arm auto leveler height kickout SW

0.5

W-G

295-01

CN.501

Rear console CN.715

CN.503

Lift arm auto leveler lower kickout SW

0.5

L-B

296-01

CN.501

Rear console CN.715

CN.503

Lift arm auto leveler lower kickout SW

0.5

W-Y

341-01

CN.504

Coupler switch (opt)

CN.501

Rear console CN.715

0.5

L-R

342-01

CN.501

Rear console CN.715

CN.504

Coupler switch (opt)

0.5

G-B

505-01

CN.501

Rear console CN.715

CN.507

Back-up alarm

0.5

Br-W

506-01

CN.501

Rear console CN.715

CN.508

Back-up alarm

0.5

W-G

515-01

CN.501

Rear console CN.715

CN.506

Joint connector (D) (waterproof)

0.5

515-02

CN.506

Joint connector (D) (waterproof)

CN.510

Ride control switch (Auto)

0.5

515-03

CN.509

Fan reverse switch (Auto/Manual)

CN.506

Joint connector (D) (waterproof)

0.5

515-04

CN.509

Fan reverse switch (Auto/Manual)

CN.506

Joint connector (D) (waterproof)

0.5

515-05

CN.512

Power mode switch

CN.506

Joint connector (D) (waterproof)

0.5

515-06

CN.511

FNR select switch

CN.506

Joint connector (D) (waterproof)

0.5

515-07

CN.505

Secondary steering check switch (opt)

CN.506

Joint connector (D) (waterproof)

0.5

- 23 33194-48820

90Z6 Floor Wiring Diagram (Side Console 2)

CN: Connector, JN: Junction From Wire No.

CN.615

Diode unit (L)

YAZAKI 62Z 7222-7740-40

CN.602 FNR switch (opt)

Gray

DPV

To rear console (p.18)

4 431-03 081-05 433-03 432-03 1 W-R Y-G L-Y Br-Y 0.5 0.5 0.5 0.5

CN.616 2

YAZAKI 090 7123-7144

CN.601 To rear console CN.717

CN.617 1

433-01 432-01 3 081-01 L-Y Br-Y Y-G 0.5 0.5 0.5 5 211-01 000-01 235-01 G-B B G-R 0.5 0.5 0.5 535-01 244-01 536-01 236-01 Br-Y W-L L-Y P-W 0.5 0.5 0.5 0.5 246-01 14 258-01 431-01 Y-B R-Y W-R 0.5 0.5 0.5

209-a W-L 616-2

244-01 W-L 0.5

FNR 210-a 000-hb B Y-B 616-3 616-4

000-02 246-01 B Y-B 0.5 0.5

YAZAKI 090 7321-9844-30

YAZAKI 62Z 7123-7740-40

3 209-b W-L 617-2 2 000-hc B 617-4 1 210-b Y-B 617-3 8

FNR 1

5 4 7

Gray

RS3 JN.F05

JN.F06

JN.F03

white tape

CN.611 Hold switch

YAZAKI SWP 7222-7564-40

1 235-01 000-07 G-R B 0.5 0.5

HOLD

YAZAKI 62Z 7123-8520-40

90Z6 A/C Control Panel Harness 5

013-01 : Wire No. Y : Wire color 47x-x : Pin No. of rear console CN.472 or CN.473

611-01 613-01 13 P W-G 472-4 472-3 31

JN.F01

CN.601

Rear console CN.717

0.5

000-02

JN.F01

CN.616

FNR switch CN.617

0.5

000-03

JN.F01

CN.604

Quick power switch (-)

0.5

000-04

CN.606

0.5

000-05

JN.F01

CN.608

Downshift switch1 (-)

0.5

000-06

JN.F01

CN.610

Downshift switch2 (-)

0.5

000-07

CN.611

081-01

JN.F04

CN.601

Rear console CN.717

Horn switch (-)

Hold switch

JN.F01

624-01 625-01 626-01 627-01 B-R B-L W-B W-R 28 2 14 27 628-01 629-01 630-01 631-01 Lg G-W Br-Y L-B 7 23 24 6 000-01 S1H-01 S1L-01 12 B L W 9 40 8

JN.F04

CN.612

Boom lower kickout detent (float)

0.5

Y-G

JN.F04

CN.613

Bucket leveler detent

0.5

Y-G

081-04

JN.F04

CN.614

Boom height kickout detent

0.5

Y-G

081-05

JN.F04

CN.615

Diode unit (L)

0.5

Y-G

211-01

CN.605

Horn switch (+)

CN.601

Rear console CN.717

0.5

G-B

235-01

CN.611

Hold switch

CN.601

Rear console CN.717

0.5

G-R

236-01

JN.F02

CN.601

Rear console CN.717

0.5

P-W

236-02

CN.607

Downshift switch1 (+)

JN.F02

0.5

P-W

236-03

CN.609

Downshift switch2 (+)

JN.F02

0.5

P-W

244-01

CN.616

FNR switch CN.617

CN.601

Rear console CN.717

0.5

W-L

246-01

CN.616

FNR switch CN.617

CN.601

Rear console CN.717

0.5

Y-B

258-01

CN.603

Quick power switch (+)

CN.601

Rear console CN.717

0.5

R-Y

431-01

JN.F05

CN.601

Rear console CN.717

0.5

W-R

431-02

JN.F05

CN.613

Bucket leveler detent

0.5

W-R

431-03

JN.F05

CN.615

Diode unit (L)

0.5

W-R

432-01

JN.F06

CN.601

Rear console CN.717

0.5

Br-Y

432-02

JN.F06

CN.614

Boom height kickout detent

0.5

Br-Y

432-03

JN.F06

CN.615

Diode unit (L)

0.5

Br-Y

433-01

JN.F03

CN.601

Rear console CN.717

0.5

L-Y

433-02

JN.F03

CN.612

Boom lower kickout detent (float)

0.5

L-Y

433-03

JN.F03

CN.615

Diode unit (L)

0.5

L-Y

535-01

CN.601

Rear console CN.717

CN.602

Dual auto leveler (opt)

0.5

Br-Y

536-01

CN.601

Rear console CN.717

11 CN.602

Dual auto leveler (opt)

0.5

L-Y

CB001

236-02 P-W 0.5

CN.608 Downshift switch1 (-) 1 CB001

000-05 B 0.5

CN.612 Boom lower kickout detent (float)

CN.609 Downshift switch2 (+) 1

236-03 P-W 0.5

CN.610 Downshift switch2 (-) 1

DSS2

000-06 B CB001 0.5

FL red tape

CN.613 Bucket detent JN.F02 JN.F01

HORN

CN.605 Horn switch (+) 1 CB001

CN.606 Horn switch (-)

211-01 G-B 0.5

ACPA 5

ACA 9

013-01 617-01 613-01 611-01 4 L-W W-G P Y 21 36 12 11 8 616-01 612-01 618-01 619-01 Y G-R B-Y P-B 15 20 19 16

CB001

258-01 R-Y 0.5

YAZAKI 62Z 7123-8520-40

000-04 B CB001 0.5

CN.614 Boom height kickout detent 2

CN.604 Quick power switch (-) 1

BKO yellow tape

Rear console cable assy 013-01 : Wire No. Y : Wire color 21 : Pin No. of A/C CN.471

081-04 432-02 1 Y-G Br-Y 0.5 0.5

YAZAKI 62Z 7123-8520-40

000-03 B CB001 0.5

CN.602 Dual auto leveler (opt)

631-01 621-01 622-01 623-01 Y-R G-R Gr O 4 5 18 3 12 SUMITOMO DL090 6195-0149

JN.F04

blue tape

CN.603 Quick power switch (+) 1

2 081-03 431-02 Y-G W-R 0.5 0.5

QICP

CN.472 To rear console CN.756

081-02 433-02 1 L-Y Y-G 0.5 0.5

YAZAKI 62Z 7123-8520-40

YAZAKI SWP 7123-7923-40

03030-39101 33194-40030

Y-G

081-03

DSS1

Black tape

- 24 -

0.5

081-02

ACPA

CAB Front Left Pillar

622-01 618-01 612-01 20 Gr B-Y G-R 472-11 472-7 472-6 38 39 000-01 B 473-9 40

CN.473 To rear console CN.753

ACA

0.5

CB001

Front console cable assy

Wire Color

000-01

To rear console (p.18)

ACB

Wire Dia.

CN.607 Downshift switch1 (+)

625-01 616-01 619-01 17 W-B Y P-B 473-2 472-5 472-8 34 35 617-01 37 L-W 472-2

ACB

624-01 623-01 632-01 621-01 631-01 630-01 S1H-01 S1L-01 10 Br-Y G-R L-B Y-R B-L O L W 473-1 472-12 472-9 472-10 473-8 473-7 473-10 473-11 26 30 628-01 629-01 25 013-01 22 627-01 626-01 29 G-W Y Lg W-R B-R 473-5 473-6 473-4 473-3 21 472-1

CN/JN No.

CN.471 To A/C control panel 1

CN/JN No.

DAL

535-01 536-01 L-Y Br-Y 0.5 0.5

YAZAKI SWP 7123-1424-40

YAZAKI SWP 7222-1424-40

Gray

Gray CLIP: MITSUBISHI CABLE PP021-55120

33194-49230

90Z6 Hydraulic Circuit Diagram P

Pump control valve

Bucket cylinder

Overload relief valve B2

cm /rev

Bucket spool

Stop valve

Check valve (slow return valve)

Steering cylinder

Steering accumulator

Flow rate control valve

Capacity: 0.2 L Gas pressure: 8.0 MPa

Orifice

Check valve (slow return valve)

Capacity: 0.2 L Gas pressure: 8.0 MPa

TS G1/4

G1/4

36.8 MPa at 50 L/min

Main relief valve

Lift arm spool

Tdr

(b2)1

2(a2)

(b1)3

4(a1)

DOWN

*Secondary steering block P

Pressure sensor (lift arm raise) (option)

Capacity: 1.4 L Gas pressure: 6.8 MPa

Pilot valve

Pressure sensor (pump output pressure)

Charge relief valve

49 MPa

Charging block Cut in: 11.8 MPa Cut out: 14.7 MPa

Cooling fan

Torque control solenoid valve

Pg Pi1

Line filter

(Priority valve) Fan motor

ACCR

ACCF MF

Pilot shutoff valve (hydraulic lock)

Pi2

Pressure sensor (for service brake pressure alarm)

Pressure sensor (pilot primary pressure)

29.4 MPa

*Secondary steering pump unit

Brake valve

Service brake accumulator

4.9 MPa

Pump Device

cm3/rev

Brake priority valve Pilot relief valve

Parking brake

3.7 MPa at 40 L/min PS1

33.1 cc/rev Dr

PS2

Dr DR2

4.9 MPa S3

170

16.8

cm /rev

*Secondary Steering Standard: EU (S/N 9001~) Option: EXP (S/N 0101~)

Hydraulic oil cooler

14.4 MPa at 26 L/min

(Pump regulator) M

(Main pump)

(Pilot pump)

RAISE (Rollback)

4.9 MPa

Capacity: 5 L Gas pressure: 3 MPa

*Steering pressure switch

SWB

Ride control accumulator (option)

DUMP

SP2

*Secondary steering pump pressure sensor

SWA

Check valve (slow return valve)

29.4 MPa at 290 L/min

Pressure sensor (declutch)

0.2 MPa at 5 L/min

34.3 MPa Pb at 50 L/min

Steering valve

Pressure switch (stop lamp)

Ride control valve (option)

Overload relief valve

Orifice

B1 DY

Steering accumulator

TS G1/4

DOWN

Lift arm (boom) cylinder

b2 B

Front axle

Stop valve

Rear axle

DUMP

32.5 MPa at 50 L/min

80 3

RAISE (ROLLBACK)

Steering pilot valve (Orbitrol)

Multiple control valve

44.5 3

cm /rev

Fan pump (accessory pump mounted on engine)

Pressure sensor (parking brake)

Parking brake solenoid

Check valve assy

ACCP

Pilot accumulator

Breather valve

0.3 0.06 MPa

Capacity: 0.75 L Gas pressure: 2 MPa

10 m

Hydraulic tank 4.0kPa

50.0kPa

=2.0

Suction strainer

177 m

Relief valve (return filter bypass)

0.15

0.02 MPa

- 25 -

Return filter 09701-05030