4. SECTION AND GROUP
CONTENTS
SHOP MANUAL
(Function & Structure)
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.
SECTION 1 GENERAL
Group 1 Specifications
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
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
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
93213-00761
90Z6
5. SECTION AND GROUP
CONTENTS
SHOP MANUAL
(Troubleshooting)
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.
SECTION 4 OPERATIONAL
PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner
93213-00771
6. SECTION AND GROUP
CONTENTS
WORKSHOP MANUAL
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.
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Releasing Pressure
Group 6 Preparation
SECTION 2 MAINTENANCE STANDARD
Group 1 Body
Group 2 Front Attachment
SECTION 3 BODY
Group 1 Cab
Group 2 Counterweight
Group 3 Center Hinge
Group 4 Engine
Group 5 Radiator Assembly
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Pilot Valve
Group 11 Charging Block
Group 12 Cooling Fan System
Group 13 Exhaust Muffler
Group 14 Ride Control Device
Group 15 Battery Disconnect Switch
93213-00781
7. SECTION AND GROUP
CONTENTS
WORKSHOP MANUAL
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.
SECTION 4 TRAVEL SYSTEM
Group 1 Tire
Group 2 Drive Unit
Group 3 Axle
Group 4 Propeller Shaft
Group 5 Brake Valve
Group 6 Steering Pilot Valve
Group 7 Steering Valve
Group 8 Steering Cylinder
Group 9 Secondary Steering Device
Group 10 Stop Valve
Group 11 Axle Oil Cooler
SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
8. IN-01
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
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.
Please refer to the other materials (operation and
maintenance manual, parts catalog, engine technical
material, Kawasaki shop materials, etc.) in addition to this
manual.
Our shop manuals consist of the Technical Manual, the
Workshop Manual and the Engine Manual.
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.
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
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 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.
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
9. INTRODUCTION
IN-02
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.
dThis 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
Quantity To Convert From Into Multiply By
Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3
yd3
1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm2
10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min-1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
fNOTE: The numerical value in this manual might be
different from the above-mentioned table.
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.
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.
10. SY-1
Symbol and Abbreviation
Symbol and Abbreviation
Symbol /
Abbreviation
Name Explanation
S/M Shop Manual Shop Manual
T/C Torque Converter Torque Converter
T/M Transmission Transmission
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
ICF Information Controller Stores the operating information and alarms.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C
HVAC
Air Conditioner
Heating, Ventilation, and Air Conditioning
Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
ATT Attachment Front attachment, such as bucket
11. 90Z6 FS
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
SECTION 1
GENERAL
CONTENTS
12. T1-1-1
Group 1 Specifications
SECTION 1 GENERAL
GSC LSC
Bucket Capacity: heaped m3
4.0 4.5
Operating Weight kg 23100 23230
Tipping Load (Full Turn) kg 15900 15770
Engine CUMMINS QSM11 CUMMINS QSM11
A: Overall Length mm 8790 8910
B: Overall Width (Bucket) mm 3100 3100
C: Overall Height mm 3470 3470
D: Wheel Base mm 3450 3450
E: Tread mm 2230 2230
F: Ground Clearance mm 505 505
G: Bucket Hinge Height mm 4410 4410
H: Dumping Clearance (45 °) mm 3095 3010
I: Dumping Reach (45 °) mm 1215 1300
R1: Minimum Rotation Radius mm 6270 6270
R2: Bucket Carry Position mm 7330 7360
Travel Speed Forward/Reverse km/h 34.7/34.7 34.7/34.7
Transmission Speeds (F/R) - 4/4 4/4
Articulation Angle (Left/Right) deg ( ° ) 37 37
Tire Size - 26.5-25-20PR (L-3) 26.5-25-20PR (L-3)
fNOTE: These specifications are subject to change without notice.
Values with bolt-on cutting edges.
Specifications (S/N 0101~)
90Z6-FK-GSC
37° 45°
37°
13. T1-1-2
SECTION 1 GENERAL
Group 1 Specifications
GSC LSC
Bucket Capacity: heaped m3
4.0 4.5
Operating Weight kg 23230 23360
Tipping Load (Full Turn) kg 16050 15920
Engine CUMMINS QSM11 CUMMINS QSM11
A: Overall Length mm 8790 8910
B: Overall Width (Bucket) mm 3100 3100
C: Overall Height mm 3470 3470
D: Wheel Base mm 3450 3450
E: Tread mm 2230 2230
F: Ground Clearance mm 505 505
G: Bucket Hinge Height mm 4410 4410
H: Dumping Clearance (45 °) mm 3095 3010
I: Dumping Reach (45 °) mm 1215 1300
R1: Minimum Rotation Radius mm 6270 6270
R2: Bucket Carry Position mm 7280 7315
Travel Speed Forward/Reverse km/h 34.7/34.7 34.7/34.7
Transmission Speeds (F/R) - 4/4 4/4
Articulation Angle (Left/Right) deg ( ° ) 37 37
Tire Size - 26.5-25-20PR (L-3) 26.5-25-20PR (L-3)
fNOTE: These specifications are subject to change without notice.
Values with bolt-on cutting edges.
Specifications (S/N 9001~)
90Z6-FK-GSC
37° 45°
37°
14. T1-1-3
SECTION 1 GENERAL
Group 1 Specifications
Weight of Main Components
Item Approx. Weight
(kg)
Remarks
Unit Name Part Name
Chassis
Front chassis 1950
Rear chassis 1655
Rear chassis belly guard 95 Option (S/N 0101~), Standard (S/N 9001~)
Fender (front) (RH, LH) 25 x 2
Center pin group 55
Floor board 250 With rubber cushions
Radiator guard 15 x 2
Side cover (main) (RH, LH) 30 x 2
Roof mount 65
Rear grill mount 40
Deck (RH, LH) 30 x 2 With handrails
Fender (rear) 75 40 (RH), 35 (LH)
Step (main) (RH, LH) 40 x 2 Step to CAB
Hydraulic tank 225
Fuel tank 320
Lift Arm (Boom) 1585
Z-Lever (Bell Crank) 405
Bucket Link 80
Counter weight 2540
Battery box 30 x 2
Battery 36 x 2
Cab 430 (S/N 0101~)
ROPS Cab 700 (S/N 9001~)
Bucket (GSN) 1790 The weight differs depending on the bucket type.
Tire 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.
15. T1-1-4
SECTION 1 GENERAL
Group 1 Specifications
Item Approx.
Weight (kg)
Remarks
Unit Name Part Name
Power line
Engine (dry) 940 Cummins QSM11
Transmission assy 865 Drive unit
Second propeller shaft 70
Third propeller shaft 22
Radiator mount 160 Radiator (30) + T/C oil cooler (13) + Shroud assy (110)
Cooling unit mount 50 Hydraulic oil cooler (7) + Air cooler (23)
Fan mount 50 Fan (5) + Fan motor (12) + Bracket (18)
Air cleaner 20
Exhaust group 55 Muffler (25)
Axle assy (TPD)
Front 1310 Excluding tires and oil
Rear 1510 Excluding tires and oil, Including axle supports
Axle assy (LSD) (Option)
Front 1320 Excluding tires and oil
Rear 1520 Excluding tires and oil, Including axle supports
Hydraulic
system
Main pump assy 110 Including pilot pump
Multiple control valve 65
Combination valve assy 25
Loading pilot valve 7
Steering valve 22
OrbitrolTM
6 Steering pilot valve, Eaton
Unloader valve 15 Brake charge valve
Brake valve assy 12
Brake accumulator assy 20 Accumulator (6) x 2
Lift arm cylinder 185 x 2 Excluding oil
Bucket cylinder 195 Excluding oil
Steering cylinder 27 x 2 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.
16. T1-2-1
SECTION 1 GENERAL
Group 2 Component Layout
Main Component (Overview)
1- Bucket
2- Lever (Bell Crank)
3- Bucket Cylinder
4- Headlight
5- Front Working Light
6- CAB Rear Working Light
(Option)
7- Rear Working Light
8- Rear Combination Light (Turn
Signal Light, Hazard Light,
Clearance Light, Brake Light,
Backup Light)
9- Turn Signal Light, Hazard
Light, Clearance Light
10- Lift Arm (Boom) Cylinder
11- Lift Arm (Boom)
12- Bucket Link
90Z6T1-2-01
2 3 4
5
6
8
9
10
1
7
11
12
17. T1-2-2
SECTION 1 GENERAL
Group 2 Component Layout
1- Multiple Control Valve (Loading)
2- Pilot Valve
3- Stop Valve
4- Torque Converter Oil Filter
5- Charging Block (Unloader and
Accumulators)
6- Engine
7- Fuel Filter
8- Fuel Tank
9- Engine Oil Filter
10- Hydraulic Oil Cooler
11- Inter Charge Air Cooler
12- Fan Motor
13- Torque Converter Oil Cooler
14- Radiator
15- Coolant Level and Surge Tank
16- Air Cleaner
17- Muffler
18- Hydraulic Tank
19- Safety Device (Pilot Shut-off Valve)
20- Front Attachment (Implement)
Pressure Sensor (at Pilot Valve)
21- Brake Valve
22- Orbitrol (Steering Pilot Valve)
23- Steering Valve
24- Fuel Cooler
Main Component
13
16
12
11 10
8
9
14
15
17
18
19
21
20
7 6
4
5
1
3
2
23
22
90Z6T1-2-02
90Z6T1-2-02
11
10
14
13
24
18. T1-2-3
SECTION 1 GENERAL
Group 2 Component Layout
Main Component (Travel System)
1- Front Axle
2- Brake Pressure Sensor
3- Steering Cylinder
4- Hydraulic Pump
5- Transmission
6- Axle Support (Rear)
7- Rear Axle
8- Axle Support (Front)
9- Third (Rear) Propeller Shaft
10- Steering Accumulator
11- Second (Front) Propeller
Shaft
90Z6T1-2-03
1
2 3
11
4
5
6
7
8
9
10
19. T1-2-4
SECTION 1 GENERAL
Group 2 Component Layout
Electric Component Layout (Overview)
1- Bucket Leveler Proximity Switch
2- Lift Arm Kickout Proximity Switch
3- Lift Arm Angle Sensor (Option)
4- Hydraulic Oil Temperature Sensor (at
Hydraulic Tank Bottom)
5- Air Cleaner Restriction Switch
6- Backup Alarm
7- Battery
8- Fuel Level Sensor (at Fuel Tank)
9- Secondary Steering Pump (Option)
10- Outside Temperature Sensor
11- Components Related with Cab (Refer to
T1-2-5)
9
3
7
90Z6T1-2-04
90Z6T1-2-23
90Z6T1-2-23
1
2
5 6
7
8
9
10
11 4
3
20. T1-2-5
SECTION 1 GENERAL
Group 2 Component Layout
Electrical System (Cab)
1- Radio
2- Upper Switch Panel (Option)
3- Speaker
4- Rear Wiper Motor
5- Brake Lamp Switch
6- Front Wiper Motor
7- Outside Temperature Sensor (for A/C)
8- Components in Right Side Console (Refer
to T1-2-7)
9- 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
90Z6T1-2-05 90Z7-01-02-01
10
6
5
3
2
1
11
4
9
8
7
21. 90Z6T1-2-06
T1-2-6
SECTION 1 GENERAL
Group 2 Component Layout
Controller and Relays
1- Flasher Relay
2- GSM (Option)
3- ICF (Monitor Controller)
4- MCZ (Main Controller)
5- MPDr. Connector
6- Fuse Box A
7- Fuse Box B
8- ECM Relay 1
9- Head Light Relay
10- High-Beam Relay
11- Bucket Leveler Relay
12- Lift Arm Height Kickout Relay
13- Working Lamp Relay (Front)
14- Working Lamp Relay (Rear)
15- Turn Signal Light Relay (Right)
16- Horn Relay
17- Load Dump Relay 2
18- Parking Brake Relay 1
19- Parking Brake Relay 2
20- Engine Alternate Droop Relay
21- Brake Lamp Relay
22- Load Dump Relay 1
23- Neutral Relay
24- Turn Signal Light Relay (Left)
25- Front Washer Relay
26- Rear Wiper Relay
27- Rear Washer Relay
28- ECM Relay 2
29- Backup Lamp Relay
30- CAB Working Light Relay (Front) (Option)
31- CAB Working Light Relay (Rear) (Option)
32- Secondary Steering Relay (Option)
33- Pilot Shut-Off Relay (Option)
34- Voltage Relay
7
12
22
32
17
27
10
20
30
15
25
11
21
31
16
26
9
19
29
14
24
8
18
28
13
23
33
34
1
2
3
4
5
6
A
Arrow View A
fNOTE: Refer to “Fuses and Relays” and “Floor Cable
Layout” in the Diagrams for the other parts.
22. T1-2-7
SECTION 1 GENERAL
Group 2 Component Layout
Right Console
Fingertip Control Type
Multi-Function Joystick Type (Option)
1- Auxiliary Control Lever (Option)
2- Bucket Control Lever
3- Lift Arm Control Lever
4- Forward/Reverse Switch (Option)
5- -
6- Auxiliary
7- Auxiliary
8- Power Mode Switch
9- Forward/Reverse Selector Switch (Option)
10- Fan Reverse Rotation Switch (Option)
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)
18- Hold Switch
19- Control Lever Lock Handle (Safety Device)
20- DSS (Down Shift Switch)
21- Horn Switch
22- Quick Power Switch
23- Multi-Function Joystick Lever
24- Hold Switch (Under the Lever)
25- Horn Switch (Under the Lever)
22
25
24
21
20
12
11
10
9
8
7
6
4
23
22 20
1
13
19
17 16
15 14
90Z6T1-2-07a MNEC-01-042
90Z6T1-2-07b
MNEC-01-044
12
11
10
9
8
7
6
4
3 (2)
2 (1)
1 (3)
18
17 16
15 14
13
19
fNOTE: The control lever positions can be changed.
25. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
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click on it.
26. T1-2-10
SECTION 1 GENERAL
Group 2 Component Layout
Electrical System (Relays)
1- Battery Relay
2- Fusible Link (100 A) (3 used)
3- Fusible Link (70 A)
4- Intake Air Heater Relay
90Z6T1-2-19
4
1
3
2
90Z6-05-01-01
27. T1-2-11
SECTION 1 GENERAL
Group 2 Component Layout
Engine/Fan Pump
1- Engine Oil Filter
2- Filter Outlet Pressure
3- Coolant Inlet Pressure
4- Coolant Temperature Sensor
5- Alternator
6- Intake Manifold Pressure Sensor
7- After Charge Air Cooler (Intake Manifold)
8- ECM
9- ECM Cooling Plate
10- Engine Position Sensor
11- Engine Oil Pressure and Temperature
Sensor
12- Fuel Filter
13- Fan Pump
14- Fuel Pump
15- Starter
16- DCA4 Coolant Filter
90Z6T1-2-09
9
13
12
10
6
7
14
8
11
5
15
1
16
4
3
2