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©2016 KCM Corporation. All rights reserved. Printed in Japan (K)
(輸出一般用)
93213-00761
August 2016
SHOP MANUAL
WHEEL LOADER
90Z6
General Information
Function & Structure
Powered by CUMMINS QSM11 Engine
Serial No. 90C7-0101 and up
General
Information
90Z6
SHOP
MANUAL
93213-00761
Function
&
Structure
©2016 KCM Corporation. All rights reserved. Printed in Japan (K)
(輸出一般用)
93213-00771
July 2016
SHOP MANUAL
WHEEL LOADER
90Z6
Operational Performance Test
Troubleshooting
Powered by CUMMINS QSM11 Engine
Serial No. 90C7-0101 and up
Operational
Performance
Test
90Z6
SHOP
MANUAL
93213-00771
Troubleshooting
©2016 KCM Corporation. All rights reserved. Printed in Japan (K)
(輸出一般用)
93213-00781
August 2015
SHOP MANUAL
WHEEL LOADER
90Z6
Disassembly & Reassembly
Powered by CUMMINS QSM11 Engine
Serial No. 90C7-0101 and up
90Z6
SHOP
MANUAL
Disassembly
&
Reassembly
93213-00781
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
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
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
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
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
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.
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
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
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°
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°
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.
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.
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
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
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
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
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
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.
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.
T1-2-8
SECTION 1 GENERAL
Group 2 Component Layout
Monitor and Switches
1- Front/Rear Wiper Switch
2- Hazard Switch
3- Working Light Switch
4- Parking Brake Switch
5- Forward/Reverse Lever, Shift Switch
6- Monitor Panel (Refer to T1-2-9)
7- Travel Mode Selector Switch
8- Key Switch
9- Declutch Position Sensor
10- Shift Change Delay Mode Switch (Option)
11- Turn Signal Lever, Light Switch, High-Low
Beam Switch
5
8 9
4
7
6
11
10
3
2
1
90Z6T1-2-08
T1-2-9
SECTION 1 GENERAL
Group 2 Component Layout
Monitor Panel
1 2 3 4 5 6 7
8
9
10
11
12
13
14
15
16
17
18
20
21
22
23
24
25
26
27
28
29
30
31
32
33
19
34
35
36
37
38
39
40
MNDB-01-034
1- 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
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
33- Air Filter Restriction Indicator
34- (Not used)
35- (Not used)
36- (Not used)
37- Hydraulic Oil Temperature
Indicator
38- Transmission Warning
Indicator
39- Transmission Oil Temperature
Indicator
40- Transmission Oil Temperature
Gauge
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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
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
T1-2-12
SECTION 1 GENERAL
Group 2 Component Layout
Transmission and Torque Converter Assembly
90Z6T1-2-10
1- Torque Converter
2- Torque Converter Charging Pump
3- Machine Speed Sensor
4- Transmission Output Speed Sensor
5- Transmission Middle Shaft Sensor
6- Parking Brake
7- Transmission Control Valve
8- Regulator Valve
9- 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)
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)
1 2 18
7 8
15
16
9
10
11
12
13
14
5
17
4 3
6
fNOTE: Parking Brake pressure sensor is installed to the
charging block.

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Kawasaki 90Z6 WHEEL LOADER Service Repair Manual (Serial No. 90C7-0101 and up).pdf

  • 1. ©2016 KCM Corporation. All rights reserved. Printed in Japan (K) (輸出一般用) 93213-00761 August 2016 SHOP MANUAL WHEEL LOADER 90Z6 General Information Function & Structure Powered by CUMMINS QSM11 Engine Serial No. 90C7-0101 and up General Information 90Z6 SHOP MANUAL 93213-00761 Function & Structure
  • 2. ©2016 KCM Corporation. All rights reserved. Printed in Japan (K) (輸出一般用) 93213-00771 July 2016 SHOP MANUAL WHEEL LOADER 90Z6 Operational Performance Test Troubleshooting Powered by CUMMINS QSM11 Engine Serial No. 90C7-0101 and up Operational Performance Test 90Z6 SHOP MANUAL 93213-00771 Troubleshooting
  • 3. ©2016 KCM Corporation. All rights reserved. Printed in Japan (K) (輸出一般用) 93213-00781 August 2015 SHOP MANUAL WHEEL LOADER 90Z6 Disassembly & Reassembly Powered by CUMMINS QSM11 Engine Serial No. 90C7-0101 and up 90Z6 SHOP MANUAL Disassembly & Reassembly 93213-00781
  • 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.
  • 23. T1-2-8 SECTION 1 GENERAL Group 2 Component Layout Monitor and Switches 1- Front/Rear Wiper Switch 2- Hazard Switch 3- Working Light Switch 4- Parking Brake Switch 5- Forward/Reverse Lever, Shift Switch 6- Monitor Panel (Refer to T1-2-9) 7- Travel Mode Selector Switch 8- Key Switch 9- Declutch Position Sensor 10- Shift Change Delay Mode Switch (Option) 11- Turn Signal Lever, Light Switch, High-Low Beam Switch 5 8 9 4 7 6 11 10 3 2 1 90Z6T1-2-08
  • 24. T1-2-9 SECTION 1 GENERAL Group 2 Component Layout Monitor Panel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 19 34 35 36 37 38 39 40 MNDB-01-034 1- 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 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 33- Air Filter Restriction Indicator 34- (Not used) 35- (Not used) 36- (Not used) 37- Hydraulic Oil Temperature Indicator 38- Transmission Warning Indicator 39- Transmission Oil Temperature Indicator 40- Transmission Oil Temperature Gauge
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  • 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
  • 28. T1-2-12 SECTION 1 GENERAL Group 2 Component Layout Transmission and Torque Converter Assembly 90Z6T1-2-10 1- Torque Converter 2- Torque Converter Charging Pump 3- Machine Speed Sensor 4- Transmission Output Speed Sensor 5- Transmission Middle Shaft Sensor 6- Parking Brake 7- Transmission Control Valve 8- Regulator Valve 9- 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) 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) 1 2 18 7 8 15 16 9 10 11 12 13 14 5 17 4 3 6 fNOTE: Parking Brake pressure sensor is installed to the charging block.