50 90ZV 2 - KCM600 08 2006 00 (9 07 830am)

KCM600-08/2006-00
Kawasaki Service Training Manual
This Manual covers Electrical Group Materials for Models 50~90ZV-2

This
Current for 70/80/85/90ZV-2 production; August 10, 2006
• Safety and General Information
• Reading diagrams
• Layout of electrical pieces
• Electrical components
• Line and address diagrams
ARL
Important
Read and understand the Operation and Maintenance Manual. It will familiarize you
better with the product you are supporting.
This Training Manual supplements materials found in the Shop Manual.
This is section 600 of the Product Support Service Training Manual. Pages in this
section are numbered from 601~800 [with lettered suffixes].
Consult the Shop Manual for specific details on each machine.

Electrical Group Materials for 50~90ZV-2
IMPORTANT
This is a Kawasaki Service Training Manual that is intended for use with Kawasaki Service Training.
Materials in this manual are based on the Shop Manual. Periodically information may change and
information in this Training Manual may be superceded by the newest Shop Manual. Always verify
that you have the most current information available by reviewing the latest Shop Manual.
To ensure good machine performance, reduce failures or problems & prolong service life of each component,
it is necessary to operate and maintain the machine as is directed in the Operator and Maintenance Manual.
Some references may be made to 50/60/65ZV-2 or 65TMV-2, although these units have not yet gone into prod-
uction. Materials referring to these units mention only what is known at time of publishing this training manual.
References may be updated at any time as further information becomes available.
Much of what applies to 70ZV-2 also will apply to 70TMV-2. At times discernment is needed to determine this.
- An example is rear chassis parts - It would make no sense that the engine would differ between these models,
as well as rear chassis electrical, radiators, axles, brakes, transmission, etc. Only the front chassis related elec-
trical, hydraulic and chassis components are affected by this. Use this assumption while working in this manual.
Key to retaining information

While taking notes for future reference, make it a point to write down concepts to teach to others when
you return to the repair shop or to the region where you work.
If you share information with others, the following will happen:
1. You will retain better what you have to be able to explain. Think about it; if you cannot explain it,
you do not thoroughly understand it.
2. If you teach something to others, you must also apply what you teach. You become a more depend-
able and safer worker. (Get ready to set the example for the ones you teach also.)
3. You help others; you'll help the "other guy" you share this with to learn something.
Get involved in the learning process and you will never forget this information!
You will get out what you put into this course.
Be a professional. NEVER GIVE IN TO THINKING THAT YOU ARE NOT SMART OR GIFTED ENOUGH.
Be willing to ask the right questions to be able to find out what you need to know.
601
Safety Symbols
An accident may occur if you disregard safety rules.
In this manual, several expressions are used according to levels of danger for inspection and repair work as shown
below. Read the work procedures and cautions described in this manual, and take preventive measures against
possible problems before starting service work.
DANGER
This danger symbol identifies special warnings or
procedures which, if not strictly observed, will result
in death or serious injury.
WARNING
This warning symbol identifies special warnings or
procedures which, if not strictly observed, could result
in death or serious injury.
CAUTION
This caution symbol identifies special instructions or
procedures which, if not strictly observed, may result
in minor or moderate injury.
IMPORTANT
This important symbol identifies special instructions
or procedures which, if not correctly followed, may
result in serious machine damage.
We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident that
is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when doing
service work.
602
Warning
Safety precautions
The most important point in providing repair service is - Contact tire manufacturer's local dealer for tire ser-
safety. To ensure safety, observe the general cautions vicing and changing.
described below.
- Always store the tools in good condition, and use
- This manual is intended for properly trained and them properly.
equipped service technicians.
- Keep the work area clean. Clean up spills immedi-
- Any work on the machine must be performed by the ately.
trained personnel only.
- Avoid the use of flammable solvents and cleaners.
- Carefully read this manual to thoroughly understand
the operation method before you operate or repair - When working outdoors keep work areas, ladders,
the machine. steps, decks and work platforms clear of snow, ice,
and mud.
- Be sure to wear appropriate clothes and protectors,
such as safety boots, hard hat and goggles. - Use safe work platforms to reach higher areas of the
machine.
- Place the machine on level and solid ground, and
place chocks against the wheels to prevent move-
ment.
- Remove the cables from batteries before starting

the service work, and attach a "DO NOT OPERATE!"
tag to the steering wheel.
- Be sure to release the internal pressure before you

remove a pipe, such as the hydraulic oil, air, or
engine coolant pipe.
- Be sure to apply the articulation stopper before start-

ing work.
- While supporting the bottom of the chassis using a

jack, be sure to support the chassis using the blocks.
- When the boom or bucket is raised or when a unit is

lifted by a crane, be sure to place a stand or ade-
quate cribbing under the unit to prevent unexpected
dropping.
- Do not start to work in an enclosed area if adequate

ventilation is not provided.
- To remove a heavy unit (20 kgf (40 lbs) or more), be

sure to use a crane or other lifting tool.
- Just after stopping operation, be careful not to

directly touch a hot component. You may get burned.
603
604
Contents
Prologue ............................................................................ 601
Safety ................................................................................ 603
Things to consider when repairing ..................................... 607
Dealer and customer call form ........................................... 608
How to Use Electrical Wiring Diagram .............................. 612
Way of looking at connectors ............................................. 613
Electrical wiring diagram abbreviation chart ...................... 615
Electrical Cable Color Codes ............................................ 616
Simple electrical terminology ............................................ 617
Electrical Circuit Symbols ................................................. 618
Sensor mount ................................................................... 619
Cab diagram (common for ZV-2) ...................................... 623
Diagrams .......................................................................... 624
Fuses ............................................................................... 674
Start circuits ..................................................................... 684
Relays .............................................................................. 687
Generators ....................................................................... 690
ECM ................................................................................. 691
MCU ................................................................................. 710
Diodes .............................................................................. 758
605
606
THINGS TO CONSIDER WHEN MAKING WARRANTY REPAIRS
Warranty Coverage
• Standard Warranty is 1 year (12 months) or 1,500 hours -- whichever occurs first.
• For rental fleet machines, warranty coverage is 2 years (24 months) or 1,500 hours,
whichever occurs first. (These machines do not get the same amount of use at times as a
non-rental machine.)
• There are a variety of extended warranties available. These may be Extended Base
Machine type (same as Base Warranty but longer), or Extended Powertrain type.
• Replacement rental machine, down-time, lost production, and transportation of machine
to a service facility for repairs are not covered by Kawasaki Warranty.
Important Points to Remember
1. Do your homework. Do not arrive at the jobsite “cold turkey”. Get the facts about the
symptoms of the troubles the customer is experiencing prior to going to the jobsite.
There is a Kawasaki Dealer Call Form in this manual for this purpose that is also
available on the KCM website. This can be saved, emailed or faxed to customer, and
returned to you, or you can get the facts to fill in while on the phone with the customer.
Help the customer understand that this is to help everyone save money in the long run.
• USE THE DEALER CALL FORM TO ESTABLISH WHAT IS WRONG PRIOR TO LEAVING TO A JOBSITE.
TAKE ALL NECESSARY LITERATURE WITH YOU PRIOR TO GOING TO A JOBSITE.
• Kawasaki Warranty will only pay for one round trip to and from the jobsite.
2. You are a student that takes pride in your talent. This is reflected in the quality of your
work. Your goal is to establish yourself as a technically sound and well-trained
journeyman in your field.
• Find, Confirm, and Fix any problem(s). (You may have more than one.)
• Provide details on what was wrong in your work order.
i. What was the symptom?
ii. Why did the problem happen?
1. What caused it to fail?
2. Was the machine modified in any way that may have contributed
to the failure?
3. What is the application? Is it caustic or corrosive? Are there
constant machine impacts as with a hammer? Is there intense
heat in the application?
iii. What was done to keep from repeating the same problem again?
iv. Was the customer satisfied? If not, why not?
• Do not relegate yourself to the position of becoming a parts changer! That
position we hope is already being occupied by the competition. And once a part
is installed on a machine, it cannot be returned to Kawasaki for a credit.
3. Do not indiscriminately discard parts.

Keep all parts until the claim is resolved, or we have asked that you return the part to us.
Securely identify the part with a tag that indicates the work order number, machine serial
number, hours on machine, and file any related photos and supportive notes that will
serve to support any issues that may arise in processing the claim. If there are no notes
or supportive parts, the claim may automatically be rejected!
In summary, you are the person that can gather information better than anyone else, because
you are the on-site specialist. A warranty clerk or manager who submits the claim will not be able
to answer the questions that you can, so please provide them with the needed information so
they can get the claim processed. Use the Parts Catalogs and Shop Manual to help with this task.
607
Kawasaki Loader Dealer / Customer call form Date: ________________________

Time of Call: __________________
Customer's name: ____________________________________________________
Customer's address: ____________________________________________________

____________________________________________________
Machine Serial No. Hrs.
____________________________________________________
Description of problem:
Important! A clear description of problem needs to be given, so technician will be equipped to go
to jobsite. A lack of information will cause technician to leave ill equipped, and cause customer to
feel not properly attended in the long run.
1. What system(s) is giving trouble? Hydraulic, Transmission, Electrical, etc.?
____________________________________________________
____________________________________________________
2. What did the operator hear, see, feel or smell that seemed different than
normal? Provide exact symptoms IN DETAIL, not what operator thinks is wrong.
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
3. What is the machine application? Where is it working, and what is it doing?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
4. Name of person that gave information _______________________________
608
Clear directions of how to arrive at the jobsite:

Attach map if needed.
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
Other notes:
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
Required support publications or Service / Parts News documents:
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
609
Symbols
For safe and effective service work, the following sym-
bols are used for notes and useful information in this
manual.
Symbol Item Description
Shows the condition or procedure that will be useful

Reference
or efficient in doing service work.
Shows the weight of a part or unit. The weight

should be considered in selecting wire rope or cable
Weight
for slinging work or determining the working pos-
ture.
Tightening Shows the tightening torque of a section that should

torque be carefully tightened during assembly work.
Shows the type of coating or adhesive and the coat-

Coating
ing section.
Oil or
Shows the oil or water supply port and the refill
water
amount.
supply
Shows the oil or water drain port and the drain

Drainage
amount.
IMPORTANT
If the specified conditions are not satisfied or the specified procedure is not
observed, there is a strong possibility that the product will be damaged or the per-
formance of the product will be reduced.
The message shows the preventive measures.
Abbreviation
To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the follow-
ing abbreviation list. Additional abbreviations are listed in Z fold sections.
E/G ........... Engine RH ............Right hand side 3rd ............3rd speed

T/C ........... Torque converter LH ............Left hand side 4th ............4th speed
T/M ........... Transmission H ............High M/C ............Machine
SOL ........... Solenoid valve L ............Low min-1 ............RPM
SW or S/W.. Switch GND (or E)..Ground ELS ............Efficient loading system
F ........... Front or Forward OPT ............Option MODM ........Machine operation diag-
A/M ........... Auto/Manual Assy ............Assembly nostic module
B ........... Battery 1st ............1st speed C/W ........... Counterweight
R ........... Rear or Reverse 2nd ............2nd speed CW ............ Clockwise
CAC ........... Charge Air Cooler CCW ......... Counter Clockwise
610
Function & Structure

Electrical Group
611
How to Use Electrical Wiring Diagram

Example
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
WIDTH LAMP RIDE CONTROL NEUTRAL BACK LAMP HORN RELAY CONTROLLER
RELAY RELAY RELAY RELAY FAULT RELAY
A520 RB RB LgSb YV RL SbP RL LB GW GL B LgW

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
R R Br Lg G L R Lg G G LgW L
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLUE)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1 Note
D507 A306 F306 A905 A503 D112 E802 E803
OR RO RW RLg YB Br GL GO Our diagrams will contain addresses, colors & circuit numbers.
C206 A302 F303 E312 E523 G302 E804
181
PB RBr RY WO SbY BrB WY
C205 F504 F704 F804

PL RB RL GW
E109 G402 A105 E522
W BrW WP BrL
Circuit number (as on line diagram)
181
E501 C801 A005 B304 E520 E108 F004 E601
E601 Address
WL RG RGy LgG LgL W LgSb BrR
40 36 35 31
(3)
BrR Color code (may change w/o notice)
The address method is used for electrical wiring dia- Example 3

grams. For this method, a symbol is attached to each Checking the other connector terminal where F704 RL
connector and connector terminal in order to easily (item (3)) is connected:
locate the other terminal where the other end of the
cable is connected. 1. F704
Shows that the terminal is connected to the 4th ter-
Example 1 minal of the F7 connector.
Symbol under (or above) connector, such as F6: Check the description in the 4th terminal of the F7
Shows the address of the connector. connector (F704), it shows that the F704 terminal is
connected to H128. This means that the 4th termi-
Example 2 nal of the F7 connector is connected to the 28th ter-
Symbol at the multi-terminal connector, such as 1 and minal of the H1 connector.
10: 2. RL
Shows the terminal number and the numbering direc- Shows the color of the wire "RL" represents that the
tion. insulation color is red, and "L" represents a blue
612 stripe is on the red insulation.
Electrical Wiring Diagram

Way of looking at connectors (70TMV-2/70~90ZV-2)
Controller
Male pin connector

Controller
CONTROLLER
A 1.2S_SO A16.TT_L A31.1/4_L B12.X_R E 1.SSR_SO E16.SPD E31.TT_SE C 1.2S_SE C16.EP C31.BSL D12.SL_A
A 2.2_SO A17.D_SO A32.FR_L B13.F_SO E 2.FC_SO E17.BATT E32.OT_SE C 2.DSUB2 C17.F C32.EG_M D13.SS_N
A 3.ES_R A18.1_SO A33.3/4_L B14.B_SO E 3.KEY E18.CANL1 E33.OUT_RSE C 3.DSUB4 C18.ASUB1 C33.DD_S D14.KD
A 4.DD_SO A19.EP_L A34.EG_SW1 B15.EG_SW2 E 4.KEY E19.SS_P E34.ET_M C 4.BSL- C19.ASUB2 C34.AFR D15.INCH_S
A 5.3_SO A20.AB_L B 1.H_SO B16.RIN1 E 5.GND E20.CANLO C 5.TT C20.1/2 D 1.PRK D16.OD_SW
A 6.HM A21.A_L B 2.PWM_SO B17.OUT_MD2 E 6.GND E21.TM_M C 6.AC C21.1/8 D 2.AM_SW D17.SH
Female pin A 7.LU_SO A22.1/2_L B 3.IP_SO B18.N_R E 7.GND E22.B_SE2 C 7.ET C22.2S D 3.SL_2 D18.SS_SW
A 8.4_SO A23.E_L B 4.R_SO B19.BR_L E 8.GND E23.WT_SE C 8.BL C23.EG_H D 4.SL_R D19.SS_F
connector A 9.OTH_OUT A24.SS_L B 5.MO_SO B20.CAN_R1 E 9.+5V E24.ALT C 9.BD C24.IP_SW D 5.SL_3 D20.TMP
A10.R_L A25.SC_SW B 6.FR_SO B21.CAN_R2 E10.TGEG E25.RXD1 C10.DSUB1 C25.FR D 6.S_UP D21.INCH
A11.F_L A26.TF_L B 7.SSL_SO B22.DOUT1 E11.KEY E26.TGSP C11.DSUB3 C26.KO_P D 7.S_DOWN D22.KO_S
A12.ST_L A27.AC_L B 8.BSL_SO B23.OUT_FEW E12.KEY E27.INCH_SE C12.DR C27.ES_SE D 8.EG_SW D23.SC
A13.WL_L A28.BP_L B 9.BZ B24.MT E13.CANH1 E28.SC_P C13.BSL+ C28.3/4 D 9.M_SW D24.AR
A14.CW_L A29.N_L B10.BSL_R B25.ET_SE E14.EGR2 E29.CANHO C14.TF C29.1/4 D10.SL_1 D25.SM_SW
A15.ET_L A30.SC_L B11.KO_R B26.TXD1 E15.EGR1 E30.B_SE1 C15.WL C30.DC D11.SL_F D26.SS_R
A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 E1 E2 E3 E4 E5 E6 E7 E8 E9 C1 C2 C3 C4 C5 C6 C7 C8 C9 D1 D2 D3 D4 D5 D6 D7
A10 A11 A12 A13 A14 A15 A16 A17 B8 B9 B10 B11 B12 B13 E10 E11 E12 E13 E14 E15 E16 E17 C10 C11 C12 C13 C14 C15 C16 C17 D8 D9 D10 D11 D12 D13
Controller
LgW LgY GR RL SbLg GR YB WL GyG YO LgR S2H SbY GyL G YG YB BrR SbR Y B GyW LgY LLg BrG LB PW YW
A502 A507 A701 A608 H718 T103 T303 A806 H136 T305 C703 C201 H114 H126 C901 T302 A603 H113 E802 T202 E603 E501 B002 F002 E006 S201 E012
H701
LY Gy GY LgR LgB WR SbW GL YBr SbP RG G S2L BrW SbY GyO WL YL GL GyW Lg YL LP PB YSb YV YO
A708 A506 A807 A808 A604 H117 H703 T104 T301 F701 H139 E003 C202 A602 H104 H727 H140 T304 A302 A202 E503 G101 F001 S301 G901 A001 E005
H201 H702
RL 0 GyB GyG GyL LP SbR LgBr L BrB LgW LR L L W Y G BrY R BW Gy B LY LR LW
H128 A609 A809 A505 A501 H207 F102 E701 T001 T901 F901 H205 D203 D204 H731 H726 D107 H728 T203 F003 F303 B703 B709 B706
T801 C702
GB LG YGy LgL LO YSb LLg LW SbP LBr LgL BL BR LgB L L B B BY Y V E803 GyB LgL GO PG LG LBr LO
H121 A709 E804 H122 A710 A901 H110 A711 F202 H206 E502 E001 E002 H132 D201 D202 H736 E004 H131 H135 B503 S401 B702 B708 B701
H202 H203 H204 H101
Male pin connector 9
T101
1 1 7 1 9 1 9 1 7
C701 E007
C902 H120
S5 S6 S7 E801 T102 S8 S9
Female pin connector
Female pin
connector
613
(70TMV-2/70~90ZV-2)
40 pin connector 6 pin connector
Female pin connector
Male connector Female connector

Male pin connector
Male Male stud block

H7
Female pin
connector 10
C201 C202 C203
6 5 1
F704 T406 T405 T404 T403 C002 F203 S615 S722 S730
RL S2H S2L S2S YL BLg Sb SbW SbY SbY
C404
C401
C004
PARKING
D101 A606 S534 T402 C001 G004 C309 F103 G001 S/W
WR BrW SbLg RLg YO YV BrG BL OR SbY
H808 A607 S811 S723 S716

C402
C003 C005 G002 C307 F302 Male connector L
WY BrB BrY GyO Y BrW GyW PW PB GyR G White
Female tab
C403 Y
A503 A605 A802 S708 D105 C006 G003 C308 S715 R
40
WG BrR BG GyR Y
36 35
BW GyY PG PL W
31
Females pins B
Male screw
B Y R (Male
Female threads L G connector)
40
BrR GyR Y
36 35
GyY PG PL W
31
Male pins 4
L LgG
6
Male pin
P743 P742 M901 P701 P724 M803 P741
D206 H137
Female (Female connector)
connector WY BrB BrY GyO Y
P201 P744 M401 L701 M902
BrW GyW PW PB GyR
P722 P711 P725 M802 P749 GO SbW B
WR BL YO YV BrG BL OR SbY S901 A712
P739 P734 P720 P709 P702 P734 M801 P713 Female connector
3 1
S2H S2L S2S YL BLg Sb SbY SbY
P901 P902 P903 P710 P723 P731 M303 M203
B5
10 6 5 1
H7 Black
Male tab
Female stud block receiver
614
Electrical wiring diagram abbreviation chart (70TMV-2/70~90ZV-2)
INSTRUMENT PANEL INSTRUMENT PANEL CONTROLLER CONTROLLER CONTROLLER CONTROLLER
WL Radiator water level warning lamp P Parking brake lamp A20 Auto brake lamp B26 Communication TXD1 C4 Spare digital input D8 E/G speed sensor selection
C Charge lamp A AUTO lamp A21 Auto shift indicator lamp E1 S/S solenoid valve R C5 T/M oil temperature switch (not used) D9 Meter selection
AC Air cleaner clogging alarm AB Auto brake lamp A22 Fuel level lamp (1/2) E2 Fan speed control solenoid valve C6 Air cleaner clogging switch D10 Shift lever 1
TT T/M oil temperature alarm SM Meter (Speed/Tacho) + A23 Fuel level lamp (E) E3 Power supply +24 V E/G coolant temperature switch D11 Shift lever F
C7
WT Engine water temperature alarm SM Meter (Speed/Tacho) – A24 Reversal fan indicator lamp E4 Power supply +24 V (not used) D12 Shift lever A
EP Engine oil pressure alarm — A25 Slip control selection E5 Power supply GND C8 — D13 Spare digital input
BP Brake oil pressure alarm TC Declutch lamp A26 T/M oil filter warning lamp E6 Power supply GND C9 — D14 Downshift button
CE Controller error (failure alarm) PH Preheating lamp A27 Air cleaner warning lamp E7 Power supply GND C10 Spare digital input D15 Declutch set up
+ +24 V power supply WL Work lamp A28 Brake pressure warning lamp E8 Power supply GND C11 Hydraulic oil level switch D16 Odometer selection
ES Emergency steering W Central alarm lamp A29 Neutral indicator lamp E9 +5 V output C12 Reset switch D17 Shift hold switch
SS FR switch, S/S switch indication lamp GND GND (–) A30 Slip control indicator lamp E10 Tacho-graph E/G speed C13 Lower kick-out set-up D18 S/S shift selection switch
EG2 Engine warning lamp — A31 Fuel level lamp (1/4) E11 Power supply +24 V C14 T/M oil filter clogging switch D19 S/S shift switch F
EG1 Engine protection lamp — A32 S/S indicator lamp E12 Power supply +24 V C15 Radiator water level switch D20 —
EG3 Engine stop lamp H High-beam lamp A33 Fuel level lamp (3/4) E13 Communication CAN H1 C16 E/G oil pressure switch D21 Declutch switch
FR Reversal fan indication lamp L Turn signal (left) lamp A34 E/G droop selection 2 E14 E/G speed sensor 2 (not used) C17 Fuel level F switch D22 Kick out set up
Engine water temperature gauge R Turn signal (right) lamp B1 H solenoid valve E15 E/G speed sensor 1 C18 Spare analog input D23 Slip control switch
WTM
(sensor) — B2 — E16 Machine speed sensor C19 T/M pressure sensor D24 Armrest switch
TTM T/M oil temperature gauge (sensor) GND Hour meter (–) B3 Pressure intensifying solenoid valve E17 Power supply C20 Fuel level 1/2 switch D25 Tire diameter selection
— HM Hour meter (+) B4 R solenoid valve E18 Communication CAN L1 C21 Fuel level 1/8 switch D26 S/S shift switch R
(+) Instrument panel illumination B5 Modulation valve (SPCC) E19 S/S potentiometer C22 Efficient loading system switch
CONTROLLER
TF T/M oil filter clogging alarm B6 Reversal fan solenoid valve E20 Communication CAN L0 C23 E/G mode selection switch Note:
— A1 Efficient loading system solenoid valve B7 S/S solenoid valve L E21 T/M oil temperature gauge C24 Pressure intensifying switch
This chart contains options or
FM Fuel gauge (sensor) A2 2nd speed solenoid valve B8 E/G idle selection E22 Brake oil pressure sensor 2 C25 Reversal fan (manual) switch
— A3 Emergency steering motor relay B9 Buzzer E23 Hydraulic oil temperature sensor C26 Boom angle sensor
standard items that may not be
— A4 Ride control solenoid valve B10 Lower kick-out relay E24 Alternator Emergency steering oil pressure sen- found on all models.
C27
sor
— A5 3rd speed solenoid valve B11 Lift kick-out relay E25 Communication RXD1
Ex. Autobrake; n/a smaller units
— A6 Hour meter B12 Controller fault relay E26 Tacho-graph machine speed C28 Fuel level 3/4 switch
— A7 T/C lock-up solenoid valve B13 L solenoid valve Declutch sensor C29 Fuel level 1/4 switch
E27
GND GND (–) A8 4th speed solenoid valve B14 Auto brake solenoid valve (brake oil pressure sensor) C30 Recall switch
+ + 24 V power supply A9 E/G torque selection B15 E/G droop selection 1 E28 Spare analog input C31 Lower kick-out switch
— A10 Back-up lamp B16 Communication RINI E29 Communication CAN H0 C32 Spare digital input
— A11 Fuel level lamp (F) B17 — E30 Brake oil pressure sensor 1 C33 Ride control switch
— A12 Steering oil pressure warning lamp B18 Neutral relay E31 T/M oil temperature sensor C34 Auto fan reversal switch
— A13 Radiator water level warning lamp B19 Brake lamp E32 Air temperature probe D1 Parking switch
N Neutral A14 Central warning lamp B20 — E33 — D2 —
+ GND (–) A15 E/G coolant temperature warning lamp B21 — E34 E/G coolant temperature gauge D3 Shift lever 2
1 1st speed indication A16 T/M oil temperature warning lamp B22 Communication DOUT1 Efficient loading system oil pressure D4 Shift lever R
C1
2 2nd speed indication A17 D solenoid valve B23 — sensor D5 Shift lever 3
3 3rd speed indication A18 1st speed solenoid valve B24 Meter output (Speed/Tacho) C2 Specification change 1 D6 —
4 4th speed indication A19 E/G oil pressure warning lamp B25 E/G coolant temperature sensor C3 Specification change 2 D7 —
615
Electrical Cable Color Codes
Color of
stripe Y G Sb Br L W R B O Lg P Gy V
Color of (yellow) (green) (sky blue) (brown) (blue) (white) (red) (black) (orange) (light green) (pink) (grey) (violet)
insulation
Y (yellow) Y YG YSb YBr YL YW YR YB YO YGy YV
G (green) GY G GL GW GR GB GO
Sb (sky blue) SbY SbG Sb SbW SbR SbO SbLg SbP
Br (brown) BrY BrG Br BrL BrW BrR BrB
L (blue) LY LG LBr L LW LR LB LO LLg LP
W (white) WY WG WL W WR WB WO WP WV
R (red) RY RG RBr RL RW R RB RO RLg RGy
B (black) BY BG BL BW BR B BO BLg BP BV
O (orange) OY OG OSb OL OW OR OB O
Lg (light green) LgY LgG LgSb LgBr LgL LgW LgR LgB Lg
P (pink) PG PL PW PB P
Gy (grey) GyY GyG GyL GyW GyR GyB GyO Gy
V (violet) V
Note
B - Black is ground
Insulation color
BY - Black with yellow is common
Stripe color
V - Violet is 5 V feed.
(Others as may be noted in manual text)
616
Simple electrical terminology
IMPORTANT
Never use slang when discussing electricity. Say exactly what you mean.
Terms like “spark”, “fire” or “juice” are confusing and do not accurately describe what you are
meaning to say. These terms make a technician appear like a novice or look unprofessional.
Just say it; when you are analyzing a circuit, refer to voltage (battery or other voltage [may be AC
or DC]), amperage (flow), or ohms (resistance to current flow).
Know the difference between components
What is the difference between ”resistance”, “voltage” and “current”?
• Voltage is stored potential for electrical flow (as in a battery).
• Current is electrical flow or amperage (you may think of voltage that is moving).
• Resistance (Ohms) is just that - resistance to current or electrical flow.
Ohms law states that current [amperage] is directly proportional to voltage; Volts = amperage x resistance
Amperage = voltage ÷ resistance
current is inversely proportional to resistance. Resistance = voltage ÷ amperage
What is the difference between a potentiometer and a rheostat? They are different.
• Potentiometer is derived from two origins - Potentio [voltage] and meter [measurement].
Resister
Potentiometer - a volt- - + Voltage is measured and used at this point. In our applications,
age sensing device
sensors are a form of potentiometers and may be driven man-
ually, mechanically or by pressure, vacuum and temperature.
• Rheostat is also derived from two words - Rheo [flow] and stat [not moving (static)]
Resister
Rheostat - electrical - + Modified amperage is used at this point. Typical application is
device to control flow
a fan speed control that changed analog signal to fan motor in
older machines; typically gravity (fuel level) or manually driven.
Glossary of simple terms
Term Meaning
Conductor Any material which does allow electrons to flow through it; typical example is copper wire.
Insulator Any material which does not allow electrons to flow through it.
Analog circuit (or analogue circuit) refers to electronics systems with analog signals with any continuously variable
Analog circuit signal. It differs from digital electronics in that small fluctuations in the signal are meaningful in that they are inten-
tionally continuously variable.
A digital circuit is based on a number of discrete voltage levels, as distinct from an analog circuit that uses
Digital circuit
continuous voltages to represent variables directly.
Relay A simple electromechanical switch made up of an electromagnet & a set of contacts (typically employs a solenoid).
A solenoid is a loop of wire, often wrapped around a metallic core, which produces a magnetic field when an
Solenoid (electromagnetic application) electrical current is passed through it. Solenoids are important because they can create controlled magnetic fields
that do a specific job; Examples; transmission & hydraulic oil flow control, fuel control, electrical switching, etc.
Actuator (electrical) A device which transforms an input signal (mainly an electrical signal) into motion.
Pulse-width modulators use a square wave whose duty Example of pulse width modulation resulting in 14 V DC
Pulse width modulator [PWM] cycle is modulated, resulting in variation of average value
(Kawasaki app. primarily for voltage control)
of the waveform. Some fan speed controllers use PWM.
Diode (or rectifier) Device that permits electricity to flow one way when correctly installed in a circuit.
Zener diode A diode that permits current to flow in the forward direction like a normal diode, but also in the reverse direction if
the voltage is larger than the rated breakdown voltage or "Zener voltage".
Resistor Device that intensionally provides resistance to flow.
The transistor is a three terminal solid state semiconductor device that can be used for amplification, switching,
Transistor NPN PNP
voltage stabilization, signal modulation, etc.
A capacitor is an electrical device that can store energy in the electric field between a pair of closely spaced
Capacitor
conductors (called 'plates'). An energy storing device - analogous to an accumulator.
IC (integrated circuit) A miniature circuit which has been manufactured in the surface of a thin substrate of semiconductor material.
+
DC 0
-
half wave
rectification Direct current; electrical flow goes only one way.
+
AC 0
-
Alternating current; flows cyclically (measured in Hertz) in both directions.
Fuse Protects a circuit against overcurrent.
A device designed to open & close a circuit by non-automatic means; and to open the circuit automatically on a
CP (Circuit Protector)
pre-determined overcurrent without damage to itself when properly applied within its rating.
Ground Known as earth [E] or zero voltage
617
Electrical Circuit Symbols

Name Symbol Name Symbol
Direct current Motor M
Alternating current Equipment
Conductor (General) Fuses
Branching connection Lamp
Conductors (Connected) Rectifiers
Conductors
Mechanical coupling
(Not connected)
Relay contact
Terminal
("a" contact)
Relay contact
Ground
("b" contact)
Resistance or Resistor Switch
Variable resistance or Variable Pressure switch or

resistor Temperature switch
Inductance or Electromagnetic Negative -positive-

coil negative (NPN) transistor
Positive -negative-
Battery or Direct voltage source
positive (PNP) transistor
618
Sensor Mount (70ZV-2/TMV-2; equipped with QSB6.7)

Top view
5
1
3 4
2
8 7
2
Left view
Fuel tank
Connector address
1. Machine speed sensor M9
2. T/C oil temperature sensor M5
3. Air cleaner sensor L0
4. E/G coolant temperature sensor M6
5. Hydraulic oil level sensor M4
6. Hydraulic oil temperature sensor L7
7. Fuel level sensor J8
8. Brake oil pressure sensor M2 & M3
619
Sensor Mount (80ZV-2 equipped with QSC8.3)
Top view
2 3 4
Left view
Connector address
2.T/C oil temperature sensor M5
620
Sensor Mount (85ZV-2 equipped with QSC8.3)
Top view
5
3
2 4
Left view
2
5 4
Connector address
621
Sensor Mount (90ZV-2equipped with QSM11)
Top view 5
2 3 4
Left view
5
6
1
Connector address
622
Electrical Wiring Diagram 70TMV-2/70~90ZV-2 (Common cab diagram serves all models)
WORKING WORKING
LAMP (L) LAMP (R) SPEAKER SPEAKER
1 A1 A2 1 2 (L) (OPT) 2 (R) (OPT)
3 RLg C402 RLg C402 3
2 2
B B
9 ROOM LAMP
DOOR
+
SW WR Gy
B105 B106
512 510
G WB GyB
C404 B B108 B107
010 513 511
3 1 REAR 1 1 REAR
A6 WORKING LAMP WORKING LAMP
(L) (OPT) (R) (OPT)
1 A3 B2 B3 A4 1
3 RGy C406 RGy C406 3
2 2
B B
WIPER WIPER 11
SWITCH SWITCH CIGAR
4 (FRONT) 5 (REAR)
LIGHTER
SOCKET 8
1 RADIO (OPT)
WHITE BLACK 4
REAR WIPER
1
GR OL MOTOR
B4 A902 C410 L LR
RR RL FL FR 508 018
LW G Y G Y
_ + + +
SU I
+ + GY B M
A901 B LW
LR R L R L RR RL FL FR 507
_ _ CI A B GND 2
- - 3
B
(BLUE) (BLUE)
4 LY B PB 6 4 OL PL 6 14
7 GyB WB RB WBr G B
C202
B606 C407 C410 C408

504 500 018 506 B301 B201 C405 C403 C404
L W YW GR GY 511 513 300 022 010
B503 B502 B605 B401 B402 2 1 Gy WR RB
503 502 505 508 507 B302 B202 C405
510 512 300
3 1 3 1 6 1
O
C401
020
A7 A8 A9 A5 B1
(OPT) B
13
CAN (RESISTER)
FRONT
7 WIPER MOTOR 6
1 2 3 12 M INTERMITTENT
MODM WIPER RELAY
2 1
L W 2 4 6 No. DESCRIPTION
3
Y R R 1 3 5 1 RADIO
4 6 4 2 SPEAKER
11 20 Y OR Y YW LY 6
S2S S2L
C303 B802
B604 C409 B504 A801 A804 3 WORKING LAMP
501 019 501 505 504
C302
S2L S2H B WBr S2H
L W OR PB B 4 FRONT WIPER SWITCH
B920 B901 A803 A802 C409 C407
C403 B801 503 502 019 500 5 REAR WIPER SWITCH
022 C301
2 1 3 1 3 1 6 INTERMITTENT WIPER RELAY
10 1
7 FRONT WIPER MOTOR
B8 B9 B5 B6
8 REAR WIPER MOTOR
9 ROOM LAMP
11 CIGAR LIGHTER
12 MODM
13 CAN (RESISTER)
C3 C2 C4
2 1
2 1 Y B
S2L S2H A501 7 12
531 B602 506 B603 B404
B920 B901 A806 A906 B505 A905
PB PL OR OL
S2S
B803
(Note; this corresponds to A401 B109 B111 B907 A201 020 (Note; this corresponds to C3 on page 1/3)
A301 B103 A603 B110 A101 A701
(Note; this corresponds to C2 on page 1/3) C1 on page 1/3) RGy RB G WBr RLg O
6 1
CAN (RESISTER)
TO FLOOR BOARD AREA
623
Electrical Wiring Diagram 70TMV-2 (1/3)

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624
CONTROLLER
A 2.2_SO A17.D_SO A32.FR_L B13.F_SO E 2.FC_SO E17.BATT E32.OT_SE C 2.DSUB2 C17.F C32.EG_M D13.SS_N
A 7.LU_SO A22.1/2_L B 3.IP_SO B18.N_R E 7.GND E22.B_SE2 C 7.ET C22.2S D 3.SL_2 D18.SS_SW
A 9.OTH_OUT A24.SS_L B 5.MO_SO B20.CAN_R1 E 9.+5V E24.ALT C 9.BD C24.IP_SW D 5.SL_3 D20.TMP
SPEEDMETER 192 173 135 235 204 811 115 400 754 118 166 H701 180 415 116 401 251 240 105 260 223 165 255 230 111 233
DIVIDING LY Gy GY LgR LgB WR SbW GL YBr SbP RG G S2L BrW SbY GyO WL YL GL GyW Lg YL LP PB YSb YV YO
RATIO ODOMETER A/M A708 A506 A807 A808
H201 749 169 130
A604
224
H117
170
H703 T104 T301 F701 H139
203 810 119 145 331
E003 C202 A602 H104 H727 H140 T304
234 402 H702 220 707 117
A302 A202
265 200
E503
222
G101 F001 S301 G901 A001 E005
124 168 110 125 231 232
SELECTION SELECTION SELECTION RL 0 GyB GyG GyL LP SbR LgBr L BrB LgW LR L L W Y G BrY R BW Gy B LY LR LW
B B B H128 A609 A809 A505 A501 H207 F102 E701 T001 T901 F901 H205 D203 D204 H731 H726 D107 H728 T203 F003 F303 B703 B709 B706
T801 241 103 753 190 149 208 104 273 258 101 146 005-C 005-D 161 160 010 C702 181 106 271 750 121 126 120
PW PB PG H121 A709 E804 H122 A710 A901 H110 A711 F202 H206 E502 E001 E002 H132 D201 D202 H736 E004 H131 H135 B503 S401 B702 B708 B701
S925 S916 S902 267 H202 242 261 H203 403 140 H204 202 148 225 237 236 221 005-A 005-B 159 H101 266 182 164 109 122 128 123
111 110 109 T101
1 1 1 100
1 9 1 7 1 9 1 9 1 7
(BLUE) (BLACK)
C701 E007 114
C902 H120
S2 S3 S4 S5 S6 S7 E801 T102 S8 S9
T3 T1 T2
3 1 4 1
YB YG YBr GL V 1
S623 S733 S617 S616 S709 B
115 116 119 810 100
YL YO B GR BY
FUSE BOX (MAIN) S725 S626 S622 S707 R Y
R5 R5 R5 FUSE BOX (CAB) 117 118 811 114 S812 S830
4 6 3 2 3 106 105 2
RL RG LR LW YR YW R5 R5 R5
CONTROLLER RS232C DIAG. S/W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PROGRAM CONNECTION
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 REWRITE
003
W R Y B L G Br O WR (NOT USED)
G201 W R Y B L G Br O WR RL RG LR LW YR YW
G301
G401
H103
5
RL RG LR LW YR YW WR R YW YR LW
5
W R Y B G Br L O R
5
R
5
LR RG RL G Br O WR RG YR YW R
5 5
W R Y B L RL LR LW R R YW
8 14 4 6
F406 R R Br R RG OY L R R BW W 6 10
F502 B202 G702 B102 T501 H301 H302 E104 E202 OL OR O YG 3 2 R R
F503 B207 004 B107 007 005 910 911 062 T407 C310 C309 C301 H804 H402 H501
F602 G BW Lg G WR R WR G WR 018 019 020 H805 913 914
F603 H134 F703 H111 H401 E107 E101 E106
001 H735 014 H720 D2 912 065 064 063
R WBr W/LR R
E302 C303 H502
7 C304 1 3 1 021 022 915
A207
F802 A307 1 4 1
1 3 4 5 6 5 1
F803 A610 2 H801
G501 L
A706 L L L L E008 L H802
G802 E601 S703 S704 S711 S712 F702 B504 H803
S717 E702 005-A 005-B 005-C 005-D F902 005-b
010 029
E703
T902 D5 D6 D7 D8 D9 D0
D1 013 T002 D3 D4
005-a
625

40 36 35 31 40 36 35 31
COMBINATION 331 Y L Br L R G G BrR GyR L GyY PG PL W
HYD. OIL
303 Br
LAMP K106 M704 R605 R102 M101 M601 L806 P606 P501 L603 P743 P742 M901 P701 P724 M803 P741 TEMP.
Y K106
K501 303 R104 707 R705 312 162 754 182 012 221 266 730 752 159 736 739 506 161 SENSOR
R606 Y Y Y L Br Br G G G 4 WY BrB L G L BrW GyW PW PB GyR
1
Y K101
K502 325 R706 K107 M501 N903 P601 K206 K204 L501 R R R P201 P744 M401 L701 M902 P722 P711 P725 M802 P749 HYD. OIL
329 180 705 720 250 261 267 N201 N201 N201 141 142 143 144 605 731 181 220 160 733 737 740 500 751
L 327 Y Br L G GO WR 911 913 915 W J302 J402 J502 J602 WR BL YO YV BrG BL OR SbY LEVEL
R103
R602 K103 K102 N904 M203 K205 L804 P605 R R R
N101
901 L L L L P739 P734 P720 P709 P702 P734 M801 P713 S/W COMPRESSOR
B
K503 R702 R701 306 703 171 251 604 015 N201 N201 N201 149 148 146 015 741 748 734 738 741 019 209
330 325 Y Gy Y L R GL L 910 912 914 J702 J202 J102 S2H S2L S2S YL BLg Sb
253 003 B L L L
H001 H002 K101 K108 J801 K105 M303 K201 L803 8 5 P901 P902 P903 P710 P723 P731
K203 R601 308 404 311 172 003 603 735 205
BrW R L601 1 1 1 747
FRONT HEAD 2 2 1 M201 10 6 5 1 10 6 5 1
LAMP(OUTSIDE) M301 H2
K202
K108 K102
M502
308 306
R H7
Y
K3 M602 L602
B P502 M202
B
114 H1 M302 H3 H4 H5 H6 OR
W H9 100 2 1
Y
1 Br
PB OR
WORKING LAMP 3
WY H730
F H722 H712
(INSIDE) WASHER 500 019 G L L
8
K4 311 H727 P502
T/M SOLENOID VALVE
1
H728
Y K105 MOTOR PB
M8
220 114 181
H119 H118 H109
H106 H129 H127 H108

K401 K501 K601 K303
K901 K801 329 K003
K802 K302 K502
327 306 325
311 303 329 308

308
327 K002 325

1 2
(OPT) PL
Y
Y
B + 4 3
329 L B J1 B PL
HORN (L) Y F _ R H732
306
+ H205
K1
Y
Y
K601 146 506
_
311 303 2 1 (BLUE) B L7 M4 P2
Y
B 1 2 2 1 EFFICIENT EFFICIENT
LOADING LOADING + GROUND SPEED
K7 329 B B Y K6 B
SYSTEM(ELS) SYSTEM(ELS)
Y
HORN (H)
329
Y
K701 K107 _ L B J2 SENSOR
K703 329 SOLENOID OIL PRESS. R + H206
4
4
K601 148 L L M9
5
5
VALVE SENSOR _
2 1 H726 H736
1 3 3 1 160 159
B 10 6 5 1 1 5 6 10
R L L L L R 2 1
L103 L201 L202 H120 H101 H103 + YL YV BrG GyY
K9 311 003 100 114 114 100 003 K2 _ H706 H715 H714 H734 1 2 3 4 5 6 7 8 9 10
WORKING Y K105 G G G G G G +
1 _ L B J3 747 734 738 736
LAMP L102 L203 L401 H122 H113 H123
+ H201
141
CAN YO SbY GyW
(INSIDE) B 250 251 261 261 251 250
S
_
2 1
(RESISTER) H716
748
H711
209
H724
737
11 12 13 14 15 16 17 18 19 20
6 4 4 6 G B P7 PW PG BLg BrW
1
H121 H723 H733 H705 H725 21 22 23 24 25 26 27 28 29 30
2 1 1 267 P746
+ 740 739 735 733
FRONT 1 2 G L B J4 P737 H709 P9 WR S2S BL Sb
K108 K102
G G _ S2H
308 306
R H131 2 + H202 H707 P747

Y
K0 J902 H902 H720 P903 H713 H704 31 32 33 34 35 36 37 38 39 40

HEAD B 253 253 H0 266 142 S2S H708 015 H717 205
B
_
LAMP W R R L L
H120 H101
2 1 S2L GyR S2L S2H BrB BrR GyR W
Y
1 J903 H901 2 H721 P902 P901 H729 H739 H737 H731 41 42 43 44 45 46 47 48 49 50

(OUTSIDE) 003 003 114 100 751 731 730 752 161
2 2 1 2 + 50 46 45 41 41 45 46 50
COMBINATION L B J5
_
LAMP L5 L6
3 + H203
K801 303
_
143
1 4
Y K106
2 1 B G
K802 327 M001 4 1
Y K103 L8 M1 M2 M3 P1 P8 M002
+ B G
M001 3 2
B
K803 1 6 _ L B J6 M002
B L 2 1 2 1 4 + H204
H135 2
B L
1
L _
144 2 1
2 3
ECM
182 L L L B G
H137 H101 H120 H101 H120 2 1
B P501
162 100 114 100 114 221
L L
H114 H104 +
FORK GL GO
H102 H112 172 171
_ L B J7
LEVELER R
H002 3
603 604
4
D + H207
149
003 J9 _
3 4 2 1
G B 1 2 1 2
603 604 S S 221 114 P803 P803
W B H001 R2
253 L902 L903
GL GO P101 L702 P804 P804 312
Y R102 REAR
2 1 PARKING + _ + _
FAN SPEED
G L G G WORKING
L901
B SOLENOID CONTROL 4 1
B LAMP
G L G G 303
182
L002
SOL. VALVE H132 H120 N002 N002 R501 R3 312 REAR
BUCKET 221 114 036 036 Y B Y R102
B L
BRAKE OIL PRESS. 1 2 1 2 330 R301 WORKING
LEVELER R 1 6
R401 R201 B LAMP
Br K201
003 L1 (MAIN) P5 M0 Y Y
G B 3 2
1
L B K206 R
3 2
250 P606
R103
BG Y Y
330
L0
Y
N6 012 P601 H128 H138
2 1 L9 720 330 312
R4 BACK UP
1
P0 HEATER Y B ALARM
702
STARTER
B
L802 BW RELAY H129
303
1 2 1 N501 4 1
L 1 B C
2
C L201 1 603 604 R
BOOM L3 L L R1
L806
100 L803 L804 N502

182
L301 K202 B AIR R501

B
L
ANGLE G G
100 L302 G 100
L2 GL GO R104 Y LICENSE
SENSOR
B L203
L
K205
L 2 3 N2 HEATER R502
251 251 251 B LAMP
L
L303
114
K203
114 AIRCON FUSIBLE
A L202 2 N1 N3
2 LINK
Taped up at rear - DO NOT CONNECT!
114 FUSIBLE
3 N7 BATTERY
LINK RELAY
R
MAGNETIC
B
S/W
70A
70A
RIDE CONTROL SOLENOID 702
701 N8 30A
BW
N501 R VOLTAGE 1 2
3 N502
RELAY
2
2 WV B
B 1 N403
70A
R8 AIR CLEANER 1 4
700
G
L401
2 3 R RH
2
261 B B FUSE H301

H302 BATTERY
H401 _
L4
1
1 4 WG B B Br
RL WG H402
261 G FUEL LEVEL N904 N903 N903 N901
30A H501 +
R801 K204 704 706
2
B R901 261 T/M OIL E/G WATER SENSOR 703 704 705
H502
R9 TEMP. SENSOR TEMP. SENSOR 910~ N4 6 1 REAR

1
(CONTROLLER) 915 012 720

(CONTROLLER) COMBINATION
4
G N601 N602
L401 M7 1 4 1 R Br LAMP (R.H)
H129
H139
702 700
303
331
261 ALTERNATOR
Br
703 706 015
R
B
708
B
N702 N701 N804 N301 N401 N402 R6
1
BW Br Br WV WR Br
H109
H128
015 708
325
330
701 2 1
W
N801
Y
Y
Y
N703 N704 P605 P602
R 705 B WR Br B
2 3 2 4 3
3
1 2
1
E B R l 900
086
901 4 3 REAR
3 2 G 900
6
R
COMBINATION
4
Y Br B B
P002 706 M001 W W W
701 H125 708 M002 N303 H601 N102 LAMP (L.H)
H129
H139
303
331
Br
705
R
B
Br
B
BW W N001 R7
B Br WR Br
N901 P001 N101 H111 N901
H115 M704
H119
H128
H140 702 086 015 708
327
330
Y
703 P602
Y
2 4 1 4 1 R Br
B 1 H134 H124
706 012 720
3
1
L L Br L
707 6 1
H126 H120
180 114
H136 H120
754 114
Gy Br DIODE
1 2 1 2
H107
404 N5 N9 N0 UNIT P6
1 LH
BATTERY
M5 M6 J8 _
626
Electrical Connection Diagram 70TMV-2 (1/2)

STARTER S/W
B BR ACC R1 R2 C
ACC’ (L) (005-b) E
TO PARKING SW.
PREHEAT (005)
F5 L
2
(L) (005-a)
OFF
30A
ON
G (010)
START F10
E
(086) (900) 12V 12V ACC’ L x4 (005-A~005-D)
5
W [W ] 100
30A
E05 E06 E17 E04 E12
BATTERY E03 E11
(060) (901) (SbP) (145)
ECM(39) WL (707) B18 NR NEUTRAL RELAY
W [W 5 ] E24
LgW (101)
(065) (015) (708) B12 X CONTROLLER FAILURE RELAY (GY) (169)
R1 BR
WR
1.25 F15
WR WP LR (126) BrB (258) A20 AUTO BRAKE INDICATOR LAMP (NOT USED)
B AC D11 B11 KO LIFT KICK OUT RELAY
R2 C 5A WV LBr (128) L (273)
D04 LOWER KICK OUT RELAY
(700) F N R B10 BS
A32
(RL) (235) REVERSAL FAN
OPT INDICATOR LAMP (OPT)
LEVER
SHIFT
(062) (064) (063) (LgB)(224)
BW G
1.25
WR
1.25
YGy (242) EMERGENCY STEERING A24 S/S INDICATOR LAMP (OPT)
BATTERY A03 M
RELAY MOTOR RELAY COIL (OPT)
F12
F14
F13
15A
5A
5A
1 (146) LR
(012) (014) (013)
STARTER 2 3 A B13 F SOLENOID VALVE
LW (120)
BW G
1.25 (Lg) D12
LO (123)
70A
B C D05
100 LG (122) (148) LBr
D03 B04 R SOLENOID VALVE V (100)
5 LY (121)
[R ]x6 E09(+5V)
D10 (141) LY
(910 A18 1ST SPEED SOLENOID VALVE
~ MAGNETIC S/S POTENTIOMETER (OPT) B09
LgBr (104)
BZ BUZZER
915) S/W (702) F YO (232) G (234)
D19 E19
5
[R ] (701)
5
[BW ] VOLTAGE (LY )
RELAY F/R SW. (OPT) YW (233) BOOM ANGLE SENSOR
RL
1.25
(703) WG (704) D26 (142) LG
R A02 2ND SPEED SOLENOID VALVE BrR(251)
C26 E34
(YB ) (401)
E/G COOLANT TEMP. GAUGE
NR
DECLUTCH SENSOR
LG (122) (LG) (LgR) (166) (BrW) (402)
(013) (705) SHIFT UP SW. (OPT) D06 E27 E21 T/M OIL TEMP. GAUGE
(Lg) (WG) (707) LY (121) (143) LO
F13 WL SHIFT DOWN SW. (OPT) D07 A05 3RD SPEED SOLENOID VALVE BRAKE OIL PRESS. SENSOR 1
SbY (171) E30 (400)
CHARGE LAMP (706) (WL )
WL1.25 (LO)
BRAKE OIL PRESS. SENSOR 2 B24 METER OUTPUT (TACHOMETER)
S/S SHIFT YV (231)
D18 (144) LW SbY (172) E22
L R SELECTION SW. (OPT) F5 A08 4TH SPEED SOLENOID VALVE
20
70A B LB (230)
E ARMREST SW. (OPT) D24
(LW)
ALTERNATOR 20 LP (149) EFFICIENT LOADING SYSTEM
(YL) (124) D SOLENOID VALVE
DOWNSHIFT SW. D14 A17 OIL PRESS. SENSOR (OPT) GyB (266)
C01
PREHEAT
LAMP WR (170)
YSb (125) B14 (NOT USED) EMERGENCY STEERING
SHIFT HOLD SW. (OPT) D17 SbR (240)
OIL PRESS. SENSOR (OPT) C27
(720) LP (168) LLg (140)
(BG) DECLUTCH SET-UP D15 A07 (NOT USED) GyG (754) YSb (403)
AIR HEATER E/G COOLANT TEMP. SENSOR B25 A06 HOUR METER DRIVE
15 15 A04
LgL (261) RIDE CONTROL GyL (180)
SOLENOID VALVE (OPT) T/M OIL TEMP. SENSOR E31 SbR (208)
B08 AI E/G IDLE SELECTION
(G) (415)
BrG (255) GB (267) EFFICIENT LOADING SYSTEM AIR TEMP. PROBE E32 SbP (202)
(012) LIFT KICK OUT SET-UP D22 A01
SELECTION SOL. VALVE (OPT) A09 TC E/G TORQUE SELECTION
BW HEATER RELAY GyO (220)
HYD. OIL TEMP. SENSOR E23 SbW (203)
BW (271) B15 E/G DROOP SELECTION 1 (NOT USED)
LOWER KICK OUT SET-UP C13
BY (114) SbLg (204)
LOWER KICK OUT SW. C31 E07 A34 E/G DROOP SELECTION 2 (NOT USED)
B06
LgL (225) REVERSAL FAN
SOL. VALVE (OPT) Y(160)
GROUND SPEED SENSOR E16
M
100 EMERGENCY REVERSAL FAN SW. W(161)
M STEERING PUMP
Lg (222)
C25
E/G SPEED SENSOR ECM(41) E15 E
(OPT) (RL ) (330)
(OPT) LgY (223) BR (236) Y(159) A10 TO BACK-UP LAMP
AUTO FAN C34 E01 S/S SOLENOID VALVE R (OPT) E08 (RG) (331)
REVERSAL SW. (OPT) B19 TO BRAKE LAMP
BL (237)
(Y) (105) B07 S/S SOLENOID VALVE L (OPT)
B ACC’ E RECALL SW. C30
(R) (106)
RESET SW. C12 LgB (221)
TO PILOT LAMP E02 FAN SPEED CONTROL SOL. VALVE (100)
LLg (165) (E09) V
D21 +5V
(013) YB (115)
E F13 GO (164)
D01 (Lg) (OUT_FEW)B23 FEW
DECLUTCH F13 YG (116)
(013) GyW (200) (OUT_RES)E33 RESET
(LgR) (130) YL (117)
CUT-OFF (Lg) C23 A21 AUTO SHIFT INDICATOR LAMP (RXD0)E25 RXD CONTROLLER RENEWAL
GL (265) (GR ) (135) YO (118)
C22 A29 NEUTRAL INDICATOR LAMP (TXD0)B26 TXD
YO (176) YBr (119)
(GyW ) (260)
C33 (GyB ) (103) E (OUT_MD2)B17 MD2
A14 CENTRAL WARNING LAMP
(LgY) (167) EP (LgY) (173) P (107) GND
Gy (750) A28 BRAKE OIL PRESS. WARNING LAMP DESTINATION SWITCH 1 C02
E/G OIL PRESS. SW. C16
E
DECLUTCH SW. DECLUTCH A19
(Gy) (749)
E/G OIL PRESS. WARNING LAMP DESTINATION SWITCH 2
PL (108)
C03
BrY (181) (GyG) (753) PG (109) GL (810)
HYD. OIL LEVEL SW. C11 A15 E/G COOLANT TEMP. WARNING LAMP A/M SELECTION D02 (RIN1)B16
(163) GR (811) RS232C
(SbW) (GyL) (190) PB (110) (DOUT1)B22
ON AIR CLEANER LgL (182) A16 T/M OIL TEMP. WARNING LAMP ODOMETER SELECTION D16
C06 (LgW) (192) PW (111)
OFF CLOGGING SW. A27 AIR CLEANER WARNING LAMP TIRE DIA. SELECTION D25 S2H
(162) (CANH0)E29
PARKING SOL ON (005-b) A12
(O ) (241)
STEERING OIL PRESS. SPEED SENSOR SELECTION S2L
LgG
(L) E D08 (CANL0)E20 CAN
OFF
F5 WARNING LAMP METER SELECTION D09
S2S
MACHINE CAB PARKING SW.

E MAIN CONTROLLER E
15 5A 30 20A
14 5A 29 20A
FUEL EFFICIENT MODE SW.
13 5A 28 10A
12 15A 27 5A
EFFICIENT LOADING SYSTEM SW. (OPT)
11 10A 26 5A
10 15A 25 20A
9 15A 24 10A RIDE CONTROL SW. (OPT)
8 15A 23 10A CONTROLLER X (LgW) (102)
FAILURE
7 10A 22 3A
(LgSb) (112)
BZ
6 15A 21 15A WARNING BUZZER
5 30A 20 10A
4 15A 19 10A FUEL LEVEL
GAUGE (404)(YBr)
3 10A 18 5A
E
2 15A 17 5A ECM
1 20A 16 5A 36 30A
627
Electrical Connection Diagram 70TMV-2 (2/2)

ACC’ E ACC’ E B E
COMBINATION J3
(001) S/W F3 (086) (036)
F1 1.25 Br (003) BrB (257) F36 3
R RB (301) BOOM KICK-OUT 3
[W ] [G ]
LT LT 10A KO 4 1
20A RY (302) 30A
LH LH 3 2
RW (304) EL
UL HU
B
BrR (272)
HL FLOAT E
BS
J2
(015)
WR
LT F15 39 (730) STOP (013)
LICENSE LAMP (BrR) (Lg)
43 F13
RELIEF INDICATOR LAMP (731) WARNING
(BrB)
21 44
RELIEF INDICATOR LAMP OPT
26
MACHINE WIDTH LAMP 32 45
RB
(303) BrW (250)
MACHINE WIDTH LAMP (252)
BUCKET POSITIONER
BrW
THROTTLE PEDAL
TAIL LAMP (161) W
BrW (253) FORK POSITIONER THROTTLE OPENING 41 (E15)
SENSOR BrW (733)
TAIL LAMP 22
YV (734)
9 (751)
F7 OY (007) BLg (735) GyR E/G OIL PRESS.
C AIR-SUS. 23 49 EP
10A COMPRESSOR (752)
IDLE SW GyR
42
INSTRUMENT OFF IDLE GyY (736)
(RB) 1
PANEL LIGHTING F20
(300) O (020)
10A GyW (737)
CHARACTER IDLE
11
DISPLAY
S2H
TO
RADIO KEY GND S2L
S2H DIAGNOSTIC SW. CAN
CANH0 S2S
S2L BrG (738)
CAN CANL0 2
S2S RESISTER
(307) HIGH BEAM PL
(RY) INC/DEC SW. B
(060)
(306) RIGHT HEADLIGHT (H) INC PG (739) W
RESISTER (m) 24 B
RY
(305) UL LEFT HEADLIGHT (H) PW (740) S2H
RY 25 46 C
G (010) ROOM LAMP DEC S2L
LH F10 47 D
RIGHT HEADLIGHT (L) S2S
(308) 37 E
RW BL (741) (YL) (747)
LEFT HEADLIGHT (L) 34 10 F
(006) (310) RLg (521) (Y0 ) (748)
F6 1.25 TO FRONT CAB WORKING LIGHT 20 G
RG (RGy) RLg (206) AI
WORKING LIGHT PL WORKING SbY (209)
13 A
15A LIGHT CAB WORKING LIGHT
RLg (311)
FRONT WORKING LIGHT TC DATA LINK
FRONT RGy (520) Sb (205) E
TO REAR CAB REAR WORKING LIGHT 31 CONNECTOR
WORKING FRONT WORKING LIGHT WORKING
LIGHT S/W LIGHT CAB REAR WORKING LIGHT
TO CAB 19
(002)
RLg (521) WORKING LIGHT
F2 R
1.25
3
15A
RGy (312)
REAR WORKING LIGHT
REAR WIPER MOTOR
F19 OR (019)
WORKING REAR WORKING LIGHT M F WIPER
LIGHT S/W 10A (501)Y L (503)
TO CAB REAR
(330)
RGy (520) WORKING LIGHT
(502)W
S2 S3
WIPER S/W
E/G ECM Connection Diagram
RL WASH B
TO CONTROLLER BACK-UP LAMP Sint S1
(A10)
BACK-UP LAMP (504) LY LW (505)
1 5 3
WASHER INTER-
BACK-UP ALARM MOTOR (500) 2 MITTENT 6
PB WIPER
(331)
RG
M 4 RELAY
TO CONTROLLER RIGHT BRAKE LAMP
(B19) WIPER MOTOR
LEFT BRAKE LAMP F18 OL (018)
M R WIPER
(004) 5A (507) GY GR (508)
F4 R E WASHER
15A MOTOR (506) B S1 S2
PL
FLASHER UNIT M WASH
(WINKER) WIPER S/W

ACC’ B
E
L
(324)(RO)
(320)
RIGHT TURN SIGNAL PL
P COMBINATION (325)
S/W (321) RO RIGHT FRONT TURN SIGNAL PL
RO
TR
(322) RIGHT REAR TURN SIGNAL PL
TB
RBr
B TL OPT
LEFT FRONT TURN SIGNAL PL
(010) (327) F22 (WBr ) (022) (510) Gy
(060) F10 G RBr LEFT REAR TURN SIGNAL PL
W
FLASHER 3A (NIGHT (RB) (300) (511) GyB
15A ILLUMINATION) RADIO
UNIT LEFT TURN SIGNAL PL (512) WR
(326)(RBr) G (010)
(HAZARD) F10
(513) WB
B
E
L
B
(323) BP
DC-DC
(021) CONVERTOR (531)
F21 R
2
Y
2
15A
+ +
(329) GW CIGAR SOCKET
OUT
HORN
IN
2 (12V)
(328) (GL )
- - B
HORN RELAY HORN S/W
TO RADIO/ROOM LAMP
TO CONTROLLER (E17)
CAB
ACC’ E
628
Electrical Equipment Layout 70TMV-2

Front chassis
Bucket positioner
(L1)
Fork positioner
(J9)
Ground Ground
Head lamp Boom angle Head lamp
(K0) sensor (L3) (K3)
Horn
Front chassis ground
For ride control

(OPT)
To rear chassis
(K1/K2) To rear chassis
(K1/K2)
LH Top view RH
629
70TMV-2
Rear chassis
To front chassis
To front chassis
Transmission solenoid valve (J1-J7)
Parking brake
solenoid valve (M1) Hydraulic oil temperature sensor (L7)
To floor harness Rear to floor ground
To floor To floor ground

A-A
Brake oil pressure

sensor (M2/M3)
To floor A A
Air conditioner
condenser (L9) Transmission oil
temperature sensor
(M5)
Speed sensor
(automatic gear)
Ground Engine ground (M9)
Washer tank (M8)
(option)
Air cleaner (L0)

Air heater
Engine water
Ground
Starter ground temperature
to engine body sensor (M6)
Rear chassis ground, Air conditioner

Alternator ground Alternator (M7) compressor (P2)
ECM Rear chassis

Fuel level ground
sensor (J8)
Battery ground
To rear grill
Fan speed control
solenoid valve (P1)
Top view RH
LH
630
70TMV-2
20 Red 15 BK
Magnetic To ground
switch (N7)
100 Red E Terminal
Starter 5 Red 5 BK & White G Engine body
15 BK
(Red tape) 704 703 100 BK
012 BK White & Red &
& White Green Blue
Heater B
Fusible Fusible relay Rear
B Terminal
link (N1) link (N2) (N6) chassis
( + Mark) ground
15 BK Voltage relay (N8)
Fuse Air
(ECM)
70A 30A 70A 70A
BK x 2 heater Battery relay 100 Red
(N3) 1 4
720 2 3
Brown 704 706 To rear chassis

5 White 5 705 BK BK Brown harness
C Terminal
3 White White 5 Red 5 BK &
Brown To battery relay
Alternator wiring White
700 BK To rear chassis
White & harness
(N0) Violet
20 BK 5 Red x 6
Starter motor wiring
( + Mark) 5 White 100 2 poles 4 poles

Red
Diode
unit (N4)
+ Mark: Connected to red cable

To battery (+) To rear Mark: Connected to black cable 4
To rear chassis harness chassis harness
F 3
Engine relay unit wiring Rear working lamp connection
R
2 1
Rear working lamp Rear working lamp

Transmission solenoid wiring
Fan speed control

solenoid valve (P1)
To air heater
To battery (+)
To rear chassis harness To rear chassis harness

To starter
Relay unit wiring Radiator guard and fan wiring

(View from rear)
631
70TMV-2
Floor board
To rear ground
(Floor to rear ground)
To control box
Red tape Green tape
Accelerator pedal
(C0) Blue tape
Air temperature probe (controller)
(C9)
To rear Hazard Front working lamp
Air temperature probe (air conditioner)
(C8) To T/M Fuel efficient mode change Rear working lamp
Efficient loading system

(Floor ground) (option)
Declutch selector Selection switch for shift lever
Yellow or F/R switch (option)
tape
Declutch switch
(B0)
Operation switch connection
To operation stand
To rear
Top view
Horn switch
(B8)
Combination switch
(B9)
Instrument panel, switch
Shift lever To instrument panel, switch

(B7)
Parking switch
(B5)
Front
From operator’s seat
632
70TMV-2
To declutch setup switch

Lift kickout / lower kickout setup switch 4 poles black connector
Declutch setup switch
Lift kickout / lower kickout setup switch
4 poles blue connector

To floor harness
4 poles white connector

Flasher unit (option)
Fuse box (cab)
4 poles black connector
Fuse box (main)
Switch wiring in control box

Declutch setup switch (T6)
Lift kickout / lower kickout setup switch (T7)
Buzzer (G6)

Controller program rewrite (not used)
RS232C
3 poles white connector Front

Diagnostic switch connection
Transmission controller

Speedmeter dividing ratio selection
2 poles white connector (Ground)

Odometer selection
A/M selection Back signal (option)
Starter switch (E1/E2) To downshift button
Data link connector (T4)
To pilot
valve
DC-DC converter (E3/E4)

Diagnostic increment / decrement switch To shift hold switch
Power (option)
To air suspension directed to battery
To air conditioner
633
Electrical Wiring Diagram 70ZV-2 (1/3)

FRONT WORKING REAR WORKING
FUEL EFFICIENT EFFICIENT LAMP LAMP
MODE LOADING 1 1
2 2
SELECTION SYSTEM(ELS) 3 3
1 1 INSTRUMENT PANEL 5
4
5
4
2 2 6 6
3 3 DECLUTCH
HAZARD
4 4 1
5 5 2
3 C AC TT + ES FR EG2 EG1 EG3 SS WTM TTM + N A AB SM SM TC PH WL HM
6 6
_ 7 4 5 6 7 4 5 6
4 F/R S/W
GND
5 WT EP BP CE (+) FM GND 1 2 3 4 P W GND H L R
7 7 6 8 1 2 3 8 1 2 3 SELEDTION
5 8 11 20 7 12 9 16 5 8 5 8
GyG Gy LgY LgW RB YBr B B LY LG LO LW SbW GyB B RY RBr RO B RG RLg R RGy B
7 4 5 6 7 4 5 6 7 4 5 6 S515 S519 S528 F903 B601 H107 S518 S502 S505 S508 B502 S514 F403 A102 A107 D113 C302 D109 C306
753 749 173 102 C305 404 141 142 143 144 163 103 307 326 324 006 H106 002 H138
8 1 2 3 8 1 2 3 8 1 2 3 WG LgW GyL Lg O RL BrB BrW BrR LgB YB BrW Lg GR LgR GY WL B LgY BG RGy RG RGy R RGy YV
S506
YSb
403
H125 S527 S516 D103 S512 S532 H729 H719 H739 S524 S734 S721 D103 S529 S521 S520 S624 A407 H124 B101 D113 A801 D109 A801 S918
H740 192 190 013 241 235 731 732 730 224 401 402 013 135 130 169 400 167 H738 B201 006 310 002 310 231
5 8 5 8 5 8 5 8
RO
B911
RO
A815
BP
G803
Lg
D103
Lg
D103
LgY
A803
B 4 1 10 1 6 1 8 1 1 4 1 4 1 1
A
321 H109 323 013 013 167 A5 A6 A7 A8 A9 B1 B2 A0
RBr RBr BP B GyW B B GL B YO B
B910 A814 G803 S823 S822 B001 B3
322 H119 323 200 265 176 COMBINATION S/W DC-DC CONVERTOR
4 1 4 1 4 1 4 1 FOR LAMPS STARTER B B
BW R1 WRx2
BR S/W IN OUT
A1 A2 A3 A4 S2L B ACC WBx2 4 1
R2 804 803
BG C G
C804 C801
HORN S/W G L O B B R
3 5 802 801
SHIFT LEVER TB TL TR HU EL LT LH HL W W W C803 C802
W R
STARTER SWITCH BW WR WR G 3 2
W R B B Y
BG WB WB D605 C102
P RBr RO RW B RB RY 021 531
GW GL GY G703 A103 A106 F401 F601 F501 2 1 2 1
W
F801
320 322 321 304 301 302 WR WR
D506
PARKING G B
D501 D503
063 065
060
S/W W E3 E4
BW G
GL
H601
D504 D502 901
L GR GB B 8 1 062 064
G 1
Y
R B8 B9 4 1
B
E1 E2
LIFT KICKOUT
INCHING SET-UP/ EMERGENCY
B Y R LR LBr B CUT-OFF S/W LOWER KICKOUT STEERING
S911 S904 REVERSAL RIDE 3 4 BACK
L G SET UP
126 128
INCHING FAN S/W CONTROL S/W V YGy
F/R SWITCH/ LAMP
4 6 LW B 1 S709 S503
L LgG S912
2
3 SET-UP 3 2 100 242
1 STICK STEERING
120 Lg LgL GyW SbR 6
D206 H137 4
005-b 162 LY LG LO 5 2 S825 S606 S833 S827 BL BR G V YO LB
6 240
GO SbW B S910 S903 S905
3 222 225 260 S607 S701 S719 S709 S919 S924
YO
B LgY BY
LLg
S901 A712 121 122 123 B Lg 237 236 234 100 232 230
164 163 S834 D103 S707 YW B L BY
RB 3 1 223 013 114 S926 D205 S707
3 1 A611 RL
A402
S921
7 4 5 6 7 4 5 6 4 1 1 6 233 005-a 114

300 2 1 S510
B5 B6 B7 8 1 2 3 8 1 2 3
12
330
1 7
5 8 5 8 E5 E6 E8 E0 T8
BW B BrG LP B
F003 F002 F001
271 255 168
B0
CAN
(RESISTER) E/G IDLE TORQUE E/G OIL LIFT LOWER
4 1 4 1
SELECTION SELECTION PRESS. Hi-BEAM HEAD LAMP WIDTH LAMP NEUTRAL BUZZER KICKOUT KICKOUT
T7 T6 RELAY RELAY S/W RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY
4 1
THROTTLE PEDAL
6 4 168
T607
R B LP
GyY GyW BL G
H734 H724 H713 Y V O 271 255
6
CAB 1 3 2 C0 736 737 741 B T706 T708
S2S BW BrG
H707 PG PW YV BLg BrW O 2
RGy RB G WBr RLg O H715 H705 H725 R B G 3
H733 H723 Y
B208 A611 D107 D604 B108 D610 739 740 734 735 733 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2
S2L S2H 520 F604 010 022 521 020 V 3 4 6
Y B BrG BL BW BrG SbY SbR Sb SbP Gy GyR RW R R R R R G L Lg Lg BrB L BrR L
E401 H708 H709 PB PL OR OL S813 S922
531 S720 S729 H714 H713 1 3 H711 S608 H704 S509 S816 H721 H108 D108 D108 D108 D108 D108 D102 D205 D103 D103 G302 D205 G402 D205
531 H722 H732 D609 D608 271 255
500 506 H712 018 738 741 209 208 205 202 750 751 308 001 001 001 001 001 014 005-a 013 013 257 005-a 272 005-a
2 1 2 1 B LP RY RY RW
4 1 B B B B B B RY RY RB RB RL SbP LgSb LgBr B BrB B L
S915 A813 F504 B912 F402 B915 C305 B914 H710 S618 G601 S609 S611 S610
7 12 DATA LINK 168 H118 305 304 305 302 H129 301 H115 145 112 104 258 273
CONNECTOR 1 1 1 1 1 1 1 1 1 1
C1 C2 C3 C4 4 4 4 4 3 1 4 4 4 4 4 4
(BLACK) (BLACK) (BLUE) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLUE)
B
J C F0 F1 F2 F3 F4 F5 F6 F7 E7 T9 T0
CONTROLLER
FAULT H A D DOWNSHIFT CAB
HORN RELAY RELAY BUTTON ALARM
2 1 G E PILOT VALVE MAGNETS BUZZER
F
_ V BY BZ
+ S709 S707 KICK
INCHING 100 114 C7 SHIFT LEVELER OUT FLOAT 4
5 YG YG
SENSOR S
LgR 3 HOLD TURN D702 D702
S727
S/W SIGNAL HAZARD 025 025
166
2 YL
4 DIAG
(OPT) GL W
YO H706 S2S AIR-SUS. INC/DEC H102 D804
H716 H707 S/W H8 603 029
YL
B
3 2 3 2 R TO AIRCON
5
H123
2 2 GO W
T903
T003
3 3
BrW
BrR
250
257
BrB
272
S2L W R PG PW
G G LgW L 1 B B H112 D804
S914
A508 D205 H708 B303 B302 H733 H723 3 2 3 2 604 029

D107 D107 802 801 739 740 Br Br Br
1
010 010 102 005-a S2H OY D110 D110 D110 B P R BP G WY LR

G L BrG BL B909 D111 A101 D107
S707 S732
GW GL B LgW B D114 003 003 003 H730 D804

114 415
AIR TEMP. W H709 B304 B301 H714 H713 1

G
C9 H127 B801 S612 007 YSb B 1 1 1 320 004 A108 010 8 605 029
D506 6 804 803 738 741
PROBE 329 328 101 8 2 1 S917 (BLUE) LgSb B B 1
1 1 4 1 4 1 E704
(CONTROLLER)
BY
4 4 125 Br Br Br 112
7 G
(BLACK) (BLUE) 1 2 1 4 1 4 1
D107
2
010
BrW BrB BrR
F8 F9 T4 T5 C8 G0 G1 G9 G2 G3 G4 G5 G6 G7 G8
H1 H2
H7
H3 H4 H5 H6
B LP LBr LR
10 6 5 1 S517 S604 S613 10 6 5 1
140 325 308 404 311 172 003 603 100 149 148 146 703 C201 C202 C203 747 735 205 203 172 171
S507 A107 F404 A614 B108 S722 D110 H806 S709 LY LG LO LW 1 1 1 F704 T406 T405 T404 T403 C002 F203 S615 S722 S730 741
LLg RO RW YBr RLg SbY Br GL V S518 S502 S505 S508 RL S2H S2L S2S YL BLg Sb SbW SbY SbY C401
114 327 306 170 703 171 251 604 015 141 142 143 144 910 912 914 015 732 204 206 748 734 C404 C004
S707 A102 F403 S614 F704 S730 S826 H807 D101 D301 D401 D002 D101 A606 S534 T402 C001 G004 C309 F103 G001
1 4 R R R 901
BY RBr RY WR RL SbY BrR GO WR E201 WR BrW SbLg RLg YO YV BrG BL OR SbY
303 330 329 180 705 720 250 261 267 911 913 915 W C402
605 731 181 220 160 733 737 500 751
F604 S510 F804 S731 A503 A802 G202 S504 S501 D402 D901 D001 H808 A607 S811 S723 S716 C003 C005 G002 C307 F302
RB RL GW GyL WG BG BrW LgL GB R R R WY BrB BrY GyO Y BrW GyW PW PB GyR
707 331 312 162 754 182 012 221 266 705 730 720 752 159 012 736 C403 506 161
S724 S619 B208 B506 S625 S806 D105 S702 S801 A503 A605 A802 S708 D105 C006 G003 C308 S715
WL RG RGy LgG GyG LgL BW LgB GyB WG BrR BG GyR Y BW GyY PG PL W
40 36 35 31 40 36 35 31
634

CONTROLLER
A 1. 2S_SO A16. TT_L A31. 1/4_L B12. X_R E 1. SSR_SO E16. SPD E31. TT_SE C 1. 2S_SE C16. EP C31. BSL D12. SL_A
A 2. 2_SO A17. D_SO A32. FR_L B13. F_SO E 2. FC_SO E17. BATT E32. OT_SE C 2. DSUB2 C17. F C32. EG_M D13. SS_N
A 3. ES_R A18. 1_SO A33. 3/4_L B14. B_SO E 3. KEY E18. CANL1 E33. OUT_RSE C 3. DSUB4 C18. ASUB1 C33. DD_S D14. KD
A 4. DD_SO A19. EP_L A34. EG_SW1 B15. EG_SW2 E 4. KEY E19. SS_P E34. ET_M C 4. BSL- C19. ASUB2 C34. AFR D15. INCH_S
A 5. 3_SO A20. AB_L B 1. H_SO B16. RIN1 E 5. GND E20. CANLO C 5. TT C20. 1/2 D 1. PRK D16. OD_SW
A 6. HM A21. A_L B 2. PWM_SO B17. OUT_MD2 E 6. GND E21. TM_M C 6. AC C21. 1/8 D 2. AM_SW D17. SH
A 7. LU_SO A22. 1/2_L B 3. IP_SO B18. N_R E 7. GND E22. B_SE2 C 7. ET C22. 2S D 3. SL_2 D18. SS_SW
A 8. 4_SO A23. E_L B 4. R_SO B19. BR_L E 8. GND E23. WT_SE C 8. BL C23. EG_H D 4. SL_R D19. SS_F
A 9. OTH_OUT A24. SS_L B 5. MO_SO B20. CAN_R1 E 9. +5V E24. ALT C 9. BD C24. IP_SW D 5. SL_3 D20. TMP
A10. R_L A25. SC_SW B 6. FR_SO B21. CAN_R2 E10. TGEG E25. RXD1 C10. DSUB1 C25. FR D 6. S_UP D21. INCH
A11. F_L A26. TF_L B 7. SSL_SO B22. DOUT1 E11. KEY E26. TGSP C11. DSUB3 C26. KO_P D 7. S_DOWN D22. KO_S
A12. ST_L A27. AC_L B 8. BSL_SO B23. OUT_FEW E12. KEY E27. INCH_SE C12. DR C27. ES_SE D 8. EG_SW D23. SC
A13. WL_L A28. BP_L B 9. BZ B24. MT E13. CANH1 E28. SC_P C13. BSL+ C28. 3/4 D 9. M_SW D24. AR
A14. CW_L A29. N_L B10. BSL_R B25. ET_SE E14. EGR2 E29. CANHO C14. TF C29. 1/4 D10. SL_1 D25. SM_SW
A15. ET_L A30. SC_L B11. KO_R B26. TXD1 E15. EGR1 E30. B_SE1 C15. WL C30. DC D11. SL_F D26. SS_R
SPEEDMETER 192 173 135 235 204 811 115 400 754 118 166 H701 180 415 116 401 251 240 105 260 223 165 255 230 111 233
RATIO ODOMETER A/M A708 A506 A807 A808 A604 H117 H703 T104 T301 F701 H139 E003 C202 A602 H104 H727 H140 T304 A302 A202 E503 G101 F001 S301 G901 A001 E005
H201 749 169 130 224 170 203 810 119 145 331 234 402 H702 220 707 117 265 200 222 124 168 110 125 231 232
T801 241 103 753 190 149 208 104 273 258 101 146 005-C 005-D 161 160 010 C702 181 106 271 750 121 126 120
267 H202 242 261 H203 403 140 H204 202 148 225 237 236 221 005-A 005-B 159 H101 266 182 164 109 122 128 123
S925 S916 S902 T101
111 110 109
1 1 1 100
1 9 1 7 1 9 1 9 1 7
(BLUE) (BLACK)
C701 E007 114
C902 H120
S2 S3 S4 S5 S6 S7 E801 T102 S8 S9
T3 T1 T2
3 1 4 1
YB YG YBr GL V 1
S623 S733 S617 S616 S709 B
115 116 119 810 100
YL YO B GR BY
FUSE BOX(MAIN) S725 S626 S622 S707 R Y
FUSE BOX(CAB) 117 118 811 114 S812 S830
R5 R5 R5 106 105
4 6 3 2 3 2
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 REWRITE
003
G301
G401
H103
5
5
W R Y B G Br L O R
5
R
5
5 5
8 14 4 6
F502 B202 G702 B102 T501 005 H301 H302 E104 E202 OL OR O YG 3 2 R R
F503 B207 004 B107 007 910 911 062 T407 C310 C309 C301 H804 H402 H501
F603 H134 F703 H111 H401 E107 E101 E106
001 H735 014 H720 D2 912 065 064 063
R WBr W/LR R
E302 C303 H502
7 C304 A207 1 3 1 021 022 915
F802 A307 1 4 1
1 3 4 5 6 5 1
F803 A610 2 H801
G501 L
A706 L L L L L H802
G802 E601 E008
S703 S704 S711 S712 F702 B504 H803
S717 E702 005-A 005-B 005-C 005-D F902 005-b 029
010 E703
T902 D6 D7 D8 D9 D0
D1 013 T002 D3 D4 D5
005-a
635

40 36 35 31 40 36 35 31
HYD. OIL
COMBINATION 303 Br 331 Y L Br L R G G BrR GyR L GyY PG PL W
M704 R605 R102 M101 M601 L806 P606 P501 L603 P743 P742 M901 P701 P724 M803 P741 TEMP.
LAMP K106
K501 303 R104 707 R705 312 162 754 182 012 221 266 730 752 159 736 739 506 161 SENSOR
Y K106 R606 Y Y Y L Br Br G G G WY BrB L G L BrW GyW PW PB GyR
1 4
Y K101
K502 325 R706 K107 M501 N903 P601 K206 K204 L501 R R R P201 P744 M401 L701 M902 P722 P711 P725 M802 P749 HYD. OIL
329 180 705 720 250 261 267 N201 N201 N201 141 142 143 144 605 731 181 220 160 733 737 740 500 751
L 327 Y Br L G GO WR 911 913 915 W J302 J402 J502 J602 WR BL YO YV BrG BL OR SbY LEVEL
R103 K103 K102 N904 M203 K205 L804 P605 R R R
N101 L L L L P739 P734 P720 P709 P702 P734 M801 P713 S/W COMPRESSOR
K503 R602 R701 306 703 171 251 604 015 901 149 148 146
B R702 N201 N201 N201 015 741 748 734 738 741 019 209
325 Y Gy Y L R GL L 910 912 914 J702 J202 J102 S2H S2L S2S YL BLg Sb
330 L
K101 K108 J801 K105 M303 K201 L803 8 B L L 5 P901 P902 P903 P710 P723 P731
K203 R601 308 404 311 172 003 603 1 1 1 747 735 205
FRONT HEAD 2 L601 10 6 5 1 10 6 5 1
M201 H2
LAMP(OUTSIDE) M301
K108 K102
K202
308 306
R M502 H7
Y
K3 L602
B M602 M202
B
P502 M302
W 114 H1 H3 H4 H5 H6 OR
Y
100 2 1
1 Br
PB OR
WORKING LAMP 3
H730
F H722 H712
(INSIDE) WASHER 500 019 G L L
K4 311 H727 P502
8
8
Y K105 T/M SOLENOID VALVE MOTOR PB 220 114
H728
WY
M8 1 2
181
H119 H118 H109
H106 H129 H127 H108

(OPT)
K401 K501 K601 K303
K901 K801 329 K003
K802 K302 K502
PL
308
327 K002 325
327 306 325
311 303 329 308

B + 4 3
EFFICIENT EFFICIENT
Y
Y
329 L B J1 B PL
HORN(L) Y LOADING LOADING _
F + H205 R H732
306
K601 SYSTEM(ELS) SYSTEM(ELS) 146 506

Y
Y
K1 _
SOLENOID OIL PRESS. 2 1 (BLUE) B L7 M4 P2
311 303
VALVE SENSOR
Y
Y
B 1 2 2 1
+ GROUND SPEED
329 K7 329 B B Y K6 SENSOR
L B
B
Y
HORN(H) Y
K701 K107 _ J2
K601
K703 329 R + H206
_ 148
4
+ _ L L M9
5
5
2 1 H726 H736
1 1 160 159
B 3 3 10 6 5 1 1 5 6 10
S 2 1
R L L L L R + YL YV BrG GyY
L103 L201 L202 H120 H101 H103 G B H706 H715 H714 H734 1 2 3 4 5 6 7 8 9 10
WORKING K9 311
003 100 114 114 100 003 K2 H121 _ L B J3 747 734 738 736
Y K105 267 1 + H201
LAMP G G G G G G CAN YO SbY GyW
L102 L203 L401 H122 H113 H123 1 2 G _ 141
(INSIDE) B
250 251 261 261 251 250 H131 2 1
(RESISTER) H716 H711 H724 11 12 13 14 15 16 17 18 19 20
748 209 737
266
6 4 4 6 1 P7 PW PG BLg BrW
L L
FRONT HEAD 2 H120 H101 P746 H723 H733 H705 H725 21 22 23 24 25 26 27 28 29 30
+ 740 739 735 733
LAMP(OUTSIDE) 114 100
L B J4 P737 H709 P9
K108 K102
S2H WR S2S BL Sb
308 306
R _ H707 P747
2
Y
K0 1 2 + H202 H720 P903 H713 H704 31 32 33 34 35 36 37 38 39 40

B 142 S2S H708 015 H717 205
B
_
W 2 1 S2L GyR S2L S2H BrB BrR GyR W
Y
1 L5 L6 2 H721 P902 P901 H729 H739 H737 H731 41 42 43 44 45 46 47 48 49 50

751 731 730 752 161
L8 M1 M2 M3 + 50 46 45 41 41 45 46 50
COMBINATION L B J5
_
LAMP 3 + H203
K801 303
1 6 _
143 1 4
Y K106
B L 2 1 2 1 2 1 B G
K802 327
H135 2 1 M001 4 1
Y K103
B L L L L L P8 M002
182
B H137 H101 H120 H101 H120 B G
162 100 114 100 114 +
M001 3 2
B
K803 L L _ L B J6 M002
GL GO H114 H104 4 + H204 2 3
H102 H112 172 171 _
144 ECM
603 604 2 1
3 4 P1
BUCKET 3 4
LEVELER R 603 604 +
S S
Br K201 L902 L903
003 L1 GL GO _ L B J7
G B _ _ D + H207
2
+ + 149 1
L B K206 L901 PARKING _ B G
250 B 2 1
SOLENOID P501
1 182 221
2 R2 312
L002
Y R102 REAR
B L
1 6 BRAKE OIL PRESS. WORKING
B LAMP
1 (MAIN) 4 1
BOOM ANGLE L 1 303
SENSOR C L201 1 R501 R3 312 REAR
100 L3 L L
Y B Y R102
L301 G G K202 L2 WORKING
G 100 100 330 R301
B L203 L302 K205 L0 012 R401 R201 B LAMP
251 L 251 251 L L9 R FAN SPEED Y Y
L L303 K203 3 2
114 114 1 P606 BG CONTROL
1
A L202 2
114 2 N6 P601 3 2
3 L802 SOL. VALVE Y Y
R103
720
330
B HEATER
Y
H128 H138 R4
2 1 603 604 330 312 BACK UP
L803 L804 P0 RELAY
702 Y B ALARM
RIDE CONTROL SOLENOID GL GO
B
L806
STARTER H129
182
BW
B
L
2 3 N501 303
C 4 1
AIRCON
2
AIR
2
B R
B
N502 HEATER R1 R501
R8 R104 Y
G LICENSE
N2 R502 B LAMP
2
L401
R
261 B B
N1 FUSIBLE
N3
L4 LINK
1
FUSIBLE BATTERY
261 G N7 LINK RELAY
R801
2
K204
B R901 261 MAGNETIC RH
70A
70A
R9 S/W N8 BATTERY
1
702
BW 701 30A 1 2 1 2
G R 1 2 _
AIR N501 3 N502 VOLTAGE 221 114 P803 P803
L401 WV B P101 L702 P804 P804
261 CLEANER 2 RELAY 1 G L G G +
70A N403
1
1 700
4
2 3 R LgB BY G G
H301 H132 H120 N002 N002
FUSE H302 G L 036 036
FUEL LEVEL H401 1 2 1 2
T/M E/G 1
RL WG
4 WG B B Br H402 REAR
OIL TEMP. WATER TEMP. SENSOR N903 N901 P5 M0 COMBINATION
6
N904 H501
4
N903 30A
704 706 H502
SENSOR SENSOR 703 704 705 LAMP(R.H)
H109 H129
H128 H139
325 303
330 331
910~ N4
Br
R
(CONTROLLER) (CONTROLLER) 6 1
B
915 R6
M7 012 720
N601 N602
ALTERNATOR 1
W
4 1 R Br
Y
Y
Y
702 700
N702 703 706 N301 015 708
N701 N804 WV N401 N402
BW
3
1
Br Br WR Br REAR
701 N801 2 1 015 708
COMBINATION
6
N703 P605 P602
4
N704
R 705 B WR Br B LAMP(L.H)
E B 2 3 2 4 3
H119 H129
H128 H139
R l 1 2
327 303
330 331
Br
B
R
086
B
Y 4 3 R7
R 3 2 G 900 901 900
Br B B
P002 706 M001 W W W
Y
Y
Y
B 701 H125 708 M002 N303 H601 N102
N901 BW 705 Br W N001
H140 Br WR Br
P001 N101
3
H111 N901
1
2 4 1 702 H115 M704 086 015 708
B 703 P602
4 1 R Br
L L Br L 706 1 H134 H124
H126 H120 H136 H120 Gy 707 012 720
180 114 754 114 Br 6 1 LH
H107 DIODE
1 2 1 2 404 BATTERY
1 N5 N9 N0 UNIT _
P6
+
M5 M6 J8
636
Electrical Connection Diagram 70ZV-2 (1/2)

STARTER S/W
B BR ACC R1 R2 C
ACC’ (L) (005-b) E
TO PARKING SW.
PREHEAT (005)
F5 L
2
(L) (005-a)
OFF
30A
ON
G (010)
START F10
E
(086) (900) 12V 12V ACC’ L x4 (005-A~005-D)
5
W [W ] 100
30A
E05 E06 E17 E04 E12
BATTERY E03 E11
(060) (901) (SbP) (145)
W [W 5 ] E24
LgW (101)
R1 BR
WR
1.25 F15
R2 C 5A WV LBr (128) L (273)
(700) F N R B10 BS
A32
LEVER
SHIFT
(062) (064) (063) (LgB)(224)
BW G
1.25
WR
1.25
BATTERY A03 M
F12
F14
F13
15A
5A
5A
1 (146) LR
(012) (014) (013)
LW (120)
BW G
1.25 (Lg) D12
LO (123)
D05
70A
B C
100 LG (122) (148) LBr
5
[R ]x6 LY (121) E09(+5V)
D10 (141) LY
~ MAGNETIC S/S POTENTIOMETER (OPT) B09
LgBr (104)
BZ BUZZER
915) S/W (702) F YO (232) G (234)
E19
5
[R ] (701)
5
[BW ] VOLTAGE D19 (LY )
RL
1.25
(703) WG (704) D26 (142) LG
C26 E34
(YB ) (401)
NR
DECLUTCH SENSOR
LG (122) (LG) (LgR) (166) (BrW) (402)
(Lg) (WG) (707) LY (121) (143) LO
SbY (171) E30 (400)
WL1.25 (LO)
S/S SHIFT YV (231)
D18 (144) LW SbY (172) E22
20
70A B LB (230)
(LW)
DOWNSHIFT SW. D14 A17 OIL PRESS. SENSOR (OPT) GyB (266)
C01
PREHEAT
LAMP WR (170)
(720) LP (168) LLg (140)
15 15 A04
(G) (415)
SELECTION SOL. VALVE (OPT) A09 TC E/G TORQUE SELECTION
BY (114) SbLg (204)
B06
GROUND SPEED SENSOR E16
M
100 EMERGENCY REVERSAL FAN SW. W(161)
M STEERING PUMP
Lg (222)
C25
(OPT) (RL ) (330)
(OPT) LgY (223) BR (236) Y(159) A10 TO BACK-UP LAMP
AUTO FAN C34 E01 S/S SOLENOID VALVE R (OPT) E08 (RG) (331)
REVERSAL SW. (OPT) B19 TO BRAKE LAMP
BL (237)
(R) (106)
LLg (165) (E09) V
D21 +5V
(013) YB (115)
E F13 GO (164)
DECLUTCH F13 YG (116)
(LgR) (130) YL (117)
CUT-OFF (Lg) C23 A21 AUTO SHIFT INDICATOR LAMP (RXD0)E25 RXD CONTROLLER RENEWAL
GL (265) (GR ) (135) YO (118)
YO (176) (GyW ) (260)
C33 (GyB ) (103) E (OUT_MD2)B17
YBr (119)
MD2
(LgY) (167) EP (LgY) (173) P (107) GND
E
(Gy) (749)
PL (108)
C03
BrY (181) (GyG) (753) PG (109) GL (810)
(163)
(GyL) (190) PB (110) GR (811) RS232C
ON (SbW) AIR CLEANER LgL (182) A16 T/M OIL TEMP. WARNING LAMP ODOMETER SELECTION (DOUT1)B22
D16
C06 (LgW) (192) PW (111)
(162) (CANH0)E29
PARKING SOL ON (005-b) (O ) (241)
LgG
(L) E A12 D08 (CANL0)E20 CAN
OFF
S2S

E MAIN CONTROLLER E
15 5A 30 20A
14 5A 29 20A
13 5A 28 10A
12 15A 27 5A
EFFICIENT LOADING SYSTEM SW. (OPT)
11 10A 26 5A
10 15A 25 20A
FAILURE
7 10A 22 3A
(LgSb) (112)
BZ
5 30A 20 10A
GAUGE (404)(YBr)
3 10A 18 5A
E
2 15A 17 5A ECM
1 20A 16 5A 36 30A
637

COMBINATION J3
(001) S/W F3 (086) (036)
F1 Br (003) BrB (257) F36
R
1.25
RB (301) BOOM KICK-OUT 3
[W ]
3
[G ]
LT LT 10A KO 4 1
20A RY (302) 30A
LH LH 3 2
RW (304) EL
HU
UL
B
BrR (272)
HL FLOAT E
BS
J2
(015)
WR
LT F15 39 (730) STOP (013)
LICENSE LAMP BrW (250) (BrR) (Lg)
BUCKET LEVELER 43 F13
(BrB)
21 44
RELIEF INDICATOR LAMP OPT
26
RB
(303)
MACHINE WIDTH LAMP
THROTTLE PEDAL
TAIL LAMP (161) W
THROTTLE OPENING 41 (E15)
SENSOR BrW (733)
TAIL LAMP 22
YV (734)
9 (751)
C AIR-SUS. 23 49 EP
IDLE SW GyR
42
1
(RB) PANEL LIGHTING F20
(300) O (020)
10A GyW (737)
CHARACTER IDLE
11
DISPLAY
S2H
TO
RADIO KEY GND S2L
CANH0 S2S
S2L BrG (738)
CAN CANL0 2
S2S RESISTER
(307) HIGH BEAM PL
(RY) INC/DEC SW. B
(060)
RESISTER (m) 24 B
RY
RY 25 46 C
LH F10 47 D
(308) 37 E
RW BL (741) (YL) (747)
(006) (310) RLg (521) (Y0 ) (748)
13 A
RLg (311)
TO CAB 19
(002)
F2 R
1.25
3
15A
RGy (312)
REAR WORKING LIGHT
REAR WIPER MOTOR
F19 OR (019)
LIGHT S/W 10A (501)Y L (503)
TO CAB REAR
(330)
(502)W
S2 S3
WIPER S/W
E/G ECM Connection Diagram
RL WASH B
(A10)
1 5 3
WASHER INTER-
PB WIPER
(331)
RG
M 4 RELAY
(B19) WIPER MOTOR
M R WIPER
(004) 5A (507) GY GR (508)
F4 R E WASHER
15A MOTOR (506) B S1 S2
PL
FLASHER UNIT M WASH
(WINKER) WIPER S/W

ACC’ B
E
L
(324)(RO)
(320)
P COMBINATION (325)
RO
TR
TB
B TL
RBr OPT
(010) (327) F22 (WBr ) (022) (510) Gy
W
(326)(RBr) G (010)
(HAZARD) F10
(513) WB
B
E
B L
(323) BP
DC-DC
F21 R
2 2
+ + Y
(329) GW 15A CIGAR SOCKET
OUT
HORN
IN
2 (12V)
(328) (GL )
- - B
HORN RELAY HORN S/W
TO RADIO/ROOM LAMP
TO CONTROLLER (E17)
CAB
ACC’ E
638
Electrical Equipment Layout 70ZV-2

Front chassis
Bucket leveler (K1)
Head lamp (K0) Head lamp (K3)

Ground Ground
Horn
Boom angle
sensor (L3)
For ride control

(option)
To rear chassis
(K1/K2) To rear chassis (K1/K2)
LH Top view RH
639
70ZV-2
Rear chassis
To front chassis
To front chassis
Transmission solenoid valve (J1-J7)
Parking brake
solenoid valve (M1) Hydraulic oil temperature sensor (L7)
To floor harness Rear to floor ground
To floor To floor ground

A-A
Brake oil pressure

sensor (M2/M3)
To floor A A
Air conditioner
condenser (L9) Transmission oil
temperature sensor
(M5)
Speed sensor
(automatic gear)
Ground Engine ground (M9)
Washer tank (M8)
(option)
Air cleaner (L0)

Air heater
Engine water
Ground
Starter ground temperature
to engine body sensor (M6)
Rear chassis ground, Air conditioner

Alternator ground Alternator (M7) compressor (P2)
ECM Rear chassis

Fuel level ground
sensor (J8)
Battery ground
To rear grill
Fan speed control
solenoid valve (P1)
Top view RH
LH
640
70ZV-2
20 Red 15 BK
Magnetic To ground
switch (N7)
100 Red E Terminal
Starter 5 Red 5 BK & White G Engine body
15 BK
(Red tape) 704 703 100 BK
012 BK White & Red &
& White Green Blue
Heater B
Fusible Fusible relay Rear
B Terminal
link (N1) link (N2) (N6) chassis
( + Mark) ground
15 BK Voltage relay (N8)
Fuse Air
(ECM)
70A 30A 70A 70A
BK x 2 heater Battery relay 100 Red
(N3) 1 4
720 2 3
Brown 704 706 To rear chassis

5 White 5 705 BK BK Brown harness
C Terminal
3 White White 5 Red 5 BK &
Brown To battery relay
Alternator wiring White
White & harness
(N0) Violet
20 BK 5 Red x 6
( + Mark) 5 White 100 2 poles 4 poles

Red
Diode
unit (N4)

To battery (+) To rear Mark: Connected to black cable 4
To rear chassis harness chassis harness
F 3
Engine relay unit wiring Rear working lamp connection
R
2 1

Fan speed control

solenoid valve (P1)
To air heater
To battery (+)

To starter
Relay unit wiring Radiator guard and fan wiring

(View from rear)
641
70ZV-2
Floor board
To rear ground
To control box
Red tape Green tape
Accelerator pedal
(C0) Blue tape
(C9)
Efficient loading system Ride control (option)

(Floor ground) (option)
tape
Declutch switch
(B0)
To operation stand
To rear
Top view
Horn switch
(B8)
Combination switch
(B9)

(B7)
Parking switch
(B5)
Front
642
70ZV-2


To floor harness

Fuse box (cab)
Fuse box (main)

Buzzer (G6)

RS232C



Odometer selection
To pilot
valve

Power (option)
To air conditioner
643

MODE LOADING 1 1
2 2
4
5
4
2 2 6 6
3 3 DECLUTCH SW
HAZARD
4 4 1
2
5 5 3 C AC TT + ES FR EG2 EG1 EG3 SS WTM TTM + N A AB SM SM TC PH WL HM
6 6
_ 7 4 5 6 7 4 5 6
4 F/R S/W
GND
7 7 6 8 1 2 3 8 1 2 3 SELECTION
5 8 11 20 7 12 9 16 5 8 5 8
753 749 173 102 C305 404 141 142 143 144 163 103 307 326 324 006 H106 002 H138
S506
YSb
403
H740 192 190 013 241 235 731 732 730 224 401 402 013 135 130 169 400 167 H738 B201 006 310 002 310 231
5 8 5 8 5 8 5 8
RO
B911
RO
A815
BP
G803
Lg
D103
Lg
D103
LgY
A803
B 4 1 10 1 6 1 8 1 1 4 1 4 1 1
A
321 H109 323 013 013 167 A5 A6 A7 A8 A9 B1 B2 A0
B910 A814 G803 S823 S822 B001 B3
BW R1 WRx2
BR S/W IN OUT
R2 804 803
BG C G
C804 C801
3 5 802 801
W R
W R B B Y
BG WB WB D605 C102
021 531
P RBr RO RW B RB RY
GW GL GY G703 A103 A106 F401 F601 F501 2 1 2 1
F801
320 322 321 304 301 302 WR WR W
D506
PARKING G B
D501 D503
063 065 060
S/W W E3 E4
BW G
GL
H601
D504 D502 901
L GR GB B 8 1 062 064
G 1
Y
R B8 B9 4 1
B
E1 E2
LIFT KICKOUT
DECLUTCH SET-UP/ EMERGENCY
L G SET UP
126 128
DECLUTCH FAN S/W CONTROL S/W V YGy
F/R SWITCH/ LAMP
4 6 LW B 1 S709 S503
L LgG S912
2
3 SET-UP 3 2 100 242
1 STICK STEERING
D206 H137 4
6 222 225 240
GO SbW B S910 S903 S905
3 260 S607 S701 S719 S709 S919 S924
YO
B LgY BY
LLg
S901 A712 121 122 123 B Lg 237 236 234 100 232 230
164 163 RB S834 D103 S707 YW B L BY
3 1 223 013 114 S926 D205 S707
3 1 A611 RL
A402
S921
300 7 4 5 6 7 4 5 6 4 1 1 6 233 005-a 114

2 1 S510
B5 B6 B7 8 1 2 3 8 1 2 3
12
330
1 7
5 8 5 8 E5 E6 E8 E0 T8
BW B BrG LP B
F003 F002 F001
271 255 168
B0
CAN
4 1 4 1
4 1
THROTTLE PEDAL
6 168
4 T607
R B LP
GyY GyW BL G
H734 H724 H713 Y V O 271 255
6
CAB 1 3 2 C0 736 737 741 B T706 T708
S2S BW BrG
H733 H723 Y
B208 A611 D107 D604 B108 D610 739 740 734 735 733 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2
S2L S2H 520 F604 010 022 521 020 V 3 4 6
E401 H708 H709 PB PL OR OL S813 S922
S720 S729 H722 H732 D609 D608 H714 H713 1 3 H711 S608 H704 S509 S816 H721 H108 D108 D108 D108 D108 D108 D102 D205 D103 D103 G302 D205 G402 D205
531 738 741 271 255 209 208 205 202 750 751 308 001 001 001 001 001 014 005-a 013 013 257 005-a 272 005-a
2 1 500 506 H712 018
2 1 B LP B B B B B B RY RY RW RY RY RB RB RL SbP LgSb LgBr B BrB B L
4 1 S915 A813 F504 B912 F402 B915 C305 B914 H710 S618 S611 S610
7 12 DATA LINK 168 302
G601 S609
H118 305 304 305 H129 301 H115 145 112 104 258 273
CONNECTOR 1 1 1 1 1 1 1 1 1 1
C1 C2 C3 C4 4 4 4 4 3 1 4 4 4 4 4 4
B
J C F0 F1 F2 F3 F4 F5 F6 F7 E7 T9 T0
CONTROLLER
F
_ V BY BZ
+ S709 S707 KICK
LEVELER FLOAT
DECLUTCH 100 114 C7 SHIFT OUT 4
5 YG YG
SENSOR S
LgR 3 HOLD TURN D702 D702
S727
166
2 YL
4 DIAG
(OPT) GL W
H716 H707 S/W H8 603 029
YL
B
3 2 3 2 R TO AIRCON
H123
2 2 5 GO W
T903
T003
3 3
BrW
BrR
250
257
272
BrB
S2L W R PG PW
S914
A508 D205 H708 B303 B302 H733 H723 3 2 3 2 604 029

D107 D107 802 801 739 740 Br Br Br
1

G L BrG BL B909 D111 A101 D107
S707 S732
GW GL B LgW B D114 003 003 003 H730 D804

114 415
AIR TEMP. W H709 B304 B301 H714 H713 1

G
C9 H127 B801 S612 007 YSb B 1 1 1 320 004 A108 010 8 605 029
D506 6 804 803 738 741
PROBE 329 328 101 8 2 1
S917 (BLUE) LgSb B B 1
1 1 4 1 4 1 125 E704
(CONTROLLER)
BY
4 4 Br Br Br G 112
7
(BLACK) (BLUE) 1 2 D107 1 4 1 4 1
2
010
BrW BrB BrR
H1 H2
H7
H3 H4 H5 H6
B LP LBr LR
10 6 5 1 S517 S604 S613 10 6 5 1
140 325 308 404 311 172 003 603 100 149 148 146 703 C201 C202 C203 747 735 205 203 172 171
114 327 306 170 910 912 914 015 204 206 748 734 C404 C004
703 171 251 604 015 141 142 143 144 732
S707 A102 F403 S614 F704 S730 S826 H807 D101 D301 D401 D002 D101 A606 S534 T402 C001 G004 C309 F103 G001
1 4 R R R 901
BY RBr RY WR RL SbY BrR GO WR E201 WR BrW SbLg RLg YO YV BrG BL OR SbY
303 330 329 180 705 720 250 261 267 911 913 915 W 731 181 220 160 733 737 C402 500 751
D402 D901 D001 605
F604 S510 F804 S731 A503 A802 G202 S504 S501 H808 A607 S811 S723 S716 C003 C005 G002 C307 F302
707 331 312 162 754 182 012 221 266 705 730 720 752 159 012 736 C403 506 161
40 36 35 31 40 36 35 31
644

CONTROLLER
SPEEDMETER 192 173 135 235 204 811 115 400 754 118 166 H701 180 415 116 401 251 240 105 260 223 165 255 230 111 233
H201 749 169 130 224 170 203 810 119 145 331 234 402 H702 220 707 117 265 200 222 124 168 110 125 231 232
T801 241 103 753 190 149 208 104 273 258 101 146 005-C 005-D 161 160 010 C702 181 106 271 750 121 126 120
267 H202 242 261 H203 403 140 H204 202 148 225 237 236 221 005-A 005-B 159 H101 266 182 164 109 122 128 123
S925 S916 S902 T101
111 110 109
1 1 1 100
1 9 1 7 1 9 1 9 1 7
(BLUE) (BLACK)
C701 E007 114
C902 H120
S2 S3 S4 S5 S6 S7 E801 T102 S8 S9
T3 T1 T2
3 1 4 1
YB YG YBr GL V 1
S623 S733 S617 S616 S709 B
115 116 119 810 100
YL YO B GR BY
FUSE BOX (CAB) 117 118 811 114 S812 S830
R5 R5 R5 106 105
4 6 3 2 3 2
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 REWRITE
003
G301
G401
H103
5
5
W R Y B G Br L O R
5
R
5
5 5
8 14 4 6
F503 B207 004 B107 007 005 910 911 062 T407 C310 C309 C301 H804 H402 H501
F603 H134 F703 H111 H401 E107 E101 E106
001 H735 014 H720 D2 912 065 064 063
R WBr W/LR R
E302 C303 H502
7 C304 A207 1 3 1 021 022 915
F802 A307 1 4 1
1 3 4 5 6 5 1
F803 A610 2 H801
G501 L
A706 L L L L L H802
G802 E601 E008
S703 S704 S711 S712 F702 B504 H803
S717 E702 005-A 005-B 005-C 005-D F902 005-b
010 029
E703
T902 D5 D6 D7 D8 D9 D0
D1 013 T002 D3 D4
005-a
645

40 36 35 31 40 36 35 31 HYD. OIL
COMBINATION 303 Br 331 Y L Br L R G G BrR GyR L GyY PG PL W TEMP.
LAMP M704 R605 R102 P503 M601 L806 P606 P504 L603 P743 P742 M901 P701 P724 M803 P741
K106 SENSOR
K501 303 R104 707 R705 312 162 754 182 012 221 266 730 752 159 736 739 506 161
Y K106 R606 Y Y Y L Br Br G G G 4 WY BrB L G L BrW GyW PW PB GyR COMPRESSOR
K502 325 R706 K107 M501 N903 P601 K206 K204 L501 R R R
1
P201 P744 M401 L701 M902 P722 P711 P725 M802 P749 HYD. OIL
Y K101 329 180 705 720 250 261 267 N201 N201 N201 605 731 181 220 160 733 737 740 500 751 LEVEL
W 141 142 143 144
L 327 Y Br G GO WR 911 913 915 J302 J402 J502 J602 WR BL YO YV BrG BL OR SbY
R103 K103 K102 N904 K205 L804 P605
N101 L L L L P739 P734 P720 P709 P702 P734 M801 P713
S/W
R602 R R R
B
K503 R701 306 703 251 604 015 N201 N201 N201 901 149 148 146 015 741 748 734 738 741 019 209
R702 910 912 914 J702 J202 J102
330 325 Y Gy Y R GL L S2H S2L S2S YL BLg Sb L L
K101 K108 J802 K105 K201 L803 8 B L L L 5 P901 P902 P903 P710 P723 P731 M303 M203
K203 R601 308 404 311 003 603 1 1 1 747 735 205 172 171
FRONT HEAD 2 L601 10 6 5 1 10 6 5 1
M602
K108 K102
K202
308 306
R H7
Y
K3 P502 L602
H730
B 114 P501
B
W H1 100 H3 H4 H5 H6 OR Br
Y
2 1
1
PB OR
WY
WORKING LAMP 3 F H722 H712 G L
500 019 L
(INSIDE) K4 311 WASHER H727 P502 H728
8
8
K105 T/M SOLENOID VALVE 220 114
Y MOTOR PB 181
1
M8 1 2
(OPT)
H109
H108
K401 K501 K601 K303 PL
K901 K801 329 K003
K802 K302 K502
4 3
308
327 K002 325
325
308
B EFFICIENT EFFICIENT + P2
Y
Y
329 L B J1 B PL
HORN(L) LOADING LOADING _
Y F + H205 R H732
H118
H127
306
306
329
K601 SYSTEM(ELS) SYSTEM(ELS) 146 506
Y
Y
K1 _ L7 M4
SOLENOID OIL PRESS. 2 1 (BLUE) B
H119
H106 H129
311 303
327
311 303
VALVE SENSOR
Y
Y
B 1 2 2 1
+ GROUND SPEED
329
K7 329 B B Y K6 SENSOR
L B
B
Y
HORN(H) Y
K701 K107 _ J2
K601
K703 329 R + H206
_ 148
4
+ _ L L M9 10 6 5 1 1 5 6 10
5
5
2 1 H726 H736 YL YV BrG GyY
1 1 160 159 H706 H715 H714 H734 1 2 3 4 5 6 7 8 9 10
B 3 3
S 2 1 747 734 738 736
R L L L L R + YO SbY GyW
L103 L201 L202 H120 H101 H103 G B
WORKING K9 311 003 100 114 114 100 003 K2 H121 _ L B J3 H716 H711 H724 11 12 13 14 15 16 17 18 19 20
Y K105 267 1 + H201 748 209 737
LAMP G G G G G G 141
CAN P7
L102 L203 L401 H122 H113 H123 1 2 G _ PW PG BLg BrW
(INSIDE) B
250 251 261 261 251 250 H131 2 1
(RESISTER) H723 H733 H705 H725 21 22 23 24 25 26 27 28 29 30
266 740 739 735 733
6 4 4 6 L L 1 WR S2S BL Sb
FRONT HEAD 2 H120 H101 P746 H720 P903 H713 H704 31 32 33 34 35 36 37 38 39 40
+
LAMP(OUTSIDE) 114 100
L B J4 P737 H709 P9 015 H717 205
K108 K102
S2H
308 306
R _ H707 P747 GyR S2L S2H BrB BrR GyR W

2
Y
K0 1 2 + H202
142 S2S H708 H721 P902 P901 H729 H739 H737 H731 41 42 43 44 45 46 47 48 49 50
B
B
_ 751 731 730 752 161

W 2 1 S2L
50 46 45 41 41 45 46 50
Y
1 L5 L6 2
L8 J8 +
COMBINATION L B J5
1 4
_ B G
LAMP 3 + H203
M001 4 1
K801 303 1 6 2 _
143
M1 M2 M3 P8 M002
Y K106 1
B L 2 1 B G
K802 327 H135 M001 3 2
Y K103 B Gy
182 M002
B H107 1 1 2 3
404 + 2 2 ECM
K803 2 1
B _ L B J6 B L L L L L
P1
GL GO 4 + H204
P503 P501 P502 P501 P502
144
H102 H112 _ 162 100 114 100 114
603 604 2 1 L L
3 4
BUCKET H701 H702 2 1
3 4 171 172
R B Y B G
LEVELER 603 604 + P504
Br K201 L902 L903
003 L1 GL GO _ L B J7 221
G B D + H207
149 S S
L B K206 L901 _
250 B 2 1
1 182 + _ + _
2
L002 PARKING
B L SOLENOID
1 6 R2 312
REAR
Y R102
BOOM ANGLE
1 WORKING
L 1 FAN SPEED B
SENSOR C L201 1 BRAKE OIL PRESS. LAMP
100 L3 L L
CONTROL
G
L301
G G
K202 L2 (MAIN) 4 1 R3 312
B L203
100 L302 K205 100 L0 SOL. VALVE 303 Y R102 REAR
251 L 251 251 L L9 FUEL LEVEL R501 WORKING
L303 K203 012
L 114 1 SENSOR R
Y B B LAMP
A L202 114 330 R301
2 2 R401 R201
114 L802 P606 Br
3 Y 312
B N6 P601 3 2
2 1 720
1
603 604
L803 L804 P0 HEATER 3 2
702 Y Y
R103
RIDE CONTROL SOLENOID GL GO RELAY
330
STARTER
L806
BW
Y
182
H128 H138 R4
B
BACK UP
L
2 3 N501 330 312

AIRCON C Y B ALARM
2
B
B H129
N502 AIR 303
R8 B
HEATER 4 1
2
G
L401 N2
2
R1
2
261 B B FUSIBLE R501303 R104 Y

N1 N3 LICENSE
L4 LINK
1
FUSIBLE BATTERY R502 B LAMP

261 G
N7 LINK RELAY
R801 K204
2
B R901 261 MAGNETIC
70A
70A
R9 702 N8
1
BW 701 S/W 30A 4 1

G R VOLTAGE 1 2
L401 AIR N501 3 N502 221 M302 RH
2 RELAY WV B P101 M202 114
261 CLEANER G 100 BATTERY
70A 1 N403 L702 1 2
_
1
700 162 M301 P803 P803

1 4 M101 M201 P804 P804
2 3 R L BY G G
3 2 +
FUSE H301
H302 3 2
H401 G G
T/M E/G 1
RL WG
4 WG B Br
B N901 H402
L L
N903 H137 H120 N002 N002
OIL TEMP. WATER TEMP. N904 N903
704 706 30A H501 162 114 036 036
703 704 H502
SENSOR SENSOR 705
910~ G L 1 2
REAR
(CONTROLLER) (CONTROLLER) 915 N4 6 1 H132 H101
221 100 M0 COMBINATION
4
M7 012 720
N601 N602 4 1 LAMP(R.H)
H109 H129
H128 H139
ALTERNATOR 1 R
325 303
330 331
4 1 Br
Br
Y
R
B
B
702 700 R6
N702 703 706 N301 015 708 P5
N701 N804 WV N401 N402
BW Br Br WR Br
Y
Y
Y
701 N801 2 1 015 708
N703 N704 P605 P602
R 705 B WR Br B
3
1
E B R l 2 3 2 1 2 4 3 REAR
086 COMBINATION
4
R 3 2 G 900 901 4 3 900
Br B B LAMP(L.H)
P002 706 M001 W W W
H129
H139
303
331
H125
Br
701 708 M002 N303 H601 N102
R
B
Y
B
N901 BW
705 Br W N001 R7
H140 Br WR Br
N101
H119
H128
P001 H111 N901
327
330
H115 M704
W
1
Y
702
Y
4 086 015 708
703 P602
4 1 R Br
L L Br L 706 1 H134 H124
3
1
H126 H120 H136 H120 707 012 720
180 114 754 114 Br 6 1
1 2 1 2 DIODE
N5 N9 N0 UNIT P6 LH
BATTERY
_
M5 M6
+
646

STARTER S/W
B BR ACC R1 R2 C
ACC’ (L) (005-b) E
TO PARKING SW.
PREHEAT (005)
F5 L
2
(L) (005- )
OFF
30A
ON
G (010)
START F10
E
(086) (900) 12V 12V ACC’ L x4 (005-A 005-D)
5
W [W ] 100
30A
E05 E06 E17 E04 E12
BATTERY E03 E11
(060) (901) (SbP) (145)
W [W 5 ] E24
LgW (101)
R1 BR
WR
1.25 F15
R2 C 5A WV LBr (128) L (273)
(700) F N R B10 BS
A32
LEVER
SHIFT
(062) (064) (063) (LgB)(224)
BW G
1.25
WR
1.25
BATTERY A03 M
F12
F14
F13
15A
5A
5A
1 (146) LR
(012) (014) (013)
LW (120)
BW G
1.25 (Lg) D12
LO (123)
70A
B C D05
100 LG (122) (148) LBr
5 LY (121)
[R ]x6 E09(+5V)
D10 (141) LY
MAGNETIC S/S POTENTIOMETER B09
LgBr (104)
BZ BUZZER
915) S/W (702) F YO (232) G (234)
D19 E19
5
[R ] (701)
5
[BW ] VOLTAGE (LY )
RL
1.25
(703) WG (704) D26 (142) LG
C26 E34
(YB ) (401)
NR
DECLUTCH SENSOR
LG (122) (LG) (LgR) (166) (BrW) (402)
(Lg) (WG) (707) LY (121) (143) LO
SbY (171) E30 (400)
WL1.25 (LO)
S/S SHIFT YV (231)
D18 (144) LW SbY (172) E22
20
70A B LB (230)
(LW)
QUAD SW. D14 A17 OIL PRESS. SENSOR GyB (266)
C01
PREHEAT
LAMP WR (170)
(720) LP (168) LLg (140)
15 15 A04
(G) (415)
SELECTION SOL. VALVE A09 TC E/G TORQUE SELECTION
BY (114) SbLg (204)
B06
MACHINE SPEED SENSOR E16
100 M
EMERGENCY REVERSAL W(161)
M STEERING PUMP FAN SW. (OPT)
Lg (222)
C25
(RL ) (330)
(OPT) AUTO FAN LgY (223) BR (236) Y(159) A10 TO BACK-UP LAMP
C34 E01 S/S SOLENOID VALVE R (OPT) E08
REVERSAL SW. (OPT) B19
(RG) (331)
TO BRAKE LAMP
BL (237)
(R) (106)
LLg (165) (E09) V
D21 +5V
(013) YB (115)
E F13 GO (164)
F13 YG (116)
DECLUTCH C23 (LgR) (130) YL (117)
(Lg) A21 AUTO SHIFT INDICATOR LAMP (RXD0)E25 RXD CONTROLLER RENEWAL
GL (265) (GR ) (135) YO (118)
YO (176) YBr (119)
(GyW ) (260)
C33 (GyB ) (103) E (OUT_MD2)B17 MD2
(LgY) (167) EP (LgY) (173) P (107) GND
E
(Gy) (749)
PL (108)
C03
BrY (181) (GyG) (753) PG (109) GL (810)
(163) GR (811) RS232C
(SbW) (GyL) (190) PB (110) (DOUT1)B22
C06 (LgW) (192) PW (111)
(162) (CANH0)E29
(O ) (241)
LgG
OFF
S2S

E MAIN CONTROLLER E
15 5A 30 20A
14 5A 29 20A
13 5A 28 10A
12 15A 27 5A
EFFICIENT LOADING SYSTEM SW.
11 10A 26 5A
10 15A 25 20A
9 15A 24 10A RIDE CONTROL SW.
FAILURE
7 10A 22 3A
(LgSb) (112)
BZ
5 30A 20 10A
GAUGE (404)(YBr)
3 10A 18 5A
E
2 15A 17 5A ECM
1 20A 16 5A 36 30A
647

COMBINATION J3
(001) S/W F3 (086) (036)
F1 1.25 Br (003) BrB (257) F36 3
[W ] [G ]
LT LT 10A KO 4 1
20A RY (302) 30A
LH LH 3 2
RW (304) EL
UL HU
B
BrR (272)
HL FLOAT E
BS
J2
(015)
WR
LT F15 39 (730) STOP (013)
(BrB)
21 44
RELIEF INDICATOR LAMP OPT 26
RB
(303)
MACHINE WIDTH LAMP
THROTTLE PEDAL
TAIL LAMP (161) W
SENSOR BrW (733)
TAIL LAMP 22
YV (734)
9 (751)
C AIR-SUS. 23 49 EP
IDLE SW GyR
42
(RB) 1
PANEL LIGHTING F20
(300) O (020)
10A GyW (737)
11
MODM IDLE
S2H
TO
RADIO KEY GND S2L
CANH0 S2S
S2L BrG (738)
CAN CANL0 2
S2S RESISTER
(307) HIGH BEAM PL
(RY) INC/DEC SW. B
(060)
RESISTER (m) 24 B
RY
RY 25 46 C
LH F10 47 D
(308) 37 E
RW BL (741) (YL) (747)
(006) (310) RLg (521) (Y0 ) (748)
13 A
RLg (311)
TO CAB 19
(002)
F2 R
1.25
3
15A
RGy (312)
REAR WORKING LIGHT
REAR WIPER MOTOR
F19 OR (019)
LIGHT S/W 10A (501)Y L (503) ECM
TO CAB REAR (502)W WIPER S/W
(330) S2 S3
RL WASH B
(A10)
1 5 3
WASHER INTER-
PB WIPER
(331)
RG
M 4 RELAY
(B19) WIPER MOTOR
M R WIPER
(004) 5A (507) GY GR (508)
F4 R E WASHER
15A MOTOR (506) B S1 S2
PL
FLASHER UNIT M WASH
(WINKER) WIPER S/W

ACC’ B
E
L
(324)(RO)
(320)
P COMBINATION (325)
RO
TR
TB
RBr
B TL OPT
(010) (327) F22 (WBr ) (022) (510) Gy
W
(326)(RBr) G (010)
(HAZARD) F10
(513) WB
B
E
L
B
(323) BP
DC-DC
F21 R
2
Y
2
15A
+ +
OUT
HORN
IN
2 (12V)
(328) (GL )
- - B
HORN RELAY HORN S/W
TO RADIO/ROOM LAMP
TO CONTROLLER (E17)
CAB
ACC’ E
648
80ZV-2
Front chassis
Bucket leveler
(L1)
Head lamp Head lamp

(K0) (K3)
Ground Ground
Horn
Boom angle sensor

(L3)
For ride control

(option)
To rear chassis
(K1/K2) To rear chassis
(K1/K2)
LH Top view RH
649
80ZV-2
Rear chassis
Fuel level sensor (J8)

Efficient loading system Efficient loading system
solenoid valve (L5) oil pressure sensor (L6)
To front chassis Hydraulic oil level switch (M4)
To front chassis
Floor
harness
To floor ground
To floor harness To floor
A-A Washer motor (M8) Hydraulic oil

(option) temperature
Floor harness sensor (L7)
To washer motor
A A
Parking brake To floor
solenoid (M1)
Starter (P0) Transmission oil
temperature sensor Speed sensor
(M5) (automatic gear)
(M9)
Ground Air conditioner Brake oil pressure
condenser (L9) sensor (M2/M3)
Transmission solenoid
valve (J1 - J7)
Air cleaner (L0) ECM (50 poles)
Air heater
Engine ground Engine water
temperature Ground
sensor (M6)
ECM (4 poles)
Rear chassis ground
alternator ground
Starter to
engine body
Rear chassis ground Alternator (M7)
to engine body
Rear chassis ground,
Air conditioner battery ground
compressor
(P2)
To combination To combination lamp

To rear grill lamp
Fan speed control solenoid valve (P1)
LH Top view RH
To starter To fusible link
To rear chassis harness

To battery
To air heater
Engine relay wiring (screen board) Engine relay wiring (beside starter)
650
80ZV-2
Screen board
704
20 Red 705
Brown
85 Red BK 2
1
Starter
BK Voltage relay (N8)
(Red tape) 012 3
4
To ground
Red 15 BK
706
Heater Brown G
Fusible Fusible Magnetic
link (N1) relay
link (N2) switch (N7)
(N6)
70A 30A 70A 70A BK Battery relay (N3) 5 BK & B

15 BK
Air White
703
720 heater Brown ( + Mark)
Brown 704 5 Red G 85 Red
Fuse (ECM) Brown
S
5 Red
700 BK 5 BK &
5 White 5 5 Red x 6 White
White 20 BK 2 Red Brown To rear chassis 85 BK To battery
harness relay
Alternator wiring
Engine ground
( + Mark) 2 poles 4 poles To rear chassis
5 White 100 (N0)
harness
Red
( + Mark) Diode Starter motor wiring
unit (N4)
To battery (+) To rear To rear

chassis chassis harness
harness
Engine relay unit wiring
To back buzzer
F 1

R
Mark: Connected to black cable 3 2

Radiator guard wiring Rear working lamp connection Transmission solenoid wiring
651
80ZV-2
Floor board
To rear ground
To control box
Red tape Green tape
Accelerator pedal
(C0) Blue tape
(C9)

(Floor ground)
tape
Inching cut-off switch
(B0)
To operation stand
To rear
Top view
Horn switch
(B8)
Combination switch
(B9)

(B7)
Parking switch
(B5)
Front
652
80ZV-2


To floor harness

Fuse box (cab)
Fuse box (main)

Buzzer (G6)

RS232C



Odometer selection
To pilot
valve

Power (option)
To air conditioner
653

MODE LOADING 1 1
2 2
4
5
4
2 2 6 6
3 3 DECLUTCH SW
HAZARD
4 4 1
2
6 6
_ 7 4 5 6 7 4 5 6
4 F/R S/W
GND
7 7 6 8 1 2 3 8 1 2 3 SELECTION
5 8 11 20 7 12 9 16 5 8 5 8
753 749 173 102 C305 404 141 142 143 144 163 103 307 326 324 006 H106 002 H138
S506
YSb
403
H740 192 190 013 241 235 731 732 730 224 401 402 013 135 130 169 400 167 H738 B201 006 310 002 310 231
5 8 5 8 5 8 5 8
RO
B911
RO
A815
BP
G803
Lg
D103
Lg
D103
LgY
A803
B 4 1 10 1 6 1 8 1 1 4 1 4 1 1
A
321 H109 323 013 013 167 A5 A6 A7 A8 A9 B1 B2 A0
B910 A814 G803 S823 S822 B001 B3
BW R1 WRx2
BR S/W IN OUT
R2 804 803
BG C G
C804 C801
3 5 802 801
W R
W R B B Y
BG WB WB D605 C102
GW GL GY G703 A103 A106 F401 F601 F501 2 1 2 1
W
F801
320 322 321 304 301 302 WR WR
D506
PARKING D501 D503 060
G B 063 065 E3 E4
S/W BW G
W
GL
H601
D504 D502 901
L GR GB B 8 1
062 064
G 1
Y
R B8 B9 4 1
B
E1 E2
LIFT KICKOUT
L G SET UP
126 128
F/R SWITCH/ LAMP
4 6 LW B 1 S709 S503
L LgG S912
2
3 SET-UP 3 2 100 242 STICK STEERING
Lg LgL GyW SbR 1 6
D206 H137 120 4
6 222 225 240
S910 S903 S905
3 260 S607 S701 S719 S709 S919 S924
GO SbW B
YO
B LgY BY
LLg
S901 A712 121 122 123 B Lg 237 236 234 100 232 230
164 163 RB S834 D103 S707 YW B L BY
A611 3 1 223 013 114 S926 D205 S707
3 1 RL
A402
S921
300 7 4 5 6 7 4 5 6 4 1 1 6 233 005-a 114

2 1 S510
B5 B6 B7 8 1 2 3 8 1 2 3
12
330
1 7
5 8 5 8 E5 E6 E8 E0 T8
BW B BrG LP B
F003 F002 F001
271 255 168
B0
CAN
4 1 4 1
4 1
THROTTLE PEDAL
6 168
4 T607
R B LP
GyY GyW BL G
H734 H724 H713 Y V O 271 255
6
CAB 1 3 2 C0 736 737 741 B T706 T708
S2S BW BrG
H733 H723 Y
B208 A611 D107 D604 B108 D610 739 740 734 735 733 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2
S2L S2H 520 F604 010 022 521 020 V 3 4 6
E401 H708 H709 PB PL OR OL S813 S922
531 738 741 271 255 209 208 205 202 750 751 308 001 001 001 001 001 014 005-a 013 013 257 005-a 272 005-a
2 1 500 506 H712 018
2 1 B LP B B B B B B RY RY RW RY RY RB RB RL SbP LgSb LgBr B BrB B L
4 1 S915 A813 F504 B912 F402 B915 C305 B914 H710 S618 G601 S609 S611 S610
7 12 DATA LINK 168 301 145 258 273
H118 305 304 305 302 H129 H115 112 104
CONNECTOR 1 1 1 1 1 1 1 1 1 1
C1 C2 C3 C4 4 4 4 4 3 1 4 4 4 4 4 4
B
J C F0 F1 F2 F3 F4 F5 F6 F7 E7 T9 T0
CONTROLLER
F
_ V BY BZ
DECLUTCH + S709 S707 KICK
FLOAT
100 114 C7 SHIFT LEVELER OUT 4
SENSOR LgR 5 YG YG
S 3 HOLD TURN D702 D702
S727
166
2 YL
4 DIAG
(OPT) GL W
H716 H707 S/W H8 603 029
YL
B
3 2 3 2 R TO AIRCON
H123
BRW
T903
T003
2 2 5 GO W
BRR
3 3
250
257
BrB
272
S2L W R PG PW
S914
A508 D205 H708 B303 B302 H733 H723 3 2 3 2 604 029

D107 D107 802 801 739 740 Br Br Br
1

G L BrG BL B909 D111 A101 D107
S707 S732
GW GL B LgW B D114 003 003 003 H730 D804

114 415
AIR TEMP. W H709 B304 B301 H714 H713 1

G
C9 H127 B801 S612 007 YSb B 1 1 1 320 004 A108 010 8 605 029
D506 6 804 803 738 741
1 1 4 1 4 1 125 E704
(CONTROLLER)
BY
4 4 Br Br Br 112
7 G
(BLACK) (BLUE) 1 2 D107 1 4 1 4 1
2
010
BRW BrB BRR
H1 H2
H7
H3 H4 H5 H6
B LP LBr LR
10 6 5 1 S517 S604 S613 10 6 5 1
140 325 308 404 311 172 003 603 100 149 148 146 703 C201 C202 C203 747 735 205 203 172 171
114 327 306 170 703 171 251 604 015 910 912 914 015 732 204 206 748 734 C404 C004
141 142 143 144 D301 D401 D002
S707 A102 F403 S614 F704 S730 S826 H807 D101 901 D101 A606 S534 T402 C001 G004 C309 F103 G001
BY RBr RY WR RL SbY BrR GO WR 1 4 R R R WR BrW SbLg RLg YO YV BrG BL OR SbY
E201
303 330 329 180 705 720 250 261 267 911 913 915 W 605 731 181 220 160 733 737 C402 500 751
707 331 312 162 754 182 012 221 266 705 730 720 752 159 012 736 C403 506 161
40 36 35 31 40 36 35 31
654

CONTROLLER
A 1. 2S_SO A16. TT_L A31.1/4_L B12.X_R E 1. SSR_SO E16.SPD E31.TT_SE C 1. 2S_SE C16.EP C31.BSL D12.SL_A
A 2. 2_SO A17. D_SO A32.FR_L B13.F_SO E 2. FC_SO E17.BATT E32.OT_SE C 2. DSUB2 C17.F C32.EG_M D13.SS_N
A 3. ES_R A18. 1_SO A33.3/4_L B14.B_SO E 3. KEY E18.CANL1 E33.OUT_RSE C 3. DSUB4 C18.ASUB1 C33.DD_S D14.KD
A 4. DD_SO A19. EP_L A34.EG_SW1 B15.EG_SW2 E 4. KEY E19.SS_P E34.ET_M C 4. BSL- C19.ASUB2 C34.AFR D15.INCH_S
A 5. 3_SO A20. AB_L B 1. H_SO B16.RIN1 E 5. GND E20.CANLO C 5. TT C20.1/2 D 1. PRK D16.OD_SW
A 6. HM A21. A_L B 2. PWM_SO B17.OUT_MD2 E 6. GND E21.TM_M C 6. AC C21.1/8 D 2. AM_SW D17.SH
A 7. LU_SO A22. 1/2_L B 3. IP_SO B18.N_R E 7. GND E22.B_SE2 C 7. ET C22.2S D 3. SL_2 D18.SS_SW
A 8. 4_SO A23. E_L B 4. R_SO B19.BR_L E 8. GND E23.WT_SE C 8. BL C23.EG_H D 4. SL_R D19.SS_F
A 9. OTH_OUT A24. SS_L B 5. MO_SO B20.CAN_R1 E 9. +5V E24.ALT C 9. BD C24.IP_SW D 5. SL_3 D20.TMP
A10. R_L A25. SC_SW B 6. FR_SO B21.CAN_R2 E10. TGEG E25.RXD1 C10.DSUB1 C25.FR D 6. S_UP D21.INCH
A11. F_L A26. TF_L B 7. SSL_SO B22.DOUT1 E11. KEY E26.TGSP C11.DSUB3 C26.KO_P D 7. S_DOWN D22.KO_S
A12. ST_L A27. AC_L B 8. BSL_SO B23.OUT_FEW E12. KEY E27.INCH_SE C12.DR C27.ES_SE D 8. EG_SW D23.SC
A13. WL_L A28. BP_L B 9. BZ B24.MT E13. CANH1 E28.SC_P C13.BSL+ C28.3/4 D 9. M_SW D24.AR
A14. CW_L A29. N_L B10.BSL_R B25.ET_SE E14. EGR2 E29.CANHO C14.TF C29.1/4 D10.SL_1 D25.SM_SW
A15. ET_L A30. SC_L B11.KO_R B26.TXD1 E15. EGR1 E30.B_SE1 C15.WL C30.DC D11.SL_F D26.SS_R
SPEEDMETER 192 173 135 235 204 811 115 400 754 118 166 H701 180 415 116 401 251 240 105 260 223 165 255 230 111 233
H201 749 169 130 224 170 203 810 119 145 331 234 402 H702 220 707 117 265 200 222 124 168 110 125 231 232
T801 241 103 753 190 149 208 104 273 258 101 146 005-C 005-D 161 160 010 C702 181 106 271 750 121 126 120
267 H202 242 261 H203 403 140 H204 202 148 225 237 236 221 005-A 005-B 159 H101 266 182 164 109 122 128 123
S925 S916 S902 T101
111 110 109
1 1 1 100
1 9 1 7 1 9 1 9 1 7
(BLUE) (BLACK)
C701 E007 114
C902 H120
S2 S3 S4 S5 S6 S7 E801 T102 S8 S9
T3 T1 T2
3 1 4 1
YB YG YBr GL V 1
S623 S733 S617 S616 S709 B
115 116 119 810 100
YL YO B GR BY
FUSE BOX (CAB) 117 118 811 114 S812 S830
R5 R5 R5 106 105
4 6 3 2 3 2
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 REWRITE
003
G301
G401
H103
5
5
W R Y B G Br L O R
5
R
5
5 5
8 14 4 6
F503 B207 004 B107 007 005 910 911 062 T407 C310 C309 C301 H804 H402 H501
F603 H134 F703 H111 H401 E107 E101 E106
001 H735 014 H720 D2 912 065 064 063
R WBr W/LR R
E302 C303 H502
7 C304 A207 1 3 1 021 022 915
F802 A307 1 4 1
1 3 4 5 6 5 1
F803 A610 2 H801
G501 L
A706 L L L L L H802
G802 E601 E008
S703 S704 S711 S712 F702 B504 H803
S717 E702 005-A 005-B 005-C 005-D F902 005-b 029
010 E703
T902 D5 D6 D7 D8 D9 D0
D1 013 T002 D3 D4
005-a
655

40 36 35 31 40 36 35 31 HYD. OIL
COMBINATION K106 Br 331 Y L Br L R G G BrR GyR L GyY PG PL W TEMP.
LAMP R104 M704 R605 R102 P503 M601 L806 P606 P504 P501 P743 P742 M901 P701 P724 M803 P741 SENSOR
K501 303 R606 707 R705 312 162 754 182 012 221 266 730 752 159 736 739 506 161
Y K106 R706 Y Y Y L Br Br G G G 4 WY BrB L G L BrW GyW PW PB GyR COMPRESSOR
K502 325 303 K107 M501 N903 P601 K206 K204 P502 R R R
1
P201 P744 M401 L701 M902 P722 P711 P725 M802 P749 HYD. OIL
Y K101 329 180 705 720 250 261 267 N201 N201 N201 605 731 181 220 160 733 737 740 500 751 LEVEL
W 141 142 143 144
L 327 Y Br G GO WR 911 913 915 J302 J402 J502 J602 WR BL YO YV BrG BL OR SbY S/W
R103 N101 L L L L
R602 K103 K102 N904 K205 L804 P605 R R R 901 P739 P734 P720 P709 P702 P734 M801 P713
B
K503 R701 306 703 251 604 015 N201 N201 N201 149 148 146 015 741 748 734 738 741 019 209
R702 J202 J102
330 325 Y Gy Y R GL 100 910 912 914 J702 S2H S2L S2S YL BLg Sb L L
K101 K108 J802 K105 K201 L803 K202 8 B L L L 5 P901 P902 P903 P710 P723 P731 M303 M203
K203 R601 308 404 311 003 603 P506 1 1 1 747 735 205 172 171
FRONT HEAD 2 M502 10 6 5 1 10 6 5 1
K108 K102
P505
308 306
R H7
Y
K3 114
H730
B
B
W H1 H3 H4 H5 H6 1 OR Br
Y
2
1
PB OR
WY
WORKING LAMP 3 F H722 H712 G L
500 019 L
(INSIDE) K4 311 8 WASHER H727 P505 H728
8
Y K105 220 114 181
MOTOR PB
1
M8 1 2
(OPT)
H109
H108
K401 K501 K601 K303
K901 K801 329 K003
K802 K302 K502
T/M SOLENOID VALVE PL
308
327 K002 325
325
308
B Y 4 3 P2
Y
329 B PL
HORN(L) Y + R H732
H118
H127
306
306
329
K601 506
B J1
Y
Y
K1 _ L
L7 M4
F + H205 B
146 (BLUE)
H119
H106 H129
311 303
327
311 303
_
Y
Y
B 1 2 2 1 2 1
GROUND SPEED
329 K7 329 B B Y K6 SENSOR
B
Y
HORN(H) Y K701 K107 EFFICIENT EFFICIENT
K703 329 +
K601 LOADING LOADING
4
_ L B J2 L L M9 10 6 5 1 1 5 6 10
R SYSTEM(ELS) SYSTEM(ELS)
5
5
+ H206 H726 H736
148 YL YV BrG GyY
1 3 3 1 _ SOLENOID OIL PRESS. 160 159 H706 H715 H714 H734 1 2 3 4 5 6 7 8 9 10
B
2 1 1 747 734 738 736
R L L L L R VALVE SENSOR 2
YO SbY GyW
K9 L103 L201 L202 H120 H101 H103
WORKING 311
003 100 114 114 100 003 K2 H716 H711 H724 11 12 13 14 15 16 17 18 19 20
Y K105 + 748 209 737
LAMP G G G G G G CAN P7
B L102 L203 L401 H122 H113 H123 _ L B J3 (RESISTER)
PW PG BLg BrW
(INSIDE) 250 251 261 261 251 250 1 + H201 _
+
H723 H733 H705 H725 21 22 23 24 25 26 27 28 29 30
141 740 739 735 733
4 4 _ 1
6 6 2 1 WR S2S BL Sb
FRONT HEAD 2 S P746 H720 P903 H713 H704 31 32 33 34 35 36 37 38 39 40
LAMP(OUTSIDE) 205
G B P737 H709 P9 015 H717
K108 K102
S2H
308 306
R + H707 P747 GyR S2L S2H BrB BrR GyR W

Y
K0 P502
267 S2S H708 H721 P902 P901 H729 H739 H737 H731 41 42 43 44 45 46 47 48 49 50
B L B J4
B
_ 751 731 730 752 161

W L8 J8 2 + H202 1 2 G S2L
50 46 45 41 41 45 46 50
Y
1 142 P501 2
_
2 1 266
1 6 2 L L
1 P505 P506
COMBINATION B L 1 4
114 100 B G
LAMP H135
B
+
M001 4 1
K801 303 182 Gy
_ L B J5 1 2 P8 M002
Y K106 H107
B 3 + H203 B G
Y K103
K802 327 404
_ 143 M001 3 2
2 1 L5 L6 M002
GL GO 2 3
H102 H112 ECM
B
K803 3
603 604
4
M1 M2 M3 P1
+
3 4 B Y _ L B J6
603 604 4 + H204
L902 L903 _ 144 2 1 2 1
BUCKET GL GO 2 1 2 1 2 1
R B L L L L L B G
LEVELER L901 P503 P506 P505 P506 P505 P504
Br K201
003 L1 B
+
162 100 114 100 114 221
G B 182 L L
L B K206 L002 _ L B J7 H701 H702
250 B L D + H207 171 172
1 6 _ 149
2 1 2 1
S S R2 312
REAR
Y R102
1 WORKING
L 1 L0 FUEL LEVEL + _ + _ FAN SPEED B LAMP
C L201
L3 1 L L L9 PARKING
BOOM 100 L301 K202 SENSOR CONTROL
G G G L2 1 SOLENOID 4 1 R3 312
REAR
ANGLE B L203
100
L302 K205
100 SOL. VALVE 303 Y R102
SENSOR 251 L 251 251 L L802 R501 WORKING
L303 K203 B Y B
L 114 B LAMP
A L202 2
114 2 1 603 604
R BRAKE OIL PRESS. 330 R301
114 2 L803 L804 P606 Br (MAIN) R401 R201
3 GL GO 012 Y 312
N6 P601
L806
3 2
182
2 3 720
1
L
P0 HEATER 3 2
RIDE CONTROL SOLENOID AIRCON 702 RELAY Y Y
R103
330
STARTER BW H128 H138
Y
N501 330 312
R4 BACK UP
C Y B ALARM
2
B
B H129
N502 AIR
R
B 303
R8 HEATER 4 1
2
G
L401 N2
2
R1
2
261 B B FUSIBLE R501303 R104 Y

N1 N3 LICENSE
L4 LINK
1
FUSIBLE BATTERY R502 B LAMP

261 G N7
R801 K204 LINK RELAY
2
6 1
B R901 261 AIR MAGNETIC 100 266
70A
70A
L602 L603
R9 CLEANER S/W N8
1
BW R M202
30A N501 N502 L G
G 1 2 M302
L401 702 3 701 VOLTAGE 267 RH
WV B 2 RELAY L601 L501
261 1 N403 L702 L G 1 2 BATTERY
70A M201 _
1
700 221 162 P803 P803

1 4 M301 P101 M101 P804 P804
R 2 3 114 G L G G
4 3 +
FUSE H301
H302 4 3
H401 G G
T/M E/G H402
1
RL WG
4 WG B B Br
G L
N903 H132 H137 N002 N002
OIL TEMP. WATER TEMP. 30A H501 N904 N903 N901 221 162 036 036
H502 703 704 704 706
SENSOR SENSOR 910~ 705 L G 1 2
REAR
(CONTROLLER) (CONTROLLER) N4 6 1 H120 H121
915 M0 COMBINATION
6
114 267
4
M7 012 720
N601 N602 L G LAMP(R.H)
H129
H139
ALTERNATOR R Br 1 H101 H131
303
331
4 1
Br
B
R
Y
B
700 702 100 266 R6
N301 015 708 N702 703 706
N401 N402 N701 N804 6 1
WV BW
H109
H128
WR Br Br Br
325
330
Y
Y
Y
2 1 015 708 701 N801 P5
P605 P602 N703 N704
WR Br B R 705 B
3
1
E B R l 1 2 4 3 2 3 2 REAR
COMBINATION
4
G 4 3 R 3 2
B Br B 706 LAMP(L.H)
M001 W W W P002
H129
H139
303
331
M002 N303 H601 N102 701 H125 708
Br
B
R
B
R7
Y
N901 W 900 N001 900 BW 705 Br
H140 WR Br Br
N101 086 P001
H119
H128
H111 N901
327
330
W
H115 M704
Y
4 1 086 901 015 708 702
Y
Y
703 P602
706 R Br 4 1
L L Br L 1 H134 H124
3
1
H126 H120 H136 H120 707 012 720
180 114 754 114 Br 6 1
1 2 1 2 DIODE
N0 UNIT N5 N9
P6 LH
BATTERY
_
M5 M6
+
656

STARTER S/W
B BR ACC R1 R2 C
ACC’ (L) (005-b) E
TO PARKING SW.
PREHEAT (005)
F5 L
2
(L) (005- )
OFF
30A
ON
G (010)
START F10
E
(086) (900) 12V 12V ACC’ L x4 (005-A 005-D)
5
W [W ] 100
30A
E05 E06 E17 E04 E12
BATTERY E03 E11
(060) (901) (SbP) (145)
W [W 5 ] E24
LgW (101)
R1 BR
WR
1.25 F15
R2 C 5A WV LBr (128) L (273)
(700) F N R B10 BS
A32
LEVER
SHIFT
(062) (064) (063) (LgB)(224)
BW G
1.25
WR
1.25
BATTERY A03 M
F12
F14
F13
15A
5A
5A
1 (146) LR
(012) (014) (013)
LW (120)
BW G
1.25 (Lg) D12
LO (123)
70A
B C D05
100 LG (122) (148) LBr
5 LY (121)
[R ]x6 E09(+5V)
D10 (141) LY
MAGNETIC S/S POTENTIOMETER B09
LgBr (104)
BZ BUZZER
915) S/W (702) F YO (232) G (234)
D19 E19
5
[R ] (701)
5
[BW ] VOLTAGE (LY )
RL
1.25
(703) WG (704) D26 (142) LG
C26 E34
(YB ) (401)
NR
DECLUTCH SENSOR
LG (122) (LG) (LgR) (166) (BrW) (402)
(Lg) (WG) (707) LY (121) (143) LO
SbY (171) E30 (400)
WL1.25 (LO)
S/S SHIFT YV (231)
D18 (144) LW SbY (172) E22
20
70A B LB (230)
(LW)
DOWNSHIFT SW. D14 A17 OIL PRESS. SENSOR GyB (266)
C01
PREHEAT
LAMP WR (170)
(720) LP (168) LLg (140)
15 15 A04
(G) (415)
SELECTION SOL. VALVE A09 TC E/G TORQUE SELECTION
BY (114) SbLg (204)
B06
100 M
EMERGENCY REVERSAL W(161)
M STEERING PUMP FAN SW. (OPT)
Lg (222)
C25
(RL ) (330)
(OPT) AUTO FAN LgY (223) BR (236) Y(159) A10 TO BACK-UP LAMP
C34 E01 S/S SOLENOID VALVE R (OPT) E08
REVERSAL SW. (OPT) B19
(RG) (331)
TO BRAKE LAMP
BL (237)
(R) (106)
LLg (165) (E09) V
D21 +5V
(013) YB (115)
E F13 GO (164)
F13 YG (116)
DECLUTCH C23 (LgR) (130) YL (117)
(Lg) A21 AUTO SHIFT INDICATOR LAMP (RXD0)E25 RXD CONTROLLER RENEWAL
GL (265) (GR ) (135) YO (118)
YO (176) YBr (119)
(GyW ) (260)
C33 (GyB ) (103) E (OUT_MD2)B17 MD2
(LgY) (167) EP (LgY) (173) P (107) GND
E
(Gy) (749)
PL (108)
C03
BrY (181) (GyG) (753) PG (109) GL (810)
(163) GR (811) RS232C
(SbW) (GyL) (190) PB (110) (DOUT1)B22
C06 (LgW) (192) PW (111)
(162) (CANH0)E29
(O ) (241)
LgG
OFF
S2S

E MAIN CONTROLLER E
15 5A 30 20A
14 5A 29 20A
13 5A 28 10A
12 15A 27 5A
11 10A 26 5A
10 15A 25 20A
FAILURE
7 10A 22 3A
(LgSb) (112)
BZ
5 30A 20 10A
GAUGE (404)(YBr)
3 10A 18 5A
E
2 15A 17 5A ECM
1 20A 16 5A 36 30A
657

COMBINATION J3
(001) S/W F3 (086) (036)
F1 1.25 Br (003) BrB (257) F36 3
[W ] [G ]
LT LT 10A KO 4 1
20A RY (302) 30A
LH LH 3 2
RW (304) EL
UL HU
B
BrR (272)
HL FLOAT E
BS
J2
(015)
WR
LT F15 39 (730) STOP (013)
(BrB)
21 44
RELIEF INDICATOR LAMP OPT 26
RB
(303)
MACHINE WIDTH LAMP
THROTTLE PEDAL
TAIL LAMP (161) W
SENSOR BrW (733)
TAIL LAMP 22
YV (734)
9 (751)
C AIR-SUS. 23 49 EP
IDLE SW GyR
42
(RB) 1
PANEL LIGHTING F20
(300) O (020)
10A GyW (737)
11
MODM IDLE
S2H
TO
RADIO KEY GND S2L
CANH0 S2S
S2L BrG (738)
CAN CANL0 2
S2S RESISTER
(307) HIGH BEAM PL
(RY) INC/DEC SW. B
(060)
RESISTER (m) 24 B
RY
RY 25 46 C
LH F10 47 D
(308) 37 E
RW BL (741) (YL) (747)
(006) (310) RLg (521) (Y0 ) (748)
13 A
RLg (311)
TO CAB 19
(002)
F2 R
1.25
3
15A
RGy (312)
REAR WORKING LIGHT
REAR WIPER MOTOR
F19 OR (019)
LIGHT S/W 10A (501)Y L (503) ECM
TO CAB REAR (502)W WIPER S/W
(330) S2 S3
RL WASH B
(A10)
1 5 3
WASHER INTER-
PB WIPER
(331)
RG
M 4 RELAY
(B19) WIPER MOTOR
M R WIPER
(004) 5A (507) GY GR (508)
F4 R E WASHER
15A MOTOR (506) B S1 S2
PL
FLASHER UNIT M WASH
(WINKER) WIPER S/W

ACC’ B
E
L
(324)(RO)
(320)
P COMBINATION (325)
RO
TR
TB
RBr
B TL OPT
(010) (327) F22 (WBr ) (022) (510) Gy
W
(326)(RBr) G (010)
(HAZARD) F10
(513) WB
B
E
L
B
(323) BP
DC-DC
F21 R
2
Y
2
15A
+ +
OUT
HORN
IN
2 (12V)
(328) (GL )
- - B
HORN RELAY HORN S/W
TO RADIO/ROOM LAMP
TO CONTROLLER (E17)
CAB
ACC’ E
658

Front chassis
Bucket leveler
(L1)
Head lamp Head lamp

(K0) (K3)
Ground Ground
Horn
Boom angle sensor

(L3)
For ride control

(option)
To rear chassis To rear chassis

To rear chassis (K1/K2)
(K1/K2)
LH Top view RH
659
85ZV-2
Rear chassis
Fuel level sensor (J8)

To front chassis Efficient loading system oil pressure sensor (L6)
To front chassis
Efficient loading system solenoid valve (L5) Transmission solenoid valve (J1-J7)
To floor harness
Rear to floor ground
To floor ground Hydraulic oil

temperature
A-A sensor (L7)
Washer motor (M8)
(option)
Hydraulic oil
A A To washer motor level switch
(M4)
To floor
Air conditioner To floor

condenser (L9)
Speed sensor
(automatic gear)
(M9)
Transmission oil
temperature sensor
(M5) Parking brake
Ground Air cleaner (L0)
solenoid valve (M1)
ECM (50 poles)
Air heater
Engine water Ground
temperature sensor
(M6) ECM (4 poles)
Engine ground
Starter (P0)
Brake oil
pressure sensor
Rear chassis ground, Starter ground (M2/M3)
Alternator ground to engine body
Air conditioner
compressor (P2)
Alternator (M7) Fan speed control

solenoid valve Rear chassis ground
(P1)
Battery ground
To combination lamp To combination lamp
To rear grill
To rear grill
Top view RH
LH
660
85ZV-2
Engine room
20 Red
Magnetic To rear chassis C Terminal
switch To rear chassis harness
100 Red (N7) ( + Mark) 100 Red
Starter harness To battery relay
(Red tape) 15 BK 5 Red 5 BK & White B Terminal 15 BK B Terminal
012 704 703 5 Red
Red Brown Brown
Heater 5 Black
Fusible Fusible
relay & White
link (N1) link (N2) Engine body
(N6)
15 BK Voltage relay G Terminal
Air (N8)
70A 30A 70A 70A Battery relay (N3)
BK heater
1 4
720 2 3 To ground
Brown 100 BK To rear chassis
704 706
705 Brown harness
Fuse (ECM)
Brown BK BK Alternator wiring
Rear chassis
700 ground E Terminal
5 White 5 BK
Brown
3 White White 20 BK 5 Red x 6
(N0)
( + Mark) 2 poles 4 poles
5 White 100
Red
Diode
unit (N4)
To battery (+) To rear To rear

To rear chassis harness chassis chassis harness
harness Mark: Connected to black cable
Engine relay unit wiring

Rear working lamp connection
To back buzzer
To air heater F R
Rear chassis harness
To battery (+)
2
4 1

Engine relay unit wiring Radiator guard wiring Transmission solenoid wiring
661
85ZV-2
Floor board
To rear ground
To control box
Red tape Green tape
Accelerator pedal
(C0) Blue tape
(C9)

(Floor ground)
tape
Declutch switch
(B0)
To operation stand
To rear
Top view
Horn switch
(B8)
Combination switch
(B9)

(B7)
Parking switch
(B5)
Front
662
85ZV-2


To floor harness

Fuse box (cab)
Fuse box (main)

Buzzer (G6)

RS232C



Odometer selection
To pilot
valve

Power (option)
To air conditioner
663

MODE LOADING 1 1
SELECTION SYSTEM(ELS) 2
3
2
3
4
5
4
2 2 6 6
3 3 DECLUTCH SW
HAZARD
4 4 1
2
6 6 7 4 5 6 7 4 5 6
4 F/R S/W
GND
5 WT EP BP CE (+) FM GND − 1 2 3 4 P W GND H L R
7 7 6 8 1 2 3 8 1 2 3 SELECTION
5 8 11 20 7 12 9 16 5 8 5 8
763 749 173 102 C305 404 141 142 143 144 163 103 307 326 324 006 H106 002 H138
S506
YSb
403
H740 192 190 013 241 235 731 732 730 224 401 402 013 135 130 169 400 167 H738 B201 006 310 002 310 231
5 8 5 8 5 8 5 8
RO
B911
RO
A815
BP
G803
Lg
D103
Lg
D103
LgY
A803
B 4 1 10 1 6 1 8 1 1 4 1 4 1 1
A
321 H109 323 013 013 167 A5 A6 A7 A8 A9 B1 B2 A0
B910 A814 G803 S823 S822 B001 B3
BW R1 WRx2
BR S/W IN OUT
R2 804 803
BG C G
HORN S/W C804 C801
G L O B B R
TB TL TR HU EL LT LH HL 3 5 802 801
SHIFT LEVER W W W C803 C802
W R
W R B B Y
BG WB WB D605 C102
GW GL GY G703 A103 A106 F401 F601 F501 2 1 2 1
F801
320 322 321 304 301 302 WR WR W
D501 D503 D506
PARKING G B 063 065 060
S/W W
E3 E4
GL
BW G
D504 D502 H601
L GR GB B 8 1 062 064 901
G 1
R
Y
B8 B9 4 1
B
E1 E2
LIFT KICKOUT
L G S911 S904 SET-UP REVERSAL RIDE 3 4 BACK
126 128
F/R SWITCH/ LAMP
4 6 LW B 1 S709 S503
L LgG S912
2
3 SET-UP 3 2 100 242
1 STICK STEERING
D206 H137 4
6 222 225
S910 S903 S905
3 260 240 S607 S701 S719 S709 S919 S924
GO SbW B
YO
B LgY BY
LLg
S901 A712 121 122 123 B Lg 237 236 234 100 232 230
164 163 S834 D103 S707 YW B L BY
RB 223 114
3 1 013 S926 D205 S707
3 1 A611 RL
A402
S921
7 4 5 6 7 4 5 6 4 1 1 6 233 005-a 114

300 2 1 S510
B5 B6 B7 8 1 2 3 8 1 2 3
12
330
1 7
5 8 5 8 E5 E6 E8 E0 T8
BW B BrG LP B
F003 F002 F001
271 255 168
B0
CAN
4 1 4 1
4 1
THROTTLE PEDAL
6 168
4 T607
R B LP
GyY GyW BL G
H734 H724 H713 Y V O 271 255
6
CAB 1 3 2 C0 736 737 741 B T706 T708
S2S BW BrG
H733 H723 Y
B208 A611 D107 D604 B108 D610 739 740 734 735 733 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2
S2L S2H 520 F604 010 022 521 020 V 3 4 6
E401 H708 H709 PB PL OR OL S813 S922
531 738 741 271 255 209 208 205 202 750 751 308 001 001 001 001 001 014 005-a 013 013 257 005-a 272 005-a
2 1 1 500 506 H712 018
2 B LP B B B B B B RY RY RW RY RY RB RB RL SbP LgSb LgBr B BrB B L
4 1 S915 A813 F504 B912 F402 B915 C305 B914 H710 S618 G601 S609 S611 S610
7 12 DATA LINK 168 H118 305 304 305 302 H129 301 H115 145 112 104 258 273
CONNECTOR 1 1 1 1 1 1 1 1 1 1
C1 C2 C3 C4 4 4 4 4 3 1 4 4 4 4 4 4
B
J C F0 F1 F2 F3 F4 F5 F6 F7 E7 T9 T0
CONTROLLER
F
V BY BZ
− + S709 S707 KICK
LEVELER FLOAT
DECLUTCH 100 114 C7 SHIFT OUT 4
5 YG YG
SENSOR LgR 3 HOLD TURN
S D702 D702
S727
166
2 YL
4 DIAG
(OPT) GL W
H716 H707 S/W H8 603 029
YL
B
3 2 3 2 R TO AIRCON
H123
BRW
5
T003
2 2 GO W
T903
BRR
3 3
250
272
257
BrB
S2L W R PG PW
S914
A508 D205 H708 B303 B302 H733 H723 3 2 3 2 604 029

D107 D107 802 801 739 740 Br Br Br
1

G L BrG BL B909 D111 A101 D107
S707 S732
GW GL B LgW B D114 003 003 003 H730 D804

114 415
AIR TEMP. W H709 B304 B301 H714 H713 1

G
C9 H127 B801 S612 007 YSb B 1 1 1 320 004 A108 010 8 605 029
D506 6 804 803 738 741
1 1 4 1 4 1 E704
(CONTROLLER)
BY
4 4 125 Br Br Br 112
7 G
(BLACK) (BLUE) 1 2 D107 1 4 1 4 1
2
010
BRW BrB BRR
H1 H2
H7
H3 H4 H5 H6
B LP LBr LR
10 6 5 1 S517 S604 S613 10 6 5 1
140 325 308 404 311 172 003 603 100 149 148 146 703 C201 C202 C203 747 735 205 203 172 171
S507 A107 F404 A614 B108 S722 D110 H806 S709 LY LG LO LW 1 1 1 F704 T406 T405 T404 T403 C002 F203 S615 S722 S730
114 327 306 170 703 171 251 604 015 910 912 914 015 732 204 206 748 734 C404 C004
141 142 143 144 D301 D401 D002
S707 A102 F403 S614 F704 S730 S826 H807 D101 901 D101 A606 S534 T402 C001 G004 C309 F103 G001
BY RBr RY WR RL SbY BrR GO WR 1 4 R R R WR BrW SbLg RLg YO YV BrG BL OR SbY
E201 741
303 330 329 180 705 720 250 261 267 911 913 915 W 605 731 181 220 160 733 737 C402 500 751
707 331 312 162 754 182 012 221 266 705 730 720 752 159 012 736 C403 506 161
40 36 35 31 40 36 35 31
664

CONTROLLER
SPEEDMETER 192 173 135 235 204 811 115 400 754 118 166 H701 180 415 116 401 251 240 105 260 223 165 255 230 111 233
H201 749 169 130 224 170 203 810 119 145 331 234 402 H702 220 707 117 265 200 222 124 168 110 125 231 232
T801 241 103 753 190 149 208 104 273 258 101 146 005-C 005-D 161 160 010 C702 181 106 271 750 121 126 120
S925 S916 S902 267 H202 242 261 H203 403 140 H204 202 148 225 237 236 221 005-A 005-B 159 H101 266 162 164 109 122 128 123
111 110 109 T101
100
1 1 1
1 9 1 7 1 9 1 9 1 7
(BLUE) (BLACK) C701 E007
C902 H120
S2 S3 S4 E801 T102
S5 S6 S7 114 S8 S9
T3 T1 T2
3 1 4 1
YB YG YBr GL V 1
S623 S733 S617 S616 S709 B
115 116 119 810 100
YL YO B GR BY
FUSE BOX (CAB) 117 118 811 114 S812 S830
R5 R5 R5 106 105
4 6 3 2 3 2
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 REWRITE
G201
G401
H103
003
5
5
W R Y B G Br L O R
5
R
5
5 5
8 14 4 6
F502 B202 G702 B102 T501 005 H301 H302 E104 E202 OL OR O YG 3 2 R R
F503 B207 004 B107 007 910 911 062 T407 C310 C309 C301 H804 H402 H501
F603 H134 F703 H111 H401 E107 E101 E106
001 H735 014 H720 D2 912 065 064 063
R WBr W/LR R
E302 C303 H502
7 C304 A207 1 3 1 021 022 915
F802 A307 1 4 1
1 3 4 5 6 5 1
F803 A610 2 H801
G501 L
A706 L L L L L H802
G802 E601 E008
S703 S704 S711 S712 F702 B504 H803
S717 E702 005-A 005-B 005-C 005-D F902 005-b 029
010 E703
T902 D5 D6 D7 D8 D9 D0
D1 013
T002 D3 D4
005-a
665

FRONT HEAD 2
8
40 36 35 31 40 36 35 31
LAMP(OUTSIDE)
1
Br 331 Y L Br L G G Br BrR Br B L R GyY PG PL W
K108 K102
K106
308 306
L802 H119 H118 H109
H106 H129 H127 H108

K401 K501 K601 K303
K901 K801 329 K003
K802 K302 K502
R
308
327 K002 325
327 306 325
311 303 329 308

Y
K3 R104 M701 R605 R102 M101 M601 L806 M003 L603 N905 P706 N903 M901 N904 P703 P714 M803 P711
Y
B R606 707 R705 312 162 754 182 221 266 705 730 720 159 012 736 739 506 161
B
R706 Y Y Y L G G G 4 R R R WY BrB L G L BrW GyW PW PB GyR
W 1
306
Y
303 K107 M501 K206 K204 L501 P201 P716 M401 L701 M902 P748 P713 P724 M802 P827
Y
1 K1 329 180 250 261 267
N201 N201 N201
W 605 731 181 220 160 733 737 740 500 751
141 142 143 144 911 913 915 HYD. OIL
WORKING LAMP 3 L 327 Y L G GO J302 J402 J502 J602 N101 WR BrW B YO YV BrG BL OR SbY
311 303
R103 R R R 901 TEMP.
Y
(INSIDE) K4 311 R602 K103 K102 M203 K205 L804 L L L L N201 N201 N201 P602 P705 P727 P747 P744 P709 M801 P745
Y K105 R702 R701 306 171 251 604 K202 149 148 146 910 912 914 P738 732 748 734 738 P710 019 209 SENSOR
325 Y Gy Y L R GL L L602 J702 J202 J102 Br S2H S2L S2S YL BLg Sb
330 COMPRESSOR
Y
K101 K108 J802 K105 M303 K201 L803 M202 8 B L L L 5 N906 P901 P902 P903 P726 P749 P702
B 1 1 1 HYD. OIL
R601 308 404 311 172 003 603 M302 703 747 735 205
4
10 6 5 1 100 10 6 5 1 LEVEL
5
K203 M201 H2
M502 M301 H3 H4 H5 H6 S/W
COMBINATION 1 3 3 1
M602 M004 H7
L601 114 H1
LAMP R L L L L R
K501 303 L103 L201 L202 H120 H101 H103
Y K106 003 100 114 114 100 003 K2
K502 325 FAN SPEED CONTROL
Y K101 G G G G G G
L102 L203 L401 H122 H113 H123 SOL. VALVE
250 251 261 261 251 250 EFFICIENT
LOADING T/M SOLENOID VALVE
K503 4 4
H730
6 6
B SYSTEM(ELS) +
OIL PRESS. L B J1 Br
Y
WY
EFFICIENT SENSOR F − + H205
HORN (L) K601 146 L G
329 LOADING − 2 1 G B H727 M004
L
H728
SYSTEM(ELS) M003 114 220 181
221 1 2
B 1 2 2 1 SOLENOID − + 1 2
+
VALVE L B P2
Y K7 329 B B Y K6 J2
HORN (H) K601
K701 K107 S R − + H206
K703 329 148
329 − P1 L7 M4
2 1
B G OR
H131 + 2 1
266 L B J3 PB OR
G B L L 1 − + H201 F H722 H712 10 6 5 1 1 5 6 10
H121 H120 H101 141 500 019 BL BL GY GY BrR BrW GyY Sb
COMBINATION 267 114 100 − WASHER
2 1 H713 H713 N001 N001 H739 H719 H734 H704 1 2 3 4 5 6 7 8 9 10
LAMP 1 2 MOTOR PB 741 741 031 031 730 732 736 205
K801 303 1 2 M8
Y K106 (OPT) 4 3 PL GR GY BrB PG GyW W
K802 327 + B PL N005 N001 H729 H733 H724 H731 11 12 13 14 15 16 17 18 19 20
Y K103 R H732 035 031 731 739 737 161
L5 L6 L B J4 P7 B B GR YO YL PW
2 − + H202 506
N005 H716 H706 H723 21 22 23 24 25 26 27 28 29 30
142
K803 − 2 1 (BLUE) B 035 748 747 740
B B B WR S2L S2S
L8 J8 M1
H720 P902 P903 31 32 33 34 35 36 37 38 39 40
015
1 6 2
+ GROUND SPEED B BLg BrW YV S2H SbY BrG
WORKING LAMP 1 L B J5 H705 H725 H715 P901 H711 H614 41 42 43 44 45 46 47 48 49 50
B L 3 − + H203 SENSOR 735 733 734 209 738
(INSIDE) H135 2 1
K9 311 B Gy B L 143
182 L L 50 46 45 41 41 45 46 50
Y K105
B H107 H137 − 2 1 M9
162 H726 H736
K104 404 160 159
B
GL GO + 2 1
FRONT HEAD 2 H102 H112 L B J6
LAMP (OUTSIDE) 603 604 4 − + H204
3 4 221
K108 K102
144
308 306
R
Y
K0 3 4 B Y − 2 1 CAN 745 746 31 20

B
B
603 604 Br Br
W L902 L903 (RESISTER) 30 8 21
Y
1 GL GO
PARKING + 1 19 9
L901 SOLENOID L B J7 P746
B D − + H207 P736 H709
18 2 10
182 149 S2H P9
BUCKET L002 −
H707 P737
29 7 3 22
LEVELER R B L
2 1 S2S H708 P8
Br K201 1 6 S2L 17 1 11
003 L1 2
G B 28 6 4 23
L B K206 16 5 12
250
2 1 15 13
BOOM ANGLE L0 FUEL LEVEL 751
L9 27 14 24
SENSOR SENSOR
H721
1 26 25
1 L802
L 1 B
C L201 1
100 L3 L L 2 1 603 604 ECM
L301 K202 L803 L804 R
G 100 G G 100 L2
L806
GL GO N904 BG
182
B L203 L302 K205

L
L L
B
251 251 251 2 3 N6 N903

L303 K203 312
L 114 720 R2
A L202 2
114 AIRCON HEATER Y R102 REAR
2
114
3 P0 RELAY WORKING
BW B LAMP
STARTER N501 4 1
702 303 312
R3
R
C
B
RIDE CONTROL SOLENOID R

R501
Y R102 REAR
AIR Y B
N502 330 R301 WORKING
B
701 HEATER B
R401 R201 LAMP
2
B Y 312
3 2
1
R8 3 2
R103
N7
330
G Y Y
Y
K204 FUSIBLE FUSIBLE N3 H128 H138 R4 BACK UP
2
B B AIR BW MAGNETIC N8
261 LINK LINK BATTERY W N501 330 312 ALARM
261 261 CLEANER 702 R S/W VOLTAGE Y B
B
L4 3 N502
1
RELAY N102 H129

261 G 900 2 701 RELAY 303
30A
R801 K204
2
4 1
2
70A
70A
B R901 261 1 4 303

R501 Y RB
R9 2 3 4 1 R1 LICENSE
1
FUSE BOX (ECM) 70A 1 2 114 708

G WV B L702 P601 R502 B LAMP
K204 W3 N2 1 L Br

261 N403 1 4
N1 700 RL WG WG B B Br 221 706 RH
P101 N901
1
M2 M3 N906 N801 N704 N901

G Br BATTERY
703 704 N905 706
31 32 33 34 35 3 2
704 −
705 3 2
T/M E/G 2 1 2 1 GY G GL GB GR R G Br +
H301 N4 6 1 H132 M701
OIL TEMP. WATER TEMP. L L L L H302 221 706
GY 1 2 703 706 REAR
SENSOR SENSOR H101 H120 H101 H120 H401 N701 N804 L Br
100 114 100 114 COMBINATION
6
H402 H120 M702
4
W 700 015 708 1 Br Br
L L G GR W W H501 N301 N401 N402 702 705 114 708 LAMP(R.H)
H139
H129
H114 H104 N303 H601 H502 WV 4 1
303
331
WR Br N702 N801
Br
B
R
Y
B
M7 171 172
GY GR 900 P502 910~
015 708 BW Br B R6
GL GB P503 915 P601 P602 012 720
ALTERNATOR 701 M0
H109
H128
081
325
330
W
WR Br B N601 N602
Y
N703
Y
085 R Br
1 2 R 4 3
901 2
S S 3 2 3 4
3
1
4 3 REAR
W W R R Br
E I B R N101 N101 B H735 H738 COMBINATION
6
−
4
+ − + P002
081 085 GR 701 012 720 LAMP(L.H)
H129
H139
P718 Br B
303
331
BW
Br
B
R
WR Br
B
2 1 P728
H720 M001 P001 H740 R7
GY 702 705
015 708
H119
H128
1 Br Br
W
327
330
Y
BRAKE OIL
Y
2 1 H710 M002
PRESS. 1 6 703 706
L L Br L DIODE 6 1
3
(MAIN) P707
1
H126 H120 H136 H120
180 114 754 114 P708 UNIT
1 2 1 2 P5 P717 N0 P6 N5
Br Br 031 N9
M001 M002 LH
708 H140
706 BATTERY
M5 M6 707 −
+
666

STARTER S/W
B BR ACC R1 R2 C
PREHEAT ACC’ (L) (005-b) E
TO PARKING SW.
OFF
(005)
ON F5 L
2
(L) (005-a)
START 30A
G (010)
F10
E
(081) (085) (900)

12V 12V ACC’ L x 4 (005-A~005-D)
W W [W 5 ] 100
30A
E05 E06 E17 E04 E12
BATTERY E03 E11
(060) (901) (SbP) (145)
5 ECM(38) WL (707) B18 NR NEUTRAL RELAY
W [W ] E24 (GY) (169)
LgW (101) A20 AUTO BRAKE INDICATOR LAMP
(065) (015) (708) B12 X CONTROLLER FAILURE RELAY (NOT USED)
1.25
R1 BR WR F15 WR WP LR (126) BrB (258)
R2 C 5A WV LBr (128) L (273)
D04 LOWER KICK OUT RELAY (RL) (235) REVERSAL FAN
(700) F N R B10 BS A32
INDICATOR LAMP (OPT)
OPT (LgB) (224)
A24 S/S INDICATOR LAMP (OPT)
LEVER
SHIFT
(062) (064) (063)
1.25 1.25
BW G WR YGy (242) EMERGENCY STEERING
BATTERY A03 M
F12
F14
F13
15A
5A
5A
1 (146) LR
STARTER 23A B13 F SOLENOID VALVE
(012) (014) (013) LW (120)
BW G
1.25
(Lg) D12
LO (123)
70A
B C D05
LG (122) (148) LBr V (100)
100 D03 B04 R SOLENOID VALVE E09(+5V)
5 LY (121)
[R ] x 6 D10 S/S POTENTIOMETER (OPT) LgBr (104)
(910 (141) LY B09 BZ BUZZER
MAGNETIC A18 1ST SPEED SOLENOID VALVE G (234)
~ E19
915) S/W (702) F YO (232)
5
[R ] (701)
5
[BW ] VOLTAGE D19 (LY ) BOOM ANGLE SENSOR
RELAY F/R SW. (OPT) YW (233) BrR (251) (YB) (401)
1.25 D26 (142) LG C26 E34 E/G COOLANT TEMP. GAUGE
RL (703) WG (704) R A02 2ND SPEED SOLENOID VALVE
DECLUTCH SENSOR
NR (LgR) (166) (BrW) (402)
LG (122) (LG)
E27 E21 T/M OIL TEMP. GAUGE
(013) (705) SHIFT UP SW. (OPT) D06 BRAKE OIL
(Lg) (WG) (707) LY (121) (143) LO PRESS. SENSOR 1 SbY (171) (400)
F13 WL SHIFT DOWN SW. (OPT) D07 A05 3RD SPEED SOLENOID VALVE E30
(WL)
(706) BRAKE OIL B24 METER OUTPUT (TACHOMETER)
CHARGE LAMP
WL
1.25 (LO) PRESS. SENSOR 2 SbY (172) E22
S/S SHIFT YV (231)
D18 (144) LW
R SELECTION SW. (OPT) F5 A08 4TH SPEED SOLENOID VALVE
20
70A B I LB (230)
E ARMREST SW. (OPT) D24 EFFICIENT LOADING SYSTEM
(LW)
ALTERNATOR 20
OIL PRESS. SENSOR GyB (266)
LP (149) C01
(YL) (124) A17 D SOLENOID VALVE
DOWNSHIFT SW. D14
PREHEAT EMERGENCY STEERING
WR (170)
LAMP YSb (125) B14 (NOT USED) OIL PRESS. SENSOR (OPT) SbR (240)
C27
SHIFT HOLD SW. (OPT) D17
(720) LLg (140) GyG (754) YSb (403)
LP (168) A07 (NOT USED) E/G COOLANT TEMP. SENSOR B25 A06 HOUR METER DRIVE
(BG) DECLUTCH SET-UP D15
AIR HEATER GyL (180)
LgL (261) T/M OIL TEMP. SENSOR E31 SbR (208)
15 15 A04 RIDE CONTROL B08 AI E/G IDLE SELECTION
SOLENOID VALVE (OPT) (G) (415)
AIR TEMP. PROBE E32 SbP (202)
A09 TC E/G TORQUE SELECTION
BrG (255) GB (267) EFFICIENT LOADING SYSTEM GyO (220)
(012) LIFT KICK OUT SET-UP D22 A01 HYD. OIL TEMP. SENSOR E23 SbW (203)
BW HEATER RELAY SELECTION SOLENOID VALVE B15 E/G DROOP SELECTION 1 (NOT USED)
BW (271) BY (114) SbLg (204)
LOWER KICK OUT SET-UP C13 E07 A34 E/G DROOP SELECTION 2 (NOT USED)
LOWER KICK OUT SW. C31 Y (160)
LgL (225) REVERSAL FAN GROUND SPEED SENSOR E16
B06
SOL. VALVE (OPT)
W (161)
M EMERGENCY E/G SPEED SENSOR ECM(11) E15 E
100 REVERSAL
M STEERING
FAN SW. (OPT)
Lg (222)
C25 Y (159) A10
(RL)(330)
TO BACK-UP LAMP
PUMP (OPT) E08 (RG)(331)
AUTO FAN LgY (223) BR (236) S/S SOLENOID B19 TO BRAKE LAMP
C34 E01
REVERSAL SW. (OPT) VALVE R (OPT)
BL (237) S/S SOLENOID
(Y) (105) B07
B ACC’ E RECALL SW. C30 VALVE L (OPT)
(R) (106)
LLg (165) (E09) V
D21 +5V
(013) YB (115)
E F13 GO (164)
D01 (Lg)
(OUT_FEW)B23
YG (116)
FEW
DECLUTCH (013) GyW (200)
F13 (OUT_RES)E33
YL (117)
RESET
CUT-OFF C23 (LgR) (130) (RXD0)E25 RXD CONTROLLER PROGRAM REWRITE
(Lg) A21 AUTO SHIFT INDICATOR LAMP YO (118)
GL (265) (GR ) (135) (TXD0)B26 TXD
C22 A29 NEUTRAL INDICATOR LAMP YBr (119)
YO (176) (GyW) (260) E (OUT_MD2)B17 MD2
C33 (GyB ) (103)
A14 CENTRAL WARNING LAMP GND
(LgY) (167) EP (LgY) (173) P (107)
E/G OIL PRESS. SW. C16 PL (108) E
DECLUTCH (Gy) (749) DESTINATION SWITCH 2 C03
DECLUTCH SW. A19 E/G OIL PRESS. WARNING LAMP GL (810)
BrY (181) (GyG) (753) PG (109) (RIN1)B16
HYD. OIL LEVEL SW. C11 A15 E/G COOLANT TEMP. WARNING LAMP A/M SELECTION D02
RS232C
(163) PB (110) GR (811)
ON (SbW) (GyL) (190) ODOMETER SELECTION (DOUT1)B22
LgL (182) A16 T/M OIL TEMP. WARNING LAMP D16
AIR CLEANER C06 (LgW) (192) PW (111)
(CANH0)E29
PARKING SOL. (162)
LgG ON (005-b) A12
(O ) (241)
STEERING OIL PRESS. SPEED SENSOR SELECTION D08 (CANL0)E20
S2L
CAN
MACHINE CAB (L) S2S
OFF
15 5A 30 20A
PARKING SW. E MAIN CONTROLLER E
E
14 5A 29 20A
13 5A 28 10A
12 15A 27 5A
11 10A 26 5A
10 15A 25 20A EFFICIENT LOADING SYSTEM SW.
9 15A 24 10A
8 15A 23 10A
RIDE CONTROL SW. (OPT)
7 10A 22 3A ECM X
CONTROLLER (LgW) (102)
6 15A 21 15A SPARE FAILURE
(LgSb) (112) BZ
5 30A 20 10A 35 10A WARNING BUZZER
4 15A 19 10A 34 7.5
3 10A 18 5A 33 7.5 FUEL LEVEL
GAUGE
(404) (YBr)
2 15A 17 5A 32 7.5
E
1 20A 16 5A 31 10A
667

ACC’ E ACC’ E B
(001) COMBINATION S/W F3 Br (003) BrB (257) (081) (031) (730) STOP (013)
F1 R
1.25
RB (301) BOOM KICK-OUT W F31 GY (BrR) (Lg)
LT LT 10A KO 7 6 F13
20A RY (302) 10A
LH LH 8 (731) WARNING
EL (BrB)
RW (304) 17 16
UL HU
B (085) (035) (732) MAINTENANCE
BrR (272) F35
HL FLOAT W GR (BrW)
BS 18 5
10A
28
(015)
LT WR (161) W
LICENSE LAMP BrW (250) F15 38 11 (E15)
BUCKET LEVELER
FOR OPT LAMP
5 (745)
FOR OPT LAMP OPT 21 7 BO
MACHINE WIDTH LAMP 6 (746)

RB 19 BO
(303)
MACHINE WIDTH LAMP
THROTTLE PEDAL
TAIL LAMP THROTTLE OPENING
BrW (733) E
SENSOR 48 (751)
TAIL LAMP YV (734) GyR
47 27 EP E/G OIL PRESS.
BLg (735)
F7 OY (007) 49
C AIR-SUS.
29
10A COMPRESSOR IDLE SW.
30
OFF IDLE GyY (736)
INSTRUMENT 3 39
(RB) PANEL LIGHTING
(300) F20 O (020) 40
GyW (737)
10A 13 50
IDLE E
MODM
TO RADIO
KEY GND
DIAGNOSTIC SW. S2H
S2H BrG (738)
CANH0 44
S2L S2L
CAN CANL0 CAN
(307) HIGH BEAM PL S2S S2S
(RY) INC/DEC SW.
INC PG (739) RESISTER
(306) RIGHT HEADLIGHT (H) 14
RY RESISTER (m)
B
PW (740)
(305) UL LEFT HEADLIGHT (H) 24 (060)
RY DEC W
G (010) B
LH F10 ROOM LAMP S2H
RIGHT HEADLIGHT (L) (741) 46 C
(308)
RW BL S2L
LEFT HEADLIGHT (L) 9 37 D
TO FRONT S2S
(006) (310) RLg (521) 10 36 E
F6 1.25
(RGy) WORKING CAB WORKING LIGHT E (YL) (747)
RG 26 F
WORKING LIGHT PL LIGHT AI
15A CAB WORKING LIGHT SbY (209) (Y0) (748)
RLg (311) 45 27 G
FRONT WORKING LIGHT TO REAR
FRONT RGy (520) TC Sb (205) A
WORKING CAB REAR WORKING LIGHT 2
WORKING FRONT WORKING LIGHT LIGHT DATA LINK
LIGHT SW. CAB REAR WORKING LIGHT E CONNECTOR
TO CAB 41
(002) RLg (521) WORKING LIGHT
F2 1.25
R E
15A
RGy (312)
REAR WORKING LIGHT 43
REAR WIPER MOTOR
F19 OR (019)
WORKING REAR WORKING LIGHT M (503)
F WIPER 20
10A L
LIGHT SW. (501) Y
TO CAB REAR (502)W WIPER SW.
(330) S2 S3
RL WASH B
TO CONTROLLER BACK-UP LAMP
(A10)
Sint S1 E/G ECM Connection Diagram
1 5 3
WASHER INTER-
(331) PB WIPER
RG M 4 RELAY
(B19) WIPER MOTOR
(004)
M R WIPER
5A (507) GY GR (508)
F4 R WASHER
E
15A MOTOR (506) B S1 S2
PL
FLASHER UNIT M WASH
(WINKER) WIPER SW.
ACC’ B
E
L
(324)(RO)
(320)
P COMBINATION (325)
S/W (321) RO RIGHT FRONT TURN SIGNAL
RO
TR
(322) RIGHT REAR TURN SIGNAL
TB
B
RBr OPT
TL
LEFT FRONT TURN SIGNAL
(010) (327) F22 (WBr ) (022) (510) Gy
(060) F10 G RBr LEFT REAR TURN SIGNAL
W FLASHER 3A (RB)(300) (511) GyB
15A (NIGHT RADIO
UNIT LEFT TURN SIGNAL PL ILLUMINATION) (512) WR
(326)(RBr) G (010)
(HAZARD) F10
(513) WB
B
E
L
B
(323) BP
DC-DC
F21 R
2
Y
2
+ +
(329) GW
HORN
15A CIGAR SOCKET
OUT
IN
2 (12V)
(328) (GL ) B
- -
HORN RELAY HORN SW.
TO RADIO/ROOM LAMP
TO CONTROLLER (E17)
CAB
ACC’ E
668

Front chassis
Bucket leveler (L1)
Head lamp (K0) Head lamp (K3)

Ground Horn Ground
Boom angle sensor (L3)
For ride control

(option)
To rear chassis To rear chassis
(K1/K2/J9) (K1/K2/J9)
LH Top view RH
669
90ZV-2
Rear chassis
Efficient loading system oil To front chassis Hydraulic oil level switch (M4)
pressure sensor (L6)
Efficient loading system Transmission solenoid valve Hydraulic oil
To front chassis solenoid valve (L5)
Fuel level sensor (J8) Parking brake solenoid (M1) (J1 - J7) temperature sensor (L7)
To floor Rear to floor ground
To floor harness
To floor ground
A-A
To washer motor
To floor
A
Brake oil pressure sensor (M2/M3) A
Washer motor (M8) To floor

Air conditioner condenser (L9) (option)
Speed sensor
(automatic gear)
Transmission oil (M9)
temperature sensor
(M5)
Ground Ground
ECM (31 poles)
Air cleaner (L0)
Engine water
temperature sensor
(M6) Engine ground
ECM (50 poles)
Heater ground
Alternator ground Air heater
Rear chassis ground Rear chassis
Starter ground ground
to Engine body
Air conditioner
compressor
Alternator (M7)
Fan speed
control solenoid
valve (P1)
Battery ground
To combination lamp To combination lamp
To rear grill
LH Top view RH
670
90ZV-2
Magnetic 706
switch (N7) White & 707
20 Red
Blue Brown
(Red tape) Ground To battery
harness 100 Red
100 Red 708 relay
Starter G Terminal R Terminal
Brown B Terminal
To fusible
15 BK 5 Red 5 BK & White + I Terminal C Terminal 5 Red
(Red tape) link
704 703 B Terminal
Brown Brown 5 Bk
Fusible Fusible & White
link (N1) link (N2) Engine body 15 BK
012
Battery Heater Red Voltage relay
70A 30A 70A 70A relay relay (N8)
(N3) (N6) 720 To rear
1 4
Brown 2 3 100 BK chassis
Fuse box
704 harness
(ECM)
705 BK BK 706 Engine
Air 15 BK BK Brown Brown ground
heater Alternator wiring
5 White 5 700 BK E Terminal
White x 2 White 20 BK 5 Red x 6 Brown
100 5 White
3 poles 6 poles ( + Mark) Red 2 poles 6 poles
Diode
unit (N4)
3
To rear To rear To To rear To battery To rear To rear To rear + Mark: Connected to red cable
chassis chassis alternator chassis (+) chassis chassis chassis Mark: Connected to black cable
harness harness (B) harness harness harness Engine relay unit wiring harness F R
2
Rear working lamp connection 4 1

To back buzzer

Engine relay unit wiring Radiator guard wiring
671
90ZV-2
Floor board
To rear ground
To control box
Red tape Green tape
Accelerator pedal
(C0) Blue tape
Air temperature probe (controller) To rear
(C9)

(Floor ground)
tape
Declutch switch
(B0)
To operation stand
To rear
Top view
Horn switch
(B8)
Combination switch
(B9)

(B7)
Parking switch
(B5)
Front
672
90ZV-2

To floor harness
Fuse box (cab)
6 poles white connector 4 poles Fuse box (main)
black connector

Buzzer (G6) Lift kickout / lower kickout setup switch (T7)
RS232C
Speedmeter dividing ratio selection Front
Odometer selection
A/M selection
Back signal (option) (Ground)
Starter switch (E1/E2)
To downshift button
To pilot
valve
4 poles white connector To shift hold switch

Diagnostic increment / decrement switch
Power (option)
To air conditioner
673
Electrical Protection
(1) Cab (2) Chassis
LIGHTING
Fuse Boxes (70ZV-2 & 70TMV-2) SPARE 5A 20A
HEAD LIGHT
SPARE 5A R. WORK LIGHT 15A

2
R. WIPER / BOOM KICKOUT
1 WASHER
5A
BUCKET LEVELER
10A
F. WIPER / WASHER 10A TURN SIGNAL 15A

PARKING BRAKE
MODM 10A CONTROLLER 30A
(MACHINE)
DC-DC CON-
15A F. WORK LIGHT 15A
VERTER
Front
AIR SUSPENSION
RADIO 3A 10A
SEAT
SPARE 10A SPARE 15A
SPARE 10A SPARE 15A

3
4 WAY FLASHER
HORN
AIRCON 20A 15A
DOME LAMP
RADIO BACK UP
SPARE 5A SPARE 10A
SPARE 5A PREHEAT 15A

BUZZER
SPARE 10A MONITOR 5A
(CONTROLLER)
AIRCON 20A NEUTRAL RELAY 5A
Main Fuse Boxes are located in the right hand side BATTERY RELAY
SPARE 20A 5A
console in the cab and contain thirty fuses. The ECM (ENGINE)
additional fuse box (3) is located in the engine com- Right Right
(3)
partment on the left hand side of the machine. It
contains 1 fuse, 30 amp. See illustration & photo. ECM (ENGINE) 30A
IMPORTANT If this fuse blows, the engine stops.

When replacing fuse, be sure to turn the starter
switch to the "OFF" position. Starter
30 A Fuse
IMPORTANT
Using wrong capacity fuse or bypassing fuse
may cause electrical system damage.
Engine
Never replace fuses with higher amperage rat-
ing. Block
Left rear of m/c.
674
Fuse (70ZV-2 & 70TMV-2)

The following fuses are provided to protect electrical cir- Fuse box
cuits.
For chassis
Fusible link
70 A x 2, 30 A x 1 Fuse
Fuse No. capacity Protective circuit
(A)
Fuse box LIGHTING
15 fuses x 2 (for chassis and cab) 1 20A
HEAD LIGHT
1 fuse x 1 (for engine controller ECM) 2 15A R. WORK LIGHT 20A
BOOM KICKOUT
3 10A
For installation positions, refer to previous page. BUCKET LEVELER SPARE
4 15A TURN SIGNAL
PARKING BRAKE
5 30A 15A
CONTROLLER (MACHINE)
CAUTION 6 15A F. WORK LIGHT
SPARE
Possible burn hazard. Before replacing a fuse, be 7 10A AIR SUS. SEAT (OPT)
sure to turn off the starter switch. 8 15A SPARE 10A
9 15A SPARE
4WAY FLASHER
IMPORTANT HORN SPARE
10 15A
ROOM LAMP
Replace a fuse with the same capacity. RADIO
If a fuse blows immediately after replacement, the 11 10A SPARE 5A
electric system is defective. Locate the defective part, 12 15A PREHEAT
and then repair it.
BUZZER SPARE
13 5A MONITOR LAMP
TACHOMETER
14 5A NEUTRAL RELAY
BATTERY RELAY
15 5A
ECM (ENGINE)
For cab
Fuse
(A)
16 5A SPARE
17 5A SPARE 20A
Fuse box for cab Fuse box for chassis
18 5A R. WIPER / WASHER
SPARE
19 10A F. WIPER / WASHER
20 10A MODM 15A
21 15A DC-DC CONVERTER
SPARE
22 3A RADIO
23 10A SPARE 10A
24 10A SPARE
SPARE
25 20A SPARE
26 5A AIRCON 5A
27 5A AIRCON
SPARE
28 10A AIRCON
29 20A AIRCON
30 20A SPARE
675
For ECM - model 70ZV-2/TMV-2 (Engine Control Module)
Fuse
(A)
36 30A ECM (ENGINE)
If this fuse blows, the engine stops.
Starter
30 A Fuse
Engine
Block
Left rear of m/c.
676
(1) Left (2) Left
LIGHTING
Fuse Boxes (80ZV-2) SPARE 5A 20A
HEAD LIGHT
85ZV-2 is similar but is on right side of engine.
2
BOOM KICKOUT
1 R. WIPER /
5A BUCKET POSI- 10A
WASHER
TIONER
PARKING BRAKE
CHARACTER DIS-
10A CONTROLLER 30A
PLAY
(MACHINE)
DC-DC CON-
Front 15A F. WORK LIGHT 15A
VERTER
AIR SUS SEAT
RADIO 3A 10A
(option)
SPARE 10A SPARE 15A
3 SPARE 10A SPARE 15A

4 WAY FLASHER
HORN
AIRCON 20A 15A
DOME LAMP
RADIO BACK UP
SPARE 5A SPARE 10A
SPARE 5A PREHEAT 15A

BUZZER
(CONTROLLER)
Main Fuse Boxes are located in the right hand side
BATTERY RELAY
console in the cab and contain thirty fuses. The SPARE 20A
ECM (ENGINE)
5A
additional fuse box (3) is located in the engine com-
Right Right
partment on the left hand side of the machine. It
contains a 30 amp fuse. See illustration & photo. (3)
ECM (ENGINE) 30A

IMPORTANT
If fuse blows, engine will stop.
When replacing fuse, be sure to turn the starter
switch to the "OFF" position. Brake & Pilot
Accumulators
IMPORTANT
Using wrong capacity fuse or bypassing fuse 30 amp fuse
may cause electrical system damage.
Never replace fuses with higher amperage rat-

ing.
Batt Relay Starter

677
Fuses (90ZV-2)
The following fuses are provided to protect electrical cir- Fuse box
cuits.
For chassis
Fusible link
70 A x 2, 30 A x 1 Fuse
(A)
Fuse box LIGHTING
15 fuses x 2 (for chassis and cab) 1 20A
HEAD LIGHT
1 fuse x 1 (for engine controller ECM) 2 15A R. WORK LIGHT 20A
BOOM KICKOUT
3 10A
(For installation positions, refer to "Electrical Equipment BUCKET LEVELER SPARE
Layout".) 4 15A TURN SIGNAL
PARKING BRAKE
5 30A 15A
CONTROLLER (MACHINE)
CAUTION 6 15A F. WORK LIGHT
SPARE
Possible burn hazard. Before replacing a fuse, be 7 10A AIR SUS. SEAT (OPT)
sure to turn off the starter switch. 8 15A SPARE 10A
9 15A SPARE
4WAY FLASHER
IMPORTANT HORN SPARE
10 15A
ROOM LAMP
Replace a fuse with the same capacity. RADIO
If a fuse blows immediately after replacement, the 11 10A SPARE 5A
electric system is defective. Locate the defective part, 12 15A PREHEAT
and then repair it.
BUZZER SPARE
13 5A MONITOR LAMP
TACHOMETER
14 5A NEUTRAL RELAY
BATTERY RELAY
15 5A
ECM (ENGINE)
For cab
Fuse
(A)
16 5A SPARE
17 5A SPARE 20A
Fuse box for cab Fuse box for chassis
18 5A R. WIPER / WASHER
SPARE
19 10A F. WIPER / WASHER
20 10A MODM 15A
21 15A DC-DC CONVERTER
SPARE
22 3A RADIO
23 10A SPARE 10A
24 10A SPARE
SPARE
25 20A SPARE
26 5A AIRCON 5A
27 5A AIRCON
SPARE
28 10A AIRCON
29 20A AIRCON
30 20A SPARE
678
(1) Cab (left) (2) Chassis (left)
LIGHTING
Fuse Boxes (90ZV-2) SPARE 5A
HEAD LIGHT
20A

2
BOOM KICKOUT
1 R. WIPER / WASHER 5A 10A
BUCKET LEVELER

PARKING BRAKE
MODM 10A CONTROLLER 30A
(MACHINE)
DC-DC CON-
15A F. WORK LIGHT 15A
VERTER
Front
AIR SUSPENSION
RADIO 5A 10A
SEAT (option)
SPARE 10A SPARE 15A
SPARE 10A SPARE 15A

4 WAY FLASHER
HORN
AIRCON 20A 15A
DOME LAMP
RADIO BACK UP
SPARE 5A SPARE 10A
3 SPARE 5A PREHEAT 15A

BUZZER
(CONTROLLER)
Main Fuse Boxes are located in the right hand side BATTERY RELAY
SPARE 20A 5A
ECM (ENGINE)
console in the cab and contain thirty fuses. The
(right) (right)
additional fuse box (3) is located in the engine com-
partment at the rear right hand side of machine. It
contains 6 fuses, of which two are used (see next pg). (3)
Refer to next page for photograph of fuse box. ECM (ENGINE) x 2 10A
More on next page
679
For ECM - model 90ZV-2 (Engine Control Module)
Fuse
(A)
31 10A ECM (ENGINE)
32 7.5A SPARE
33 7.5A SPARE
34 7.5A SPARE
35 10A ECM (ENGINE)
Photograph of
Extra
35
32
33
34
31
fuses as mounted
at rear right of the
chassis (QSM11)
680
Fusible link Problems caused by blown fusible link

70ZV-2/TMV-2 (80/85ZV-2 are similar) Problem (symptom)
Fuse
Fusible link damaged During engine operation During engine stop
Cover
Fuse - Engine will be stopped. - All the electrical circuit
element - All the power for all will not function.
30A
electrical circuit will be - Engine can not be
OFF. started
- Horn [and opt. flasher]
- The same conditions
will operate.
as "During engine oper-
- All the others will not
ation" but engine can
70A operate and the
be started and stopped.
(1) machine can not be
operated.
- Engine can not be
stopped.
- The machine can be - The same conditions
Box for fusible link Fusible link operated but the batter- as "During engine oper-
70A
ies can not be charged ation".
(2)
and the batteries will be
discharged soon.
(086) (900) 12V 12V
W [W5] 100
30A
(060) (901)
BATTERY
W [W5] ECM (39)
CONTROLLER
R1 BR
B AC
R2 C
(065)
WR1.25 F15
5A
(015)
WR
WV
(708)
WP
IMPORTANT
(700)
(062) (064) (063)

When replacing fusible link, you may want to discon-
BW G1.25 WR1.25
BATTERY nect the battery negative terminal to avoid arcing out
15A
F12
F14
F13
5A
5A
RELAY
(012)
BW
(014)
G1.25
(013)
(Lg)
STARTER a circuit and damaging wire.
1 If so, after you reconnect battery, do following:
70A
B C
[R5] x 6
(910
1. Turn on key
~ MAGNETIC (702)
915) [R5] (701)
S/W
[BW5] VOLTAGE 2. Press throttle pedal fully down and up 3 times in
RELAY
NR
RL1.25 (703) WG (704)
5~6 seconds.
(013)
(Lg)
(705)
(WG) (707)
3. Turn off key switch.
F13 WL
CHARGE LAMP (706)

WL1.25
20 L R
70A B
E
2 ALTERNATOR 20
100 M
M EMERGENCY
STEERING
PREHEAT PUMP (OPT)
LAMP
(720)
(BG)
AIR
HEATER
15 15
(012)
BW HEATER
RELAY
B ACC’ E
TO PILOT LAMP
Fusible link location
The fusible link is located in the box as shown in the For replacement of a fusible link, remove 2 bolts and
above figures. If excessive current flows through the pull it up.
starter switch or the electric line downstream of the
starter switch due to shortcircuit, the fuse element will
be blown to protect the circuit. The condition of the fuse
element can be seen through the transparent cover.
Determine the cause before replacing the fusible link.
681
Fusible Link (70ZV-2/TMV-2)
Fusible link protects the main hot + 24 V DC wire from

short circuits.
This page shows the location of fusible links on 70ZV-2

and 70TMV-2.
CAUTION
Contact with moving parts or engine components
may result in injury or burns.
1. If the fusible link is blown, the following prob- 2. Refer to previous page for more details.
lem occurs.
Problem (symptom)
Fuse
damaged
During engine operation During engine stop
- Engine will be stopped. - All the electrical circuit

- All the power for all will not function.
30A
OFF. started
- Horn [and opt. flasher] - The same conditions

will operate. as “During engine
- All the others will not operation” but engine
70A operate and the can be started and
(1) machine can not be stopped.
operated.
- Engine can not be
stopped.

operated but the bat- as “During engine
70A teries can not be operation”.
(2) charged and the batter-
ies will be discharged
soon.
682
Fusible link (90ZV-2) Problems caused by blown fusible link
Fuse Problem (symptom)

Fusible link damaged During engine operation During engine stop
Cover
Fuse - Engine will be stopped. - All the electrical circuit
element - All the power for all will not function.
30A
OFF. started
- Horn [and opt. flasher]
- The same conditions
will operate.
as "During engine oper-
- All the others will not
ation" but engine can
70A operate and the
be started and stopped.
(1) machine can not be
operated.
- Engine can not be
stopped.
Box for fusible link Fusible link operated but the batter- as "During engine oper-
70ZV62010 70A
ies can not be charged ation".
(2)
and the batteries will be
discharged soon.
(086) (900) 12V 12V
W [W5] 100
30A
(060) (901)
BATTERY
W [W5] ECM (38)
CONTROLLER
R1 BR
B AC
R2 C
(065)
WR1.25 F15
5A
(015)
WR
WV
(708)
WP
IMPORTANT
(700)
(062) (064) (063)

When replacing fusible link, you may want to discon-
BW G1.25 WR1.25
BATTERY nect the battery negative terminal to avoid arcing out
15A
F12
F14
F13
5A
5A
RELAY
(012)
BW
(014)
G1.25
(013)
(Lg)
STARTER a circuit and damaging wire.
If so, after you reconnect battery, do following :
70A
B C
[R5] x 6
(910
1. Turn on key
~ MAGNETIC (702)
915) [R5] (701)
S/W
[BW5] VOLTAGE 2. Press throttle pedal fully down and up 3 times in
RELAY
NR
RL1.25 (703) WG (704)
5~6 seconds.
(013)
(Lg)
(705)
(WG) (707)
3. Turn off key switch.
F13 WL
CHARGE LAMP (706)

WL1.25
20 R
70A B I
E
ALTERNATOR 20
100 M
M EMERGENCY
STEERING
PREHEAT PUMP (OPT)
LAMP
(720)
(BG)
AIR
HEATER
15 15
(012)
BW HEATER
RELAY
B ACC’ E
TO PILOT LAMP
Fusible link location
The fusible link is located in the box as shown in the For replacement of a fusible link, remove 2 bolts and
above figures. If excessive current flows through the pull it up.
starter switch or the electric line downstream of the
starter switch due to shortcircuit, the fuse element will
be blown to protect the circuit. The condition of the fuse
element can be seen through the transparent cover.
Determine the cause before replacing the fusible link.
683
Engine Start Circuit
Engine start circuit diagram (circuit for 90ZV shown; 70~85ZV-2 are similar)
Starter switch
B BR ACC R1 R2 C
Preheat
Off
On
Start
Controller
E05 E06 E17 E04 E12
E03 E11 12V 12V
Shift lever F/R position
B18 30A
E24
B12 Fusible link Battery
D11 B11 ECM
D04
F N R F15 Diode unit
F14
5A
5A
1
23A
D12 Battery
relay
D05
D03 Starter motor
70A
D10
+24 V B C
Magnetic
switch
Voltage
relay
3 4
2 1
Neutral relay
F13
+24 V Charge lamp Controller
(F5) E24
* When shift lever is in F/R position: OFF
When shift lever is in N position: ON R
70A B I
E
Alternator
Neutral starter Shift lever neutral (N) position
To prevent the machine from unexpected movement at When the starter switch is turned to the ON position
engine start up, the machine is so designed that the while the shift lever is located in the N position, the coil
actuation circuit of the neutral relay is connected to the
engine can start only while the shift lever is in the neu-
ground of the controller unit and the contact of the neu-
tral (N) position.
tral relay is switched over to ON.
684
When the starter switch is turned to the START position,

the start command current flows from the starter switch
terminal C to the neutral relay, the magnetic switch and
the voltage relay. As a result, the magnetic switch turns
ON, the starting current flows in the starter motor, and
the engine starts.
Shift lever forward/reverse (F/R) position
While the shift lever is located in the F or R position, the

power is not supplied to the neutral relay coil, and the
main contact is OFF. As a result, the starting current
from the starter switch terminal C does not flow in the
magnetic switch, and the engine does not start.
685
Starter switch (common to all ZV-2) Off

Enables insertion and removal of the starter key.
All the electrical circuits (except the horn and hazard
flasher [OPT.]) will be turned off.
On
Supplies power to the charge, lamp, and monitor cir-
cuits.
Start
Starts the engine.
Starter switch
Control box Preheat
Preheats the intake air to ensure smooth starting in cold
weather.
Starter switch location
OFF
35º 30º
Preheat ON
35º
Start
B
C
AC BR
R1
R2
W3 Connection table
W5
B BR AC R1 R2 C
BW R1 BR WR x 2 Preheat
B AC WB x 2 Off
BBG
G R2 C G On
Start
To battery relay
To neutral relay
To heater relay
From battery
1.25
BW WR WR G W5
BG WB WB W3
686
Battery relay Alternator surge dampening terminal wire

(Common to all ZV-2)
12V 12V
30A
ECM Battery
Terminals for coil Moving contact (1)
F15 (2) (3)
energizing current R1 BR
B AC
(4 mm) Main contacts

R2 C 5A
(2)(3): Diode unit
Suppression diode
15A
F12
F14
F13
5A
5A
BR Charge From
circuit alternator
I terminal
Terminals for B Neutral
main current relay
Coil for energizing (8 mm)
When the starter switch is placed to the ON position or Engine motion-active circuit:
the start position, the battery relay is turned on. When
the starter switch is set to the OFF position, the alterna- If the battery relay turns OFF while the alternator is gen-
tor stops generating power, and the battery relay is erating power, the charging circuit is shut down, load
automatically turned off so that the electrical circuits will dump surge may be generated, and related circuits and
not function. equipment may be damaged. In order to prevent this
trouble, this circuit (1) is provided to hold the battery
If the battery relay was not used, a large amount of cur- relay in the "ON" position.
rent would be directly sent through the starter switch
when it is turned on. However, use of the battery relay
reduces the amount of current because this relay needs
only a small amount of current to energize it.
Diode unit
Battery relay operation

WV:To battery relay
Starter switch WV WR:To starter switch terminal AC (VIA F15) and
WR WP to ECM
From AC B WP:To alternator
charge
circuit Battery relay
(B) Diode storage section
To main (E)
circuit
Battery
The diode unit is incorporated in the milky white connec-

tor near the battery relay. It is provided for the following
purpose.
Suppression
diode 85V2E62014
1. Diode (2)
This diode is provided to prevent the roundabout
current from the alternator to the ECM. If this diode
Battery relay
is not provided (or is defective), the ECM does not
Rated voltage DC 24 V turn OFF and the engine cannot be stopped.
Minimum operating voltage 20 V or less
Release voltage 9 V or less 2. Diode (3)
This diode is provided to prevent the roundabout
When current flows from the starter switch terminal AC, current from the starter switch AC to the alternator I
the coil will be energized, and the moving contact will terminal.
lower to close the main contact. As a result, current will
flow from the battery to the main circuit.
687
Neutral relay
1 2
SbP
L
RL
G
4 3
Internal connection dia.

Body black
Position of Between Between

Starting
shift lever 1 and 3 2 and 4
F or R Not energized OFF Impossible
N Energized ON Possible
The structures of the neutral relay, engine idle selection

relay, engine torque selection relay, engine oil pressure
switch relay, horn relay, width lamp relay and the head
lamp relay are identical each other.
Note
This illustration shows relay in the de-energized condition.
Magnetic switch
Rating 24V x 200A

M C
C C’
M’
M’ C’
Note
The illustration shows magnetic switch in the de-energized condition.
688
Voltage relay
1
2 3
1 4
4
Voltage relay
Contact point closed 6V
Contact point open 9V
Note
The illustration shows relay in the de-energized condition.
689
Power Generating/Charging Circuit

Alternator
Engine Mechanical energy supply
The alternator driven by the engine rectifies, with 6

diodes, full waves in three phases of the AC output gen-
erated in the stator coil by the three-phase start connec-
tion (Y connection) into DC output, then supplies it as
Alternator Electrical energy conversion the electric power to the battery and the machine load.
In the electricity generated in the alternator, the voltage

Rotor coil fluctuates depending on the number of revolutions of
excitation current Generated power the engine and the load size if no measures are taken.
IC regulator
To prevent fluctuation, a regulator is integrated so that
Voltage adjustment the voltage supplied to the battery and the load circuit is
For battery relay
For rotor coil always constant.

initial excitation
Adjusted
voltage
operation
For
battery relay
operation
Starter
Load circuit operation
switch
Battery charge
<Load>
For rotor coil Battery

initial excitation 70ZV62021
The power generating/charging device and the charging

circuit consisting of an alternator, regulator, battery, etc.
generate and supply the power required to all electrical
units of the machine.
690
ECM (Engine Control Module)
Function of ECM
- Stops the engine.
- Operates the engine.
- Monitors the engine, and diagnoses it for faults.
Connection diagram
(Diagram is typical to 70~85ZV-2)
B E
J3
(086) (036)
3 F36 3
[W ] [G ]
4 1
30A
3 2
B
E
J2
(015)
WR
F15 39 (730) STOP (013)
(BrR) (Lg)
43 F13
(731) WARNING
(BrB)
21 44
26
32 45
THROTTLE PEDAL
(161)W
SENSOR BrW(733)
22
YV (734)
9 (751)
BLg (735) GyR E/G OIL PRESS.
23 49 EP
(752)
IDLE SW 42
GyR
OFF IDLE GyY (736)
1
IDLE GyW(737)
11
S2H
S2L
DIAGNOSTIC SW CAN
S2S
BrG(738)
2 RESISTOR
INC/DEC SW B
(060)
INC PG (739) W
(m) 24 B
PW (740) S2H
25 46 C
DEC S2L
47 D
S2S
37 E
BL (741) (YL) (747)
34 10 F
(Y0) (748)
20 G
RLg(206) AI SbY(209)
13 A
TC Sb (205) E
DATA LINK
31 CONNECTOR
19
ECM
E/G ECM connection diagram
691
ECM (Engine Control Module)
Function of ECM
- Stops the engine.
- Operates the engine.
- Monitors the engine, and diagnoses it for faults.
Connection diagram
(Diagram applies to 90ZV-2)
B
(081) (031) (730) STOP (013)

W F31 GY (BrR) (Lg)
7 6 F13
10A
8 (731) WARNING
(BrB)
17 16
B
(085) (035) (732) MAINTENANCE
W F35 GR (BrW)
18 5
10A
28
(015)
WR (161) W
F15 38 11 (E15)
5 (745)
21 7 BO
6 (746)
19 BO
THROTTLE PEDAL
THROTTLE OPENING BrW (733) E
SENSOR 48 (751)
YV (734) GyR
47 27 EP E/G OIL PRESS.
BLg (735)
49
IDLE SW 29
30
OFF IDLE GyY (736)
3 39
40
GyW (737)
13 50
IDLE E
DIAGNOSTIC SW
S2H
BrG (738)
44 S2L
CAN
S2S
INC/DEC SW
INC PG (739) RESISTOR
(m) 14
PW (740) B
24 (060)
DEC W
B
S2H
(741) 46 C
BL S2L
9 37 D
S2S
10 36 E
E (YL) (747)
26 F
AI SbY (209) (Y0) (748)
45 27 G
TC Sb (205) A
2
E
DATA LINK
41
CONNECTOR
43
20
E/G ECM connection diagram
692
Monitor lamp test (applies to 70TMV-2 & 70~90ZV-2)
ON
Key switch Approx.
OFF
2 sec
ON
Engine maintenance lamp Orange
OFF
ON
Engine warning lamp Lights when
abnormality Yellow
OFF
occurs.
ON
Engine stop lamp Red
OFF
STOP
Engine maintenance lamp (Orange) [informational]
Engine warning lamp (Yellow) [attend to soon]
Engine stop lamp (Red) [pull to safe place and stop engine; repair before use]
When the starter switch is set to ON, three engine mon- After that, if there is an abnormality in a circuit, a corre-
itor lamps (engine protection, engine warning and sponding monitor lamp lights.
engine stop) are lit for approximately 2 seconds.
Check bulb operation prior to diagnosing system troubles.
693
Failure diagnosis Note

(applies to 70TMV-2 & 70~90ZV-2) This may be used as last resort if no other diagnostic
Engine diagnostic switch (option) tool is available; No MODM*, no Quick Check III and
Diag. switch Inc./Dec. switch no Quick Check QC5100.
(Part Number : 35010-60130) (Part Number : 35010-60180)
This method is not normally recommended.
Refer to *Maintenance Operation and Diagnostic Monitor
Training Manual for details on checking for engine faults.
The diagnosis for the engine failure should be done by

the following steps.
G R R
Step 1. Starter switch key "OFF"
L W G Y
Step 2. Diagnostic switch "ON"
Step 3. Starter switch key "ON"
Cable assembly The engine warning lamp flashes with these conditions.
(Part Number : 33191-49150) To diagnose the engine failure, convert the flashing pat-
tern to the 3-digit fault code.
This switch is used to check the engine failure when any
one of the engine warning lamps is turned on. The following shows how to convert the flashing pattern
to the 3-digit fault code.
Note
These code are quickly retrievable with Cummins
Quickcheck hand held analyzers or with the MODM on
OFF
ON the machine.
START
Refer to the "QUANTUM FAULT CODE INFORMA-
TION" for details.
The following steps show how to finish the diagnosis for

the engine failure.
Step 1. Diagnostic switch "OFF"

Step 2. Starter switch key "OFF"
ON
OFF
Orange
1 sec 1 sec
ON
OFF
Yellow
0.5 sec
ON
OFF
Red Second
First digit digit Third digit
1 sec 1 sec
Fault code Fault code (continued)
694
Failure diagnostic chart (See note at top right of previous page.)
ON
Key switch
OFF
ON
Diagnostic switch
OFF
[When there is no fault code]

ON
Engine maintenance lamp
OFF
Orange
ON
Engine warning lamp
OFF
Yellow
ON
Engine stop lamp STOP
OFF
Red
[When there is fault code]
ON
Orange
OFF
1 sec 1 sec
ON
Engine warning lamp
Yellow
OFF
ON
Red
OFF
100's digit 1 sec 10's digit 1 sec 1's digit
Fault code
[Example: Failure code 131]
Accelerator pedal position sensor
circuit-shorted high.
ON
Orange
OFF
1 sec 1 sec
ON
Engine warning lamp
Yellow
OFF
ON
Red
OFF
1 3 1
Following page explains more.
695
Increment decrement switch (option) - Adjusting the engine idle revolution

(See note at top right of previous page.)
When the diagnostic switch is OFF (Starter switch
Diag. switch Inc./Dec. switch key "ON"), the engine idle revolution can be adjusted
(Part Number : 35010-60130) (Part Number : 35010-60180) in 25 rpm by using the increment / decrement switch
(650 rpm ↔ 800 rpm ↔ 1,000 rpm). Move the incre-
ment / decrement switch to "+", then release it, to
increase the engine idle revolution to 1,000 min-1
(rpm).
To decrease the engine idle revolution, move this
switch to "-", then release it. As a result the engine
idle revolution is adjusted as 650 min-1 (rpm).
The engine idle revolution is not changed to over
G R
L W
R
G Y
1,000 min-1 (rpm) or to below 650 min-1 (rpm) even
though this switch is moved to "+" or "-".
Cable assembly
(Part Number : 33191-49150)
70ZV62069
The switch is used for ;
1. Checking the history of the engine failures
2. Adjusting the engine idle revolution
- Checking the history of the engine failures
When the diagnostic switch is ON (Starter switch key

"ON"), the lights will continue to flash the same fault
code until the system is advanced to the next active
fault code. To go to the second fault code, move the
increment / decrement switch to "+", then release it.
You can also go back to the previous fault code by
moving the switch to "-", then releasing it. To check
the third or fourth fault code, move the switch to "+",
then release it when all active fault codes have been
viewed. Moving the switch to "-" will go back to the
first fault code.
Refer to the section of the diagnostic switch for convert-

ing the flashing pattern to 3-digit fault code.
Refer to the "Quantum fault code information" for

details.
696
Quantum fault code information

These codes show the fault codes for the engine failure *Refer to Maintenance Operation and Diagnostic Monitor
displayed on the MODM* error log monitor, Cummins
Quick Check III / QC5100, or diagnostic switch (option).
Training Manual for details on checking for engine faults.
Please note that not all are used in the 70~90ZV-2 machine
application.
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB6.7 (70ZV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG111
Engine Control Module - Critical internal failure.
Red
EG115 Engine Speed / Position Sensor Circuit - lost both of two signals from the magnetic pickup
Red sensor.
EG121 Engine Speed / Position Sensor Circuit - lost one of two signals from the magnetic pickup
Yellow sensor.
EG122
Intake Manifold Pressure Sensor #1 Circuit - shorted high.
Yellow
EG123
Intake Manifold Pressure Sensor #1 Circuit - shorted low.
Yellow
EG124
High Intake Manifold Pressure Left Bank.
Orange
EG131
Accelerator Pedal Position Sensor Circuit - shorted high.
Red
EG132
Accelerator Pedal Position Sensor Circuit - shorted low.
Red
EG133
Remote Accelerator Pedal Position Sensor Circuit - shorted high.
Red
EG134
Remote Accelerator Pedal Position Sensor Circuit - shorted low.
Red
EG135
Engine Oil Pressure Sensor Circuit - shorted high.
Yellow
EG141
Engine Oil Pressure Sensor Circuit - shorted low.
Yellow
EG143
Engine Oil Pressure Low - Warning.
Yellow
EG144
Engine Coolant Temperature Sensor Circuit - shorted high.
Yellow
EG145
Engine Coolant Temperature Sensor Circuit - shorted low.
Yellow
EG146
Engine Coolant Temperature High - Warning.
Orange
EG147
Accelerator Pedal Position Sensor Circuit - low frequency.
Red
EG148
Accelerator Pedal Position Sensor Circuit - high frequency.
Red
EG151
Engine Coolant Temperature High - Critical.
Red
EG153
Intake Manifold Temperature Sensor #1 Circuit - shorted high.
Yellow
EG154
Intake Manifold Temperature Sensor #1 Circuit - shorted low.
Yellow
EG155
Intake Manifold Temperature #1 High - Critical.
Red 697
Refer to Maintenance Operation and Diagnostic Monitor Training Manual for details on checking
for engine faults.
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB6.7 (70ZV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG187
Sensor Supply Voltage #2 Circuit - shorted low.
Yellow
EG195
Coolant Level Sensor Circuit - shorted high.
Orange
EG196
Coolant Level Sensor Circuit - shorted low.
Orange
EG211 Additional OEM / Vehicle Diagnostic Codes have been logged. Check other ECM's for
None DTC's.
EG212
Engine Oil Temperature Sensor Circuit - shorted high.
Yellow
EG213
Engine Oil Temperature Sensor Circuit - shorted low.
Yellow
EG214
Engine Oil Temperature High - Critical.
Red
EG221
Ambient Air Pressure Sensor Circuit - shorted high.
Yellow
EG222
Ambient Air Pressure Sensor Circuit - shorted low.
Yellow
EG223
Engine Oil Burn Valve Solenoid Circuit - shorted low.
Yellow
EG227
Sensor Supply Voltage #2 Circuit - shorted high.
Yellow
EG234
Engine Speed High - Critical.
Red
EG235
Engine Coolant Level Low - Critical.
Red
EG238
Orange
EG256
Ambient Air Temperature Sensor Circuit - shorted low.
Orange
EG259
Fuel Shutoff Valve - stuck open.
Red
EG261
Fuel Temperature High - Warning.
Orange
EG263
Fuel Temperature Sensor Circuit - shorted high.
Orange
EG265
Fuel Temperature Sensor Circuit - shorted low.
Orange
EG268
Fuel Pressure Sensor Circuit - data incorrect.
Orange
EG271
High Fuel Pressure Solenoid Valve #1 Circuit - shorted low.
Orange
EG272
High Fuel Pressure Solenoid Valve #1 Circuit - shorted high.
Orange
EG284
Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted low.
Yellow
EG285
SAE J1939 Multiplexing PGN Timeout Error.
Yellow
EG286
SAE J1939 Multiplexing Configuration Error.
Yellow
EG287
SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.
Red
EG288
Red
SAE J1939 Multiplexing Remote Throttle Data Error. 698
for engine faults.
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB6.7 (70ZV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG293
Auxiliary Temperature Sensor Input #1 Circuit - shorted high.
Yellow
EG294
Auxiliary Temperature Sensor Input #1 Circuit - shorted low.
Yellow
EG295
Ambient Air Pressure Sensor Circuit - data incorrect.
Yellow
EG296
Auxiliary Pressure Sensor Input #2 Engine Protection - Critical.
Orange
EG297
Auxiliary Pressure Sensor Input #2 Circuit - shorted high.
Yellow
EG298
Auxiliary Pressure Sensor Input #2 Circuit - shorted low.
Yellow
EG299
Engine Shutdown Commanded by J1939.
Yellow
EG311
Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.
Yellow
EG312
Yellow
EG313
Yellow
EG314
Yellow
EG315
Yellow
EG319
Real Time Clock - Power Interrupt.
Maint.
EG321
Yellow
EG322
Injector Solenoid Valve Cylinder #1 Circuit - open circuit.
Orange
EG323
Orange
EG324
Orange
EG325
Orange
EG331
Orange
EG332
Orange
EG334
Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.
Orange
EG341
Engine Control Module - data lost.
Yellow
EG343
Engine Control Module - Warning internal hardware failure.
Yellow
EG352
Yellow
EG378
Fueling Actuator #1 Circuit - open circuit.
Yellow
EG379
Fueling Actuator #1 Circuit - grounded circuit.
Yellow
EG381
Yellow
699
Intake Air Heater (Relay Enable) #1 Circuit - data incorrect.
for engine faults.
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB6.7 (70ZV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG386
Yellow
EG387
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.
Yellow
EG394
Timing Actuator #1 Circuit - open circuit.
Yellow
EG395
Timing Actuator #1 Circuit - grounded circuit.
Yellow
EG396
Fueling Actuator #2 Circuit - open circuit.
Yellow
EG397
Fueling Actuator #2 Circuit - grounded circuit.
Yellow
EG398
Timing Actuator #2 Circuit - open circuit.
Yellow
EG399
Timing Actuator #2 Circuit - grounded circuit.
Yellow
EG415
Engine Oil Pressure Low - Critical.
Red
EG418
Water in Fuel Indicator High - Maintenance.
Maint.
EG419
Intake Manifold Boost Pressure Imbalance.
Yellow
EG422
Engine Coolant Level Sensor Circuit - data incorrect.
Yellow
EG426
SEA J1939 datalink - cannot transmit.
Yellow
EG428
Water in Fuel Sensor Circuit - shorted high.
Yellow
EG429
Water in Fuel Sensor Circuit - shorted low.
Yellow
EG431
Accelerator Pedal Idle Validation Circuit - data incorrect.
Yellow
EG432
Accelerator Pedal Idle Validation Circuit - out of calibration.
Red
EG433
Intake Manifold Pressure Sensor Circuit - data incorrect.
Yellow
EG434
Power Lost without Ignition Off.
Yellow
EG435
Engine Oil Pressure Sensor Circuit - data incorrect.
Yellow
EG441
Battery #1 Voltage Low - Warning.
Yellow
EG442
Battery #1 Voltage High - Warning.
Yellow
EG443
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.
Yellow
EG449
Fuel Pressure High - Warning.
Red
EG451
Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.
Yellow
EG452
Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.
Yellow
EG466
Turbocharger #1 Wastegate Control Circuit - shorted low. 700
Yellow
for engine faults.
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB6.7 (70ZV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG482
Fuel Pressure Low - Warning.
Yellow
EG483
Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.
Yellow
EG484
Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.
Yellow
EG485
Injector Metering Rail #2 Pressure High - Warning.
Yellow
EG486
Injector Metering Rail #2 Pressure Low - Warning.
Yellow
EG487
Start Assist Device - Canister Empty (Ether Injection).
Orange
EG488
Intake Manifold Temperature High - Warning.
Orange
EG489
Transmission Output Shaft (Tailshaft) Speed Low - Warning.
Yellow
EG496
Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.
Yellow
EG497
Multiple Unit Synchronization Switch Circuit - data incorrect.
Yellow
EG527
Auxiliary Input / Output #2 Circuit - shorted high.
Yellow
EG528
OEM Alternate torque validation switch - data incorrect.
Yellow
EG529
Auxiliary Input / Output #3 Circuit - shorted high.
Yellow
EG546
Fuel Delivery Pressure Sensor Circuit - shorted high.
Yellow
EG547
Fuel Delivery Pressure Sensor Circuit - shorted low.
Yellow
EG551
Accelerate Pedal Idle Validation Circuit - shorted low.
Yellow
EG553
Injector Metering Rail #1 Pressure High - warning level.
Yellow
EG554
Fuel Pressure Sensor Error.
Yellow
EG559 Injector Metering Rail #1 Pressure Low - data valid but below normal operational range -
Yellow moderately severe level.
EG584
Starter Relay Circuit - shorted high.
Orange
EG585
Starter Relay Circuit - shorted low.
Orange
EG595
Turbocharger #1 Speed High - warning level.
Yellow
EG596
Electrical Charging System Voltage High - warning level.
Yellow
EG597
Electrical Charging System Voltage Low - Warning Level.
Yellow
EG598
Electrical Charging System Voltage Low - Critical Level.
Red
EG599
OEM Commanded Dual Output Shutdown.
Red
EG611
None
Engine Hot Shutdown. 701
for engine faults.
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB6.7 (70ZV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG649
Change Lubricating Oil and Filter.
Orange
EG687 Turbocharger #1 Speed Low - data valid but below normal operation - moderately severe
Orange level.
EG689
Primary Engine Speed Sensor Error - data erratic, intermittent, or incorrect.
Orange
EG691
LBF Turbo Comp Inlet Temperature Sens Failed High.
Orange
EG692
LBF Turbo Comp Inlet Temperature Sens Failed Low.
Orange
EG731 Engine Speed Sensor #2 mechanical misalignment between camshaft and crankshaft sen-
Yellow sors - mechanical system not responding properly.
EG758
Injector Metering Rail #2 Pressure Malfunction.
Yellow
EG779
Auxiliary Equipment Sensor Input #3 (OEM Switch).
Orange
EG951
Cylinder Power Imbalance between cylinders.
None
EG1117
Power Lost with Ignition ON - data erratic, intermittent, or incorrect.
None
EG1139
Injector Cylinder #1 - mechanical system not responding properly.
Orange
EG1141
Orange
EG1142
Orange
EG1143
Orange
EG1144
Orange
EG1145
Orange
EG1242
Accelerator Pedal Position.
Red
EG2185
Orange
EG2186
Orange
EG2215 Fuel Pump Delivery Pressure - data valid but below normal operational range - moderately
Orange severe level.
EG2216 Fuel Pump Delivery Pressure - data valid but above normal operational range - moderately
Orange severe level.
EG2217
ECM Program Memory (RAM) Corruption - condition exists.
Orange
EG2265
Fuel Priming Pump Control Signal Circuit - shorted high.
Orange
EG2266
Fuel Priming Pump Control Signal Circuit - shorted low.
Orange
EG2311
Fueling Actuator #1 Circuit Error - condition exists.
Orange
EG2321
Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.
None
EG2322
Engine Speed Sensor #2 - data erratic, intermittent, or incorrect. 702
None
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB6.7 (70ZV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG2345
Turbocharger speed invalid rate of change detected - abnormal rate of change.
Orange
EG2346 Turbo charger Turbine Inlet Temperature (Calculated) - data valid but above normal opera-
Orange tional range.
EG2347 Turbocharger Compressor Outlet Temperature (Calculated) - data valid but above normal
Orange operational range - least severe level.
EG2384
Variable Geometry Turbocharger Actuator Drive Circuit - shorted low.
Orange
EG2385
Variable Geometry Turbocharger Actuator Drive Circuit - shorted high.
Orange
EG2555
Intake Air Heater #1 Circuit - shorted high.
Orange
EG2556
Intake Air Heater #1 Circuit - shorted low.
Orange
EG2557
Auxiliary PWM Drive #1 - shorted high.
Orange
EG2558
Auxiliary PWM Drive #1 - shorted low.
Orange
EG2963 Engine Coolant Temperature High - data valid but above normal operational range - least
None severe level.
EG2964 Intake Manifold Temperature High - data valid but above normal operational range - least
None severe level.
EG2973
Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.
Orange
To understand more on the fault codes for the engine failure displayed on the MODM* error log monitor,
Cummins Quick Check III / QC5100, refer to most recent Cummins Engine Troubleshooting Manual.
Refer to *Maintenance Operation and Diagnostic Monitor Training Manual for details on checking for en-
gine faults.
Information on following pages is for reference to information found when using Cummins
Quick Check III or Quick Check 5100.
703
FAULT CODES
This Appendix provides information about the engine and vehicle subsystem fault
codes that you may receive from your vehicle. CFC is the Cummins fault code.
PID is the parameter identifier. SPN is the suspect parameter number. SID is
the subsystem identifier. FMI is the failure mode identifier. Each CFC, PID,
SPN, SID, and FMI is identified by a number. You may notice some numbers
missing from the following tables, as NOT all numbers have been defined.
Cummins Fault Code [CFC] NUMBER RANGE SUPPORTED

18 - 2295*
* - Not all CFC numbers are assigned by Cummins. If QuickCheck II reads a

fault with a CFC number that is unassigned, it will have a description based on
the PID, SPN, or SID. Note that no zeros are used in CFC numbers because
CFC numbers are also used for codes flashed on diagnostic lamps.
Parameter Idetnification [PID] NUMBER RANGE SUPPORTED

1 - 511*
* - Not all PID numbers are assigned by SAE. If a fault is read by QuickCheck II
with a PID number that is unassigned, it will have a description indicating either
"Reserved - to be assigned" or "Description Not Available."
Suspect Parameter Number [SPN] NUMBER RANGE SUPPORTED

1 - 1709*
* - To minimize the size of the QuickCheck II databases, not all SPN descriptions
are supported. If a fault is read by QuickCheck II with an SPN number that is
unassigned by SAE or unsupported in the database, it will have a description
indicating either "Reserved - to be assigned" or "Description Not Available."
Subsystem Identifier [SID] NUMBER RANGE SUPPORTED

1 - 255*
* - Not all SID numbers are assigned by SAE. If a fault is read by QuickCheck II
with an SID number that is unassigned, it will have a description indicating either
"Reserved - to be assigned" or "Description Not Available."
Failure Mode Identifier [FMI] is discussed in another section.
704
QUICKCHECK User's Manual
SAE J1587* AND J1939 FAILURE MODE IDENTIFIERS (FMI)**
FMI Description
0 Data valid but above normal operational range
1 Data valid but below normal operational range
2 Data erratic, intermittent or incorrect
3 Voltage above normal or shorted high
4 Voltage below normal or shorted low
5 Current below normal or open circuit
6 Current above normal or grounded circuit
7 Mechanical system NOT responding properly
8 Abnormal frequency, pulse width or period
9 Abnormal update rate
10 Abnormal rate of change
11 Failure mode NOT identifiable
12 Bad intelligent device or component
13 Out of calibration
14 Special instructions
15 Data valid but above normal operational range (least severe)
16 Data valid but above normal operational range (moderately severe)
17 Data valid but below normal operational range (least severe)
18 Data valid but below normal operational range (moderately severe)
19 Received network data in error
20 Reserved for future assignment
31 Not available or condition exists
* - J1587 FMI numbers run from only 0 to 15.
** - FMI descriptions always follow the CFC, PID, SPN, or SID descriptions in the
detailed Fault Description zoom box.
705
GLOSSARY
Accel Ped Pos the ratio of the current accelerator pedal position to the maximum
position (in percentage)
Boost Pressure the gage pressure of air discharged from the turbocharger (in pounds
per square inch or kiloPascals)
CAN 2.0B the Bosch-defined Controller Area Network message format and
hardware interface standard that J1939 is based on
Communicating QuickCheck II is in the process of re-establishing communications on
the datalink after saving data
Cruise Set Spd the velocity control system setting (in miles per hour or kilometers per
hour)
Datalink Down! QuickCheck II is not reading any data from the datalink
Disconnected parameter data is not being read from the datalink
ECM Electronic Control Module
Eng Cool Temp the temperature of coolant in the engine cooling system (in degrees
Fahrenheit or degrees Celsius)
Eng Oil Pres gage pressure of oil in the engine lubricating system (in pounds per
square inch or kiloPascals)
Engine Speed the rotational velocity of the crankshaft (in revolutions per minute)
Equipment ID field containing the user's name of each vehicle entered into the
handheld organizer
Failure Mode the SAE-defined J1939/J1587 type of failure detected
Identifier
Fuel Rate the amount of fuel the engine consumes per unit of time (in gallons
per hour or liters per hour)
handheld organizer Palm computing devices (PDA's) for QUICKCHECK II datalink reader:
handheld device Palm III™
handheld Palm IIIe™
organizer Palm IIIx™
Palm V™ with a special adapter
Palm Vll™ PDA = Personal Digital Assistant
HotSync Manager® Palm computing device synchronization technology control software
HotSync® process Palm computing device synchronization technology
Initial the parameter data has not yet been received
INLINE™ another Cummins Inc. datalink adapter
INSITE™ another Cummins Inc. service tool
706
GLOSSARY (Cont'd)
Intake Manifold the temperature of pre-combustion air supplied to the intake manifold
(in degrees Fahrenheit or degrees Celsius)
J1587 a low-speed SAE-defined message format used on a J1708 interface
J1708 the SAE-defined hardware interface for J1587 (and J1922) messages
J1939 a high-speed, SAE-defined, CAN 2.0B based messaging format
Make the manufacturer of the engine or vehicle subsystem
Max Road Spd the maximum vehicle velocity limit (in miles per hour or kilometers per
hour)
Model the model of the engine or vehicle subsystem
No Adapter QuickCheck II is not communicating with the adapter
Output Torque the amount of torque available at the engine flywheel (in foot-pounds
of force)
% Engine Load the ratio of the current load of the engine to the maximum rated load
(in percentage)
PID Parameter Identifier, as defined in the SAE J1587 standard
QUICKCHECK™ II Cummins Inc. datalink reader
Adapter
SAE Society of Automotive Engineers, the organization that establishes
on-road and off-road motor vehicle standards
Saving indicates that data is being stored in a new record
Serial No the serial number of the engine or vehicle subsystem
SID Subsystem Identifier, as defined in the SAE J1587 standard
Software ID the software identifier of an ECM
SPN Suspect Parameter Number, as defined in the SAE J1939 standard
Total Eng Hrs accumulated time of operation of the engine (in hours)
Total Fuel Used accumulated amount of fuel used during vehicle operation (in gallons
or liters)
Total Idle Fuel accumulated amount of fuel used during vehicle operation while idling
(in gallons or liters)
Total Idle Hrs accumulated time of operation of the engine while idling (in hours)
Total PTO Hrs accumulated time of operation of the power takeoff device (in hours)
Total Veh Dist accumulated distance traveled by the vehicle during operation (in
miles or kilometers)
Unavailable data for the parameter is not available to read
VIN vehicle identification number assigned by *vehicle manufacturer
* May be assigned by end user.
707
Accelerator pedal (70TMV-2/70~90ZV-2)
Pedal
A-Black-APS signal
B-White-APS ground
C-Red-APS supply (5 V)
Throttle pedal
D-Green-Throttle active
Throttle E-Blue-Idle active
opening sensor BrW (733)
48 F-Orange-IV8 supply (5 V)
R YV (734)
47
B BLg (735)
49
W E 35
IDLE SW C
OFF IDLE GyY (736) M
3
G
GyW (737)
13
IDLE L
O
Circuit diagram
Connector
(G) 6 1 (B)
(L) 5 2 (W)
(O) 4 3 (R)
A
View A
Note Pedal Test.

Typical pedal potentiometer resistance @ 65 ºF.
To calibrate a new pedal to the ECM, do the following Wire colors are at the pedal harness with accelerator pedal
within about a 5 or 6 second time frame. unplugged.
- Turn "on" key switch Wire colors Ω at pedal up position Ω at pedal down position
- Stroke the pedal fully up and down 3 times. R-B 1,540~2,310 260~390
- Turn "off" the key switch W-B 260~390 1,540~2,310
R-W 2,000~3,000 2,000~3,000
Potentiometer voltage (V)
G-O Open 0
Input 5
L-O 0 Open
Up position 3.75~3.95
Down position 0.55~0.75
708
(70TMV-2/70~90ZV-2)
When the accelerator pedal is pressed, the voltage cor- Accelerator pedal installation
responding to the pressing angle is input as a signal
from the potentiometer to the ECM (engine controller) to Throttle pedal sends electrical signal to the engine
control the engine revolution. ECM*. When the throttle pedal or the ECM* is replaced
or when the battery cable is disconnected the throttle
pedal must be calibrated, or "initialized", with the ECM*.
Failure to initialize the throttle pedal will result in a fault
code warning light, and a possible power deration.
When a new throttle pedal or ECM* is installed or when

the battery cable is re-connected or a fault code (listed
Pedal Stroke Pedal angle below) is indicated follow these steps within a time
stop frame of about 5 or 6 seconds to initialize the throttle
17 pedal with the ECM*.
Installation
angle
45 1. Shut off the engine
28
2. Turn the key to "ON"
3. Fully depress and release the throttle pedal three

times.
Pedal Angle
4. Turn the key to "OFF".
The throttle pedal and ECM* have now been initialized

Between terminal 9 (YV-B) and 23 (BLg-W)
Refer to circuit diagram for details. or calibrated. The engine may be restarted and retested
5V for proper performance.
If the problem continues disconnect the wiring harness

when plugged in, key "ON"
4
connector at the throttle pedal and inspect both sides.
Potentiometer Voltages
The pins and sockets should be clean, dry and straight.

3
If there is a problem correct it, reconnect the connector,
follow the steps above and retest.
2
Using the Quantum fault code information section the
1 following fault codes may indicate a non-initialized throt-
tle pedal:
0
0 17 - Fault Code 132
Pedal Angle - Fault Code 134
- Fault Codes 287, 288
- Fault Code 431
- Fault Code 432
- Fault Code 443
If the problem is not corrected contact your Cummins

Engine distributor for assistance.
*Engine Control Module; Computer that controls engine

functions, and monitors engine faults.
709
Transmission Control Circuit and Monitor Circuit
Machine Control Unit (MCU)
To S5 To S6 To S7 To S8 To S9
710
Connector
Controller
Controller
A 2.2_SO A17.D_SO A32.SS_L B13.F_SO E 2.FC_SO E17.BATT E32.OT_SE C 2.DSUB2 C17.F C32.EG_M D13.SS_N
A 7.LU_SO A22.1/2_L B 3.IP_SO B18.N_R E 7.GND E22.B_SE2 C 7.ET C22.2S D 3.SL_2 D18.SS_SW
A 9.OTH_OUT A24.FR_L B 5.MO_SO B20.CAN_R1 E 9.+5V E24.ALT C 9.BD C24.IP_SW D 5.SL_3 D20.TMP
Connector details
711
Default Position of Specification Setting Monitor

O = VALID
X = INVALID 65TMV-2 70TMV-2
OPTION EITHER 65ZV-2 70ZV-2 80ZV-2 85ZV-2 90ZV-2 92ZV-2 97ZV-2 115ZV-2
ITEM
VALID OR INVALID USA USA USA USA USA USA USA USA
QUAD VALID/INVALID O O O O O O O O
FR SHIFT VALID/INVALID X X X X X X X X
SHIFT HOLD VALID/INVALID X X X X X X X X
AUTO BRAKE VALID/INVALID X X X X X X O* O*
RIDE CONTROL VALID/INVALID X X X X X X X X
EG SPEED NET/SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
EMG STEERING VALID/INVALID X X X X X X X X
K-LEVER VALID/INVALID X X X X X X X X**
EG CURVE OUTPUT/NET/INVALID OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT
POWER UP VALID/INVALID X X X X X X X X
TRACTION CONTROL VALID/INVALID X X X X X X X O
TACHOGRAPH VALID/INVALID X X X X X X X X
ELS (opt for 65/70ZV-2) VALID/INVALID X X O O O O O O
BOOM SOFT LAND VALID/INVALID O O O O O O O O
KICK OUT VALID/INVALID O O O O O O O O
COOLING FAN Atype/Btype/INVALID Atype Atype Atype Atype Atype Atype Atype Atype
TC OIL SW VALID/INVALID X X X X X X X X
EG COOLANT SW VALID/INVALID X X X X X X X X
EG COOLANT SNSR NET/SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
EG OIL PRES SW VALID/INVALID O O O O O O O O
EG OIL PRES SNSR VALID/INVALID X X X X X X X X
BRAKE OIL DIF SW INVALID/NC/NO X X X X X X X X
BRAKE OIL LEVEL INVALID/NC/NO X X X X X X X X
* Auto brake is always valid on 95/115ZV-2 units. ** Pilot operated hydraulics for K-Lever on 115/135ZV-2.
115ZV-2 has optional steering wheel; N/A 135ZV/ZV-2.
Items that are shaded in table in mid shade gray must not be changed.
Items that are shaded in table in lighter gray are addable options.
712
Design
Controller design for all ZV-2 units has changed significantly. The controller works in connection with a
“Machine Operations / Diagnostics Module” (or abbreviated as MODM). The unit displays system faults,
either active (displays when fault is active) or inactive (fault retrievable from system memory).
The controller appears as shown below. There are no longer input and output LED lamps. Input and output
data is retrieved in a different way as seen earlier in this publication.
The same style of controller is used for models 50~135ZV-2. Note the connector address identifiers in the
illustration below. Controller connectors in wire harness are designated to have addresses S5~S9.
Note on part number of controllers
The part number for the controller is in the MODM display.

The first two numbers of the part number should
correspond to the program number below.
Program
Some options are used on some models Model Option
No.
that are not used on other models. 65ZV-2 01
Controllers for each model are arranged 65TMV-2 01
accordingly. 70ZV-2 02
70TMV-2 02
Note the pattern details on the following
80ZV-2 03
pages.
85ZV-2 04
90ZV-2 05
92ZV-2 06
92ZV-2 Lock Up T/C* 07
95ZV-2 08
95ZV-2 Lock Up T/C* 09
115ZV-2 11
115ZV-2 Under Drive Lock Up T/C* 13
135ZV-2 14
Program number * Optional controller
xx_xxxxxx_xxxxxx (does not represent controller p/n)
713
Reference for data; to connectors and terminals.
The following table shows terminal & pin reference data for inputs, outputs, ground, common & power supply.
It is important to understand how this is connected to components on machine to diagnose circuits correctly.
Connector # Inputs Outputs Ground (B wire) 24V DC Power Supply Common (BY & Y wires) +5 V DC Current
S5 A1 ~ A34
B1~B15,
S6 B18, B19,
B24
E14~E16, E1, E2, E5 & E6 E3, E4, E11, E12, & E17 E7 is common (BY) for E9 is +5 V DC current
E19, E9, E10, Declutch, boom angle sensor, for K-lever, declutch,
E22~E24, E21, E26, e/s, ambient air temp probe, boom angle sensor, e/s,
E27~E28, E34 hydraulic system pressure ambient air temp probe,
E30~E32. transducer @ ELS manifold, hydraulic system
water temp-t/c temp-hyd pressure transducer @
temp inputs, t/m pressure ELS manifold, water
S7 sensor, & K-Link. temp-t/c temp-hyd temp
inputs, RS232C
E8 is common (Y) for Speed communications, t/m
Sensor. pressure sensor, brake
pressure sensors to
(F&R), and T1 connec-
tor for RS232C com-
munications.
S8 C1~C34
S9 D1~D26
Other
B17, B23, B26, E25 & E33 are used for
software downloads. B16 & B20~22 are not
used. E13, E18, E20, E25 and E29 are CAN
Link communication terminals.
Note:
Some voltages will of course vary. This should be expected as they are sensors that vary voltage signal by
position, pressure, or temperature. These will include, but may not be limited to, the following.
Examples;
• The fan output to speed control solenoid voltage will change due to temperature changes:
• MV1 will do the same, as SPPC
• K-lever input - same
Same for sensors that follow:

• Boom angle
• Declutch
• Brake accum pressure sensor 1 and 2
• ELS sensor
• T/M pressure sensor
• EMG steering pressure sensor
Same for gauge circuits and ambient temp circuit:

• Temp sensors - coolant, air temp, hyd temp, t/m temp.
714
Technical references for ZV-2 units There are now some abbreviations associated with ZV-2
units that may not have been found in literature for ZV
Abbreviations units. Some abbreviations are;
Abbreviation Explanation
Engine related
Automatic Idle (AI) or same as Engine Idle Management System (EIMS) {shorter “AI” is used for conserving
AI
space}
TC Torque Control {not to be confused with T/C for torque converter}
SC Slip Control (same as traction control)
EP Engine Oil Pressure
WL Water Level
PH Pre-heat
Machine related
Machine Operations / Diagnostics Module (Mounted in dash to display system
MODM
conditions).
S/S K-Lever {from term “stick steer”}
NR Neutral Relay
X Controller failure {for relay and circuit}
DSon Dual Stage is on (Meaning that ELS is functioning)
Vni Voltage normal idle
TWni Temperature Water normal idle
KO, Ks Kick out {for boom raise} (Ks is “Kickout set”)
BS Kick out {for boom lower; derived from boom soft landing [previously BSL]}
ES Emergency Steering
BZ Buzzer
4S 4th indicator {for relay to illuminate lamp}
BP Brake Pressure
ELS Efficient Loading System
E Ground (or Earth)
ATS Ambient temperature sensor
Others are explained as required in the publication
Communications related abbreviations
CAN Cable Area Network
CANH0 Port of CAN high signal for J1939 data link to read message in MODM and Cummins Quick Check.
{Designated “0”}
CANL0 Port of CAN low signal for J1939 data link to read message in MODM and Cummins Quick Check.
{Designated “0”}
CAN H1 Port of CAN high signal. (Designated “1”, and is not used)
CAN L1 Port of CAN low signal. (Designated “1”, and is not used)
RIN1 Receiver IN (RIN); See TXD1 below
DOUT1 Driver OUT (DOUT) See RXD1 below
TXD1(driver) Same as RIN1; Data transmitter (transmits data to Data Terminal Equipment or DTE)
RXD1 Same as DOUT1; Data receiver (receives data from Data Communications Equipment or
(receiver) DCE)
Channel 1 Used for communications with TXD1 and TXD2.
Channel 2 Used for communications with RIN1 and DOUT1.
Short for Recommended Standard-232C, a standard interface approved by the
RS232C
Electronic Industries Alliance (EIA) for connecting serial devices.
Explanation of others terms
While these are not abbreviations, they are terms that are new for ZV-2 units.
Engine droop selection 1 Selects alternate power curve for Torque, HP and RPM
Engine droop selection 2 Selects alternate power curve for Torque, HP and RPM
Tachograph (Speedometer - Option for Japan domestic machines)
715
Note the callout descriptions below as they

apply to each connector.
S5 S5 connector
connector
716

S6 connector
S6
connector
*
*
*Voltage will vary by signal (some will not read 24 V DC)

B5 is for SPPC (N/A 70TMV-2/70~90ZV-2)
B7 is for K-Lever option
B24 is for speedometer (N/A USA)
B25 is for engine coolant sensor (voltage driven by temperature)
717

S7 connector S7
connector
*
*
*
*
*
* 12~14 V DC
*
* E1 is for K-Lever option
E2 is for fan speed control voltage
E9 is 5 V DC output (5V DC constant)
* E15 [12~14 V DC] varies by E/G RPM
28 V DC
* Square wave - 50% duty cycle
* *
0V
E16 is AC Voltage (varies by m/c speed)
*
* Sine wave - 0V
E19 signal varies w/ K-Lever motion
*Voltage will vary by signal (some will not read 24 V DC)
E21, 22, 23, 27, 30, 31, 32 & 34 all
vary by changes of temp. or press.
E24 is about 12~14 V DC; driven by
(engine active) alternator signal.
718

S8 connector S8
connector
*
*
* C1 is ELS pressure sensor signal

*
C19 is driven by t/m pressure sensor
and does not apply to 70~90ZV-2
C27 is driven by pressure from op-
tional emergency steering pressure
sensor
C26 is the signal from boom angle
sensor
* Voltages will vary according to circumstances
719

S9 connector S9
connector
720
MCU connection diagram

From model 90ZV-2. Models 70~85ZV-2 are similar.
ACC’ (L) (005-b) E

TO PARKING SW.
(005)
F5 L
2
(L) (005-a)
30A
G (010)
F10
E
ACC’ L x 4 (005-A~005-D)
E05 E06 E17 E04 E12

E03 E11
(SbP) (145)
WL (707) B18 NR NEUTRAL RELAY
E24
LgW (101)
B12 X CONTROLLER FAILURE RELAY
LR (126) BrB (258)
D11 B11 KO LIFT KICK OUT RELAY
LBr (128) L (273)
F N R B10 BS
OPT
LEVER
SHIFT
YGy (242) EMERGENCY STEERING
A03 M
MOTOR RELAY COIL (OPT)
1 (146) LR
23A B13 F SOLENOID VALVE
LW (120)
D12
LO (123)
D05
LG (122) (148) LBr
D03 B04 R SOLENOID VALVE
LY (121)
D10 (141) LY
A18 1ST SPEED SOLENOID VALVE
F YO (232)
D19 (LY )
F/R SW. (OPT) YW (233)
D26 (142) LG
R A02 2ND SPEED SOLENOID VALVE
LG (122) (LG)
SHIFT UP SW. (OPT) D06
LY (121) (143) LO
SHIFT DOWN SW. (OPT) D07 A05 3RD SPEED SOLENOID VALVE
(LO)
S/S SHIFT YV (231)
D18 (144) LW
SELECTION SW. (OPT) F5 A08 4TH SPEED SOLENOID VALVE
LB (230)
ARMREST SW. (OPT) D24
(LW)
(YL) (124) LP (149)

DOWNSHIFT SW. D14 A17 D SOLENOID VALVE
WR (170)
YSb (125) B14 (NOT USED)
SHIFT HOLD SW. (OPT) D17
LP (168) LLg (140)

DECLUTCH SET-UP D15 A07 (NOT USED)
LgL (261) RIDE CONTROL
A04
SOLENOID VALVE (OPT)
BrG (255) GB (267) EFFICIENT LOADING SYSTEM
LIFT KICK OUT SET-UP D22 A01
SELECTION SOLENOID VALVE
BW (271)
LOWER KICK OUT SW. C31
B06
SOL. VALVE (OPT)
REVERSAL Lg (222)
FAN SW. (OPT) C25
AUTO FAN LgY (223) BR (236) S/S SOLENOID
C34 E01
REVERSAL SW. (OPT) VALVE R (OPT)
BL (237) S/S SOLENOID
(Y) (105) B07
RECALL SW. C30 VALVE L (OPT)
(R) (106)
E02 FAN SPEED CONTROL
LLg (165) SOL. VALVE
D21
(013)
E F13 GO (164)
D01 (Lg)
DECLUTCH (013) GyW (200)
F13
CUT-OFF C23 (LgR) (130)
(Lg) A21 AUTO SHIFT INDICATOR LAMP
GL (265) (GR ) (135)
C22 A29 NEUTRAL INDICATOR LAMP
YO (176) (GyW) (260)
C33 (GyB ) (103)
(LgY) (167) EP (LgY) (173)
Gy (750) A28 BRAKE OIL PRESS. WARNING LAMP
DECLUTCH (Gy) (749)
DECLUTCH SW. A19 E/G OIL PRESS. WARNING LAMP
BrY (181) (GyG) (753)
HYD. OIL LEVEL SW. C11 A15 E/G COOLANT TEMP. WARNING LAMP
(163)
ON (SbW) (GyL) (190)
LgL (182) A16 T/M OIL TEMP. WARNING LAMP
AIR CLEANER C06 (LgW) (192)
OFF CLOGGING SW. A27 AIR CLEANER WARNING LAMP
(162) (O ) (241)
PARKING SOL. LgG ON (005-b) A12 STEERING OIL PRESS.
(L)
F5 WARNING LAMP
OFF
PARKING SW. E
RIDE CONTROL SW. (OPT)

CONTROLLER X (LgW) (102)
FAILURE
(LgSb) (112) BZ
WARNING BUZZER
FUEL LEVEL
GAUGE
(404) (YBr)
721
Controller (continued)
(GY) (169) AUTO BRAKE INDICATOR LAMP

A20
(NOT USED)

A32
INDICATOR LAMP (OPT)
(LgB) (224)
A24 S/S INDICATOR LAMP (OPT)
V (100)
E09(+5V)
S/S POTENTIOMETER (OPT) LgBr (104)

G (234) B09 BZ BUZZER
E19
BOOM ANGLE SENSOR
BrR (251) (YB) (401)
C26 E34 E/G COOLANT TEMP. GAUGE
DECLUTCH SENSOR
(LgR) (166) (BrW) (402)
E27 E21 T/M OIL TEMP. GAUGE
BRAKE OIL
PRESS. SENSOR 1 SbY (171) (400)
E30
(WL)
BRAKE OIL B24 METER OUTPUT (TACHOMETER)
PRESS. SENSOR 2 SbY (172) E22
EFFICIENT LOADING SYSTEM

OIL PRESS. SENSOR GyB (266)
C01
EMERGENCY STEERING
OIL PRESS. SENSOR (OPT) SbR (240)
C27
GyG (754) YSb (403)
E/G COOLANT TEMP. SENSOR B25 A06 HOUR METER DRIVE
GyL (180)
T/M OIL TEMP. SENSOR E31 SbR (208)
(G) (415)
AIR TEMP. PROBE E32 SbP (202)
A09 TC E/G TORQUE SELECTION
GyO (220)
B15 E/G DROOP SELECTION 1 (NOT USED)
BY (114) SbLg (204)
E07 A34 E/G DROOP SELECTION 2 (NOT USED)
Y (160)
W (161)
(RL)(330)
Y (159) A10 TO BACK-UP LAMP
E08 (RG)(331)
B19 TO BRAKE LAMP
(100)
(E09) V
+5V
YB (115)
(OUT_FEW)B23 FEW
YG (116)
(OUT_RES)E33 RESET
YL (117)
(RXD0)E25 RXD CONTROLLER PROGRAM REWRITE
YO (118)
(TXD0)B26 TXD
YBr (119)
E (OUT_MD2)B17 MD2
P (107) GND
DESTINATION SWITCH 1 C02
PL (108) E
DESTINATION SWITCH 2 C03
PG (109) GL (810)
A/M SELECTION D02 (RIN1)B16
PB (110) GR (811) RS232C
ODOMETER SELECTION (DOUT1)B22
D16
PW (111)
TIRE DIA. SELECTION D25 S2H
(CANH0)E29
SPEED SENSOR SELECTION D08 S2L
(CANL0)E20 CAN
S2S
METER SELECTION D09
E MAIN CONTROLLER E
722
Machine Failure Codes
723
724
725
726
MCU; Controller function (70TMV-2/70~90ZV-2)

Forward/reverse (F/R) shifting and speed change
Note that there is no shift lever pin for neutral.
No F nor R = N.
From T/C pump
F/R clutch solenoid valve

N
F R F Clutch pressure regulator valve
+24 V
Shift lever
R Surge
suppression
diode
Speed clutch (incorporated
solenoid valve in solenoid To solenoid valve bank
A
1 valve)
23 1 Clutch piston
Speed
indicator lamp
(instrument panel)
+24 V 2
Shift switch
Drain Clutch control solenoid valve
3
energized clutch engage
de-energized clutch disengage
Speed sensor 4
+24 V
AUTO indicator lamp

ON when shift lever in A position
Each clutch has one solenoid valve for transmission Operation error preventive function
control. When electric current flows through the sole- (Simultaneous input of two or more commands)
noid valve, the clutch oil is fed into the clutch piston
chamber. When the piston operates, the clutch is If both the forward and reverse commands are input at
engaged. When the current stops flowing through the the same time due to a problem, the forward and
solenoid valve, the oil is drained from the clutch piston reverse clutches will not function. In addition, if two or
chamber, and the clutch is disengaged. more speed commands are input at the same time, the
machine will stay engage in the gear just before the shift
Input detection lever stuck and still move with it’s gear selection.
When the shift lever is set to the F (forward) position, Note

electric current for input detection signal is sent from the At the time that the keyswitch is first turned to the "ON"
controller to the grounding circuit via shift lever contact
position, the internal logic inside the controller does a
F. The controller, therefore, judges that the shift lever is
set to the F (forward) position. There is no shift lever circuit check and momentarily completes the circuits to
contact for the R (reverse) input circuit and electric cur- each coil to test for circuit completion. If there is a fail-
rent will not flow.
ure in a circuit the controller will log a fault to alert the
For the speed change, the controller judges the set operator that there is a problem.
speed position of the shift lever in the same way as
described above.
727
Shift lever (65~90ZV-2 & 65/70TMV-2)

2 1
Forward F
KNIGHT BEAM CO,LTD

JAPAN
>PAMXD6-G50<
Neutral N
BM51-111
Reverse R
1st speed
2nd speed
3rd speed
Auto
Grounding for
speed change side (B)
3
1st speed (GW) 2nd speed (GL)
Auto (G) 3rd speed (GY)
F (GR) Unused
R (GB) Grounding for
F/R side (BY)
1. Bracket assembly Operator controlled shifting from 2 → 1 → 2 in either "2"

2. Grip or "A" is done by momentarily depressing the downshift
3. Connecter button on the boom lever.
The shift lever has two direction and four speed posi- Shift lever neutral (N) position
tions; forward and reverse (F and R) and "1", "2", and
"3" speed positions are respectively used for 1st, 2nd, The shift lever has no neutral (N) contact.
and 3rd fixed speeds. The "A" speed position is used for
the variable speed where the 2nd through 4th speed Therefore, if neither the forward nor the reverse (F and
clutches are automatically changed in both the forward R) signal is input, the controller will judge that the shift
and reverse operation. lever is at the neutral (N) position.
Note
If both the forward and reverse commands are input at the same time due to a problem, the forward
and reverse clutches will not function. In addition, if two or more speed commands are input at the
same time, the machine will stay engaged in the gear that was engaged just before the shift lever stuck
and still move with that gear selection until diagnosed and repaired.
728
Operation of solenoid valves Automatic shift (90ZV-2 shown - others will vary slightly)
(70~90ZV-2 & 65/70TMV-2)
Clutch solenoid valve
Shift up
A 10.8 N-m (1.1 kgf-m) (8 lb-ft) Shift down
Speed
4
3
+ side
K W E 6 K- 21/ 2
- N
SKM6
G24D
20.0 18.0 10.5 8.5 0 7.5 9.5 16.5 18.5

– side
Reverse Speed km/h Forward
View from A
90ZV-2 automatic shift map (Normal mode)
35 N-m (3.6 kgf-m) (26 lb-ft)
Shift up
Shift down
4
Solenoid valve (with built-in diode)
Rated voltage DC 24 V 3
Coil resistance value Approx. 27 Ω
2
When the input signal is transmitted, the output circuit of
the corresponding solenoid valve is connected to the
18.0 16.0 9.0 7.0 0 6.5 8.5 14.5 16.5
grounding circuit. As a result, power is supplied to the
solenoid valve and the clutch is engaged. At the same Reverse Speed km/h Forward
time, the speed indicator lamp in the cab lights. 90ZV-2 automatic shift map (Fuel efficient mode)
Note that when the parking brake or declutch brake is When the shift lever is set to A, the AUTO indicator lamp
applied, the forward or reverse (F or R) clutch solenoid in the cab will light and one of the 2nd through 4th
valve is turned off and the transmission is set to neutral. speed solenoid valves will be automatically energized
according to the machine speed. In addition, the speed
indicator lamp will light. The input signal for automatic
shift is controlled by the pulse generated by the speed
sensor.
This process requires a clean sine wave signal from the

ground speed sensor.
729
Machine speed sensor (70TMV-2/70~90ZV-2)
39 N.m (4.0 kgf-m) (29 lb-ft)
Clearance adjustment
0.9 mm (0.035 in)
Internal resistance * 2.3±0.2 kΩ (25 ºC) (77 ºF) IMPORTANT

* Internal resistance changes greatly with temperature. At lower tem-
perature the resistance is lower. At operating temperature the resis- Make sure to apply the correct torque value when
tance increases. replacing the sensor. Shims help to set clearance be-
If resistance is 0 Ω or ∞ Ω the speed sensor is defective.
tween sensor & gear but over-torque can change clearance.
The detector is adjacent to the transmission output Excessive torque can stretch sensor, damage case &
gear. The pulse voltage is transmitted to the controller. coil windings.
Note
To prevent electronic "noise" from other sources that
may corrupt signal, "twist" the wire from sensor all the
way to the controller.
Clearance:
70ZV-2 0.9 mm(0.035 in)
80ZV-2 0.6 mm(0.024 in)
85ZV-2 0.6 mm(0.024 in)
90ZV-2 0.6 mm(0.024 in)
[95ZV-2 0.9 mm(0.035 in)]
730
Switching from automatic to manual Note

(70TMV-2/70~90ZV-2) Leaving a machine in manual shift should be discouraged.
Usually what is required is some operator training with the

B
goal in mind to help an operator to see the benefit of using
LgL SbY GR SbLg SbL GR WL GyG

either 1st & 2 nd with QUAD or Automatic mode with QUAD
A502 A507 A701 A608 H718 T103 A806 H136
A/M LY Gy Gy LP
A708 A506 A807 A808
LgB
A604
WO SbW GL
H117 H703 T104
SbP RG
F701 H139 while in 2nd range.
SELECTION H201
RL 0 GyB GyG GyL LP SbR LgBr L BrB LgW LR
B H128 A609 A809 A505 A501 H207 F102 G602 T001 T901 F901 H205
This makes the machine performance better in the long run.

T801
GB LG YGy LgSb LO YSb LLg LW SbP LBr LgL BL
PG H121 A709 E804 H122 A710 A901 H110 A711 F202 H206 E502 E001
H202 H203 H204
S902
1
1 9 1 7 If operated correctly will run better & consume less fuel.
(BLACK)
S4 S5 S6
The machine has automatic shift cancellation function

for troubleshooting. Connect the coupler (OPT) to S4
coupler to cancel the automatic shift function. The mode
will be switched from automatic to manual. Position "A"
of the shift lever, therefore, is fixed to the 4th speed.
Downshift (QUAD*) button operation Downshift button

Acronym for "Quick Up and Downshift"
Downshift button
YL
BY
The downshift button is attached to the boom control Max. voltage DC 24 V

Allowable value
lever. Current 10 mA
In any operation mode, pressing the downshift button The downshift button is of the momentary type. It is
during 2nd speed operation shifts the 2nd speed to the spring loaded to the "OFF" position.
1st speed. After that, if the downshift button is pressed
If it sticks in the "ON" position, it will log a CN fault code.
again, the speed is changed from the 1st to the 2nd, or
to move the shift lever to neutral or to the opposite
direction, the speed will be changed to the 2nd again.
Note that when the speed is shifted, the transmission

status monitor lamp on the instrument panel changes
from the 2nd gear to the 1st gear or from the 1st gear to
the 2nd gear.
731
Adjustable declutch preset switch (70TMV-2/70~90ZV-2)

200
Clutch OFF
There is a shaft connecting

Clutch ON
the right to the left brake pe- 0 310 510 (kPa)
dals. Declutch sensor
Declutch preset
switch Declutch sensor psi Transmission clutch
More than 75 (psi) Disengage

ON
Less than 45 (psi) Engage
Adjustable declutch preset switch is used to change both

angle & pressure of left brake pedal (Declutch pedal) to
disengage the transmission (fwd or rev) clutch.
Declutch sensor
With the engine running, step on the left brake pedal
(Declutch pedal) up to the desired angle and press the
switch to set the brake pedal (Declutch pedal) angle.
When the set pressure & pedal position has been selected
an alarm will sound - indicating that the controller has reg-
istered the new pressure as the selected set position for de-
clutch.
Switch
732
Right brake pedal (70TMV-2/70~90ZV-2)
Micro switch
for declutch Forward/reverse clutch
Transmission & m/c controller
E Dash NC
solenoid valves
s/w COM LLg (165) F
D21
NO R
YO (176)
V (100)
+24 V E09 (+5V)
LgR (166)
E27
BY (114)
E07
Roller
MD
Brake pedal .5
R48
(right)
OT
FP
OP
Micro switch
COM NC
50 05R0 CA001
L=200 05R0 CA001
50
Minimum application load: DC5V 160 mA
COM NO NC
Pressing right brake pedal opens micro switch (see above) OF (Operating force) max. 130 g
and opens circuit to ground that is at D21 in the controller. RF (Return force) min. 21 g
OT (Operating distance) min. 4 mm
This results in the declutch signal being ignored by the con-
MD (Moving distance) max. 1.6 mm
troller. Thus it ignores signal to de-energize fwd or rev.
FP (Free position) max. 36.5 mm
Result is that the transmission remains engaged with an OP (Operating position) 30.2 ± 0.8 mm
application of the right brake pedal.
733
Back-up alarm (70TMV-2/70~90ZV-2)
Back-up lights
N
F R
Back-up alarm
Shift lever
+24 V
A10
1 A
2 3
When the shift lever is set to the reverse (R) position,

the back-up lamp will light, and the alarm will sound.
734
Parking brake (70TMV-2/70~90ZV-2)
5A
+ 24V
F13
P Monitor lamp
Parking (ON)
Parking brake
Running (OFF) Cylinder
Parking
switch
ON
OFF F
D01 P
R
30A
F5
+ 24V
The parking brake solenoid valve activates the parking

brake.
Parking switch ON: Parking switch OFF:
When the power of the solenoid valve is turned off, no When the power of the solenoid valve is turned on, oil
oil will be fed to the oil cylinder. The spring inside the will be fed into the oil cylinder. The oil will depress the
cylinder applies force to make the brake apply (drum spring to release the brake.
type). If the transmission shift lever is set to the forward
or reverse (F or R) position, the buzzer will sound and
the clutch will not be engaged. Note
Loss of accumulator pressure will set the parking brake.
Parking brake operation
Parking brake
Parking switch Monitor lamp Buzzer
solenoid valve
"Parking" position Sounds when shift No electric power
Parking * P
(pulled up) lever is set to F or R supply
"Running" position
Running Off No buzzer Electric power supply
(pushed in)
*When parking switch is set to "parking", forward or reverse clutch is disengaged and set to neutral so operator cannot drive through park brake.
735
Controller failure warning (70TMV-2/70~90ZV-2)
Should the controller stop working due to any of the fol-

lowing causes, a dash mounted monitor lamp lights up
to give warning.
Controller failure monitor lamp
If a warning is given as a result of self-diagnosis of

the controller Body blue
The controller has a self-diagnosis function incorpo-

rated in it, and if the computer program becomes abnor-
mal due to abuse or defect, a dangerous condition may
occur, the monitor lamp lights up and all the outputs
from the controller are turned OFF. 1 2
LgW
L
If the circuit protector (CP) is turned OFF
LgW
B
If the circuit protector is automatically turned OFF due to 4 3
a short circuit, etc, in the output circuit, the monitor lamp
lights up and all the outputs from the controller are
Chassis side
turned OFF. Elec. circuit coupler
Controller replacement
If the monitor lamp lights up under the cause 1 above, it

is an indication that the controller's program has mal- Rating DC 24 V
functioned and the controller assembly must be Operation voltage 16 V or less
replaced. Reset voltage 2.4 V or more
Coil resistance 320 Ω
When installing a new controller on the machine, all
specifications must be registered into the controller
through the MODM.
Controller fault relay (Normally closed)
If the monitor lamp lights up under the cause 2 above,
the cause is NOT the controller.
Once the cause is removed, the controller may be reset

and continue to be used.
To reset simply turn the circuit protector switch to "ON".
736
Emergency steering function (OPT for (70TMV-2/70~90ZV-2))
Speed sensor
Pilot lamp To steering valve
F13
Controller To loading line
Pressure
sensor
Check valve Check valve

G1
G1/2
+24 V Emergency G1
steering motor G1/2
G3/8
and pump
To brake and
pilot line
11.7MPa
(119.3 kgf/cm2)
16 100.4 63.4 45.6
M cm3/rev M cm3/rev cm3/rev cm3/rev
G1/4 TS
Magnetic switch Hydraulic line
(on motor and pump)
Steering pump Electrical circuit
In normal operation, the oil from the steering pump Machine speed signal
flows into the steering valve through the check valve.
And the signal of the pressure sensor is always sent to
the controller.
The signal from controller
With some problems, as the steering hydraulic pressure

goes down while the engine is running, the pressure ON
to magnetic switch
sensor signal becomes less than the preset valve at the

controller. In this condition, if the machine speed is more
than 2 km/h, the controller sends a signal to the mag-
netic switch. Machine speed
OFF
(km/h)
1 2
As a result, the emergency steering motor and pump
are driven. Then it is ready to steer the machine.
Pressure sensor preset valve
Steering hydraulic pressure

ON: at 0.3 MPa (3 kgf/cm2) (44 psi) or lower
OFF: at 0.4 MPa (4 kgf/cm2) (58 psi) or higher
737
Monitoring system (70TMV-2/70~90ZV-2)

If a problem of a unit is detected while the engine is run- When the starter switch is set to ON, all of the monitor
ning, a monitor lamp lights to inform the operator. lamps are lit for 3 seconds and buzzer sounds to check
whether the monitor lamps are normal (not burn out).
For some problems, the buzzer sounds also, and the
central alarm lamp flashes also.
Items to be monitored and operation condition
Monitor lamp
No. Item to be monitored Operation condition Buzzer Lamp test Remarks
Lighting Symbol
color
Defective controller (CPU)

1 Controller —
Computer Processor Unit
(red)
Unloader valve accumulator port

2 Brake oil pressure oil pressure 3.9 ± 0.5 MPa
(red) (40 ± 3 kgf/cm2) (569 ± 71 psi)
While engine running

3 Engine oil pressure 0.08 ± 0.01 MPa (0.84 ± 0.14 kgf/cm2)
(red) (12 ± 2 psi) or less for more than 2 seconds
101 ± 2 ºC or more
4 Engine water temperature (214 ± 4 ºF or more) —
(red) for more than 2 seconds
Torque converter oil 120 ± 5 ºC or more

5 (transmission) (248 ± 9 ºF or more) —
temperature (red) for more than 2 seconds
Filter resistance: 635 ± 58 mmAq

6 Clogged air cleaner or more (25 inches H2O) —
(red) for more than 2 seconds
7 Charging condition Defective charge system —

(red)
8 Central alarm For items 1~6, 9 — Flashing type

(red)
When operates steering pressure is

Steering oil pressure
9 less than 0.4 MPa (4 kgf/cm2) (57 psi)
(option)
(red) machine speed more than 2 km/h
(red)
Hydraulic oil level is low when the engine is
10 Hydraulic oil level
stopped
(red)
11 Engine protection lamp —

(orange)
Any fault in engine detected by ECM

12 Engine warning lamp —
(Engine controller) (2 sec.)
(yellow)
13 Engine stop lamp —

(red) 738
Operation monitor lamps (70TMV-2/70~90ZV-2)
Monitor lamp
No. Monitor item Lighting condition Remarks
Lighting Symbol
color
1 Parking Red When parking brake switch is set to ON
2 Declutch Green When declutch switch is set to ON
When working light (rear) switch is set

3 Working light Green
to ON
When starter switch is in the

4 Preheat Orange
PREHEAT position
Turn signal indicator When turn signal lever (left) is

5 Green
(left) actuated
Turn signal indicator When turn signal lever (right) is

6 Green
(right) actuated
7 High beam Blue When head lamp is set to high beam
When transmission shift lever is set to

8 Auto shift Green
automatic position

9 Neutral Green
neutral position

10 Transmission status Orange
corresponding gear (1~4)
11 Ride control Green When ride control switch is set to ON (OPT)
Caution on storage of individual instrument panel

Pointer axis
Gauge pointer
IMPORTANT Axis hole
Main body
When storing the instrument panel individually, make frame
sure that the panel face (transparent face) faces
upward.
If the panel face faces below the vertical direction, the
damper oil may leak from meter pointer axis holes. Damper
oil Magnet
Meter
739
Instrument Panel and Switch
Instrument panel (70~90ZV-2)

70TMV-2 is similar and incorporates a switch for quick coupler
21 20 17 9 19 5 18 2 23
1 4 10
11(37)
12
30 26
28 27
13
29
34
14
35 15
36
16
STOP
6 33 32 31 24 25 22 7 8 3
(37)
Actual placement of switches should be close to what is indicated in the illustration above.
1. Tachometer 20. Auto shift indicator lamp

2. Engine coolant temperature gauge 21. Neutral indicator lamp
3. Transmission oil temperature gauge 22. Transmission status monitor
4. Fuel gauge 23. Hour meter
5. Parking brake indicator lamp 24. Reversal fan pilot lamp (option)
6. K-Lever indicator lamp (option) 25. Emergency steering warning lamp (option)
7. Working light indicator lamp (rear) 26. Working light switch (front)
8. Preheat indicator lamp 27. Working light switch (rear)
9. Central warning lamp 28. Fuel efficient mode switch
10. Controller warning lamp 29. Ride control switch (option)
11. Brake oil circuit warning lamp 30. Four-way flasher switch (option)
12. Engine oil pressure warning lamp 31. Engine protection lamp
13. Engine coolant temperature warning lamp 32. Engine warning lamp
14. Transmission oil temperature warning lamp 33. Engine stop lamp
15. Air cleaner clogging warning lamp 34. Efficient loading system switch
16. Charge warning lamp 35. Declutch selector switch
17. Turn signal indicator lamp (left) 36. Selection switch for K-Lever (option)
18. Turn signal indicator lamp (right) 37. Hydraulic oil level warning lamp
19. High beam indicator lamp
740
Switches (70TMV-2 shown)
11 4
6 5
15
16 17
STOP
12 7 8 9
3
2
10 19 18
22
21 23
20
14 13 1
1. Starter Switch 12. MODM

2. Parking Brake Switch 13. Adjustable Declutch Preset Switch
3. Light Switch 14. Kickout Control Switch
4. Front Working Light Switch 15. Efficient Loading System Switch (option)
5. Rear Working Light Switch 16. Declutch Switch
6. Fuel Efficient Mode Switch 17. Selection Switch for K-Lever
7. Front Wiper Switch 18. F/R Switch (option)
8. Rear Wiper Switch 19. Reversal Fan Switch (option)
9. 12 Volt Power-outlet Socket 20. Ride Control Switch (option)
10. QUAD Up/Downshift Button 21. Shift Hold Switch (option)
11. Four-Way Flasher Switch (option) 22. Bucket / Attachment Leveler Switch
23. Quick Coupler Lock Pin Switch (option)
741
Instrument panel rear surface (70TMV-2/70~90ZV-2)
CN4
CN1 CN3
1 4 L11 L13 29 48
L12
8P L20 12P 16P
L1 58 57
5 8 L14 L10 35 56
Hour L10 L10
L2 meter
L10 L15 S
L21
L3
L16 E V
L4 S S
L17 L10
L5 E V E V
Fuel gauge Engine water temperature L18
sensor
L6 L10 L10
L19
L7 S
CN2
L8 9 18 L22 L23 L24 L25 L26 L27
E V 20P
Transmission oil
L9 temperature sensor 19 28
Layout of connector pins (Instrument panel side)
CN1(8P) CN2(20P) CN3(12P/16P) CN4(2P)

A5 A6 A7 A8 A9
1 2 3 4 9 10 11 12 13 14 15 16 17 18 29 30 31 32 33 34 41 42 43 44 46 47 48
58 57
5 6 7 8 19 20 22 23 24 25 26 27 28 35 36 37 38 39 40 49 50 53 54 55 56
Pin Lamp Pin Lamp Pin Lamp

Signal Signal Signal
No. No. No. No. No. No.
1 — L9 21 — 41 AUTO lamp L20
2 Charge lamp L7 22 Fuel gauge (sensor) — 42 — L16
3 Air cleaner clogging alarm L6 23 — — 43 Converter (+) —
4 T/M oil temperature alarm L5 24 — — 44 Converter (–) —
5 Engine water temperature alarm L4 25 — — 45 —
6 Engine oil pressure alarm L3 26 — — 46 Declutch lamp L17
7 Brake alarm L2 27 — — 47 Preheating lamp L19
8 Controller failure alarm L1 28 GND (–) — 48 Work lamp L18
9 +24 V power supply — 29 +24 V power supply — 49 Central alarm lamp L14
10 Emergency steering (optional) L22 30 — — 50 GND (–) —
11 Reversal fan (optional) L23 31 — — 51 —
12 Engine warning lamp L25 32 — — 52 —
13 Engine protection lamp L24 33 — — 53 High-beam lamp L12
14 Engine stop lamp L26 34 Neutral L21 54 Turn signal (left) lamp L13
15 — L27 35 GND (–) — 55 Turn signal (right) lamp L11
16 E/G water temperature (sensor) — 36 1st speed indication — 56 — —
17 T/M oil temperature (sensor) — 37 2nd speed indication — 57 Hour meter (–) —
18 — — 38 3rd speed indication — 58 Hour meter (+) —
19 Instrument panel illumination L10 39 4th speed indication —
20 — L8 40 Parking brake lamp
742 L15
Gauge circuit (70TMV-2/70~90ZV-2)
Sensor
Grounding S Power supply

24V
E V 15V
Viewed from rear surface of instrument panel
Sensors respectively detect the temperature, pressure,

and fuel level, and then convert them into electric sig-
nals. The signals are transmitted to the corresponding
gauges that indicate the transmitted values. (Refer to
"Checking gauge" in back of this manual)
Note
If a gauge is removed from the panel, the resistance
between the terminals will differ from the standard value
shown in the table.
Resistance between gauge

terminals (Ω)
Between S and E 110
Between S and V 110
Between E and V 150
Gauge Engine water temperature T/C. T/M oil temperature Fuel level
E F
Indication
White Red White Red White
743
Temperature sensor (70TMV-2/70~90ZV-2)
(For engine water temperature and torque converter

oil temperature)
Flat terminal
Thermister
Temperature of 60 80 100 120

detection part (ºC) [140 ºF] [176 ºF] [212 ºF] [248 ºF]
Resistance (Ω)
between terminal 56.3 29.5 16.5 10
and body
744
Fuel level sensor (85/90ZV-2 shown; Others are similar, dimensions vary by model)
Float arm
Float
FULL
Highest position
(13.54 in)
344
1/2
(3.05 in)
77.5
(A)
(7.7 in)
195.5
(13.54 in)
1/4
344
Support
Lowest position
EMPTY
The sending unit float arm in the fuel tank moves by the
fuel level movement in the tank. The contact installed on
the float arm axis back side (A) also moves by contact-
ing the resistance wire. The contact position is fixed,
Fuel gauge
F13 based on the float position and the fuel level.
When the fuel level becomes low, the resistance value
5A rises accordingly.
The position of the fuel gauge pointer is decided by this
resistance value, and the fuel gauge shows the fuel
Fuel level sensor amount left in the tank.
E
Fuel level circuit Float position FULL 1/2 1/4 EMPTY
Resistance (Ω) 10 +1.0
- 0.5 (32) 49.5±4 85 +100
Note
Figure in ( ) is for the reference resistance, at 1/2 way
position in sweep.
745
Electrical Detent Circuit (70TMV-2)
Bucket leveler
After dumping, if the control lever is set to the "rollback"
position, the control lever will be held at that position
Could be equipped with optional until the bucket is tilted to the set angle. This is because
Detent single lever control. the detent solenoid in the pilot valve is energized so that
the fixing disc connected to the push rod is held by the
Not shown.
magnetic force. When the bucket is positioned at the set
angle, the rod will retract from the proximity switch. The
proximity switch is turned off and the detent solenoid in
the pilot valve is de-energized and demagnetized. The
control lever is automatically returned to the neutral
position by the spring. As a result, the bucket is set to
the selected digging angle automatically.
Multiple control valve
Outside boom
Bucket cylinder (R.H)
Inside boom
Indicator lamp Indicator lamp
Rod (the detected object) Proximity switch Proximity switch

(for bucket) (for fork attachment)
746
70TMV-2
Switch
In addition to the bucket leveler, the attachment leveler

(for fork) is equipped with this electrical detent circuit.
When exchanging an attachment, the leveler selection

for bucket or attachment (fork) can be controlled by
using the bucket/attachment leveler switch on the con-
sole box.
Proximity switch (70TMV-2/70~90ZV-2) 70TMV-2 is equipped with two proximity sensors due to
differences in bucket and fork lugging geometry.
Adjusting the clearance The desired proximity switch must be selected with the
switch at the dash panel.
Proximity switch +24V
LED
Switch Br 1
Coil for detent
main. B 2 inside
circuit L
3
pilot valve
+24V
Detection part
Operation indicator lamp (LED)
1(Br)
Detected View Z
object
3(L) 2(B)
5±2 mm (0.197±0.079 in)
Adjust the clearance between the sensor and the Note that the proximity switch is no longer used for
adjusting plate to 5±2 mm (0.197±0.079 in). In this con- boom raise. This function is now operated by the
dition, the operation indicator lamp (LED) is on, and the rotary sensor.
circuit between the switches (2) – (3) is on.
747
Detent solenoid (70TMV-2/70~90ZV-2)
Could be equipped with optional

single lever control.
Not shown.
Push rod
Detent
solenoid
Fixing
disc
Three detent solenoids are installed in the pilot valve.
One detent solenoid, for the bucket leveler, is installed

in the pilot valve bucket side.
Two detent solenoids, for the boom kick-out and float,

are installed in the pilot valve boom side.
Voltage DC 24 V
Coil resistance 62 ± 3 Ω
748
(70TMV-2/70~90ZV-2)
Top View
Female spade
Female spade
Male spade
Color coding and reverse coupling

make it difficult to incorrectly
connect the wires. Left
Side View Back View
Tank return "out"

Blue
Beige Pilot pressure "in"
Beige
Color coding and reverse coupling make it difficult
Bottom View to incorrectly connect the wires.
Could be equipped with optional

single lever control.
Not shown.
749
SPECIAL PROCEDURES
(70TMV-2)
Adjustments 6. To test the adjustment; start the engine, raise
the boom approximately half way, dump the
attachment, and move the bucket control lever
Bucket / Attachment Leveler Adjust-
to the "Roll Back" detent position to rollback
ment the attachment.
WARNING When the preset angle is reached, the bucket

control lever should return to the "Hold" posi-
Accidental movement of machine could result in tion. Lower the attachment to the ground and
death or serious injury. confirm the proper angle has been set.
Apply parking brake and use wheel chocks to

prevent sudden movement of machine.
4
WARNING
Standing on tire, boom or linkage could cause
accidents resulting in death or serious injury.
3
Use safe sturdy platform to reach bucket posi-
tioner adjustment.
5±2mm (1/8 ~ 1/4in)
1. Park the machine on level ground and apply

the parking brake.
2. Lower the attachment to the ground, adjust it to NOTE

the desired angle, set the bucket control lever Clearance between the switch (4) and rod (3)
to the hold position, and stop the engine. should be about 5mm (0.2in).
The switch may be adjusted in or out to set this

clearance.
1
3. Loosen the bolts (1) with a 17mm wrench.
4. Move the bracket (2) forward to increase, or

rearward to decrease the attachment preset
angle.
5. Tighten the bolts (1).

750
70TMV-2
How to Use Quick Coupler

4. Attachment hook
NOTE 5. Lock pin holes
- The procedure shown is for the JRB manufac-
tured Quick Coupler. Other manufacturers'
attachment procedures may vary. If your coupler
Before attaching
is not identified on the ID plate as "JRB", contact
manufacturer for correct procederes.
- Many attachments are available for the JRB

Quick Coupler. The attachment procedure is the
same for all JRB attachments.
- Reverse the procedures to release the attach-

ment. a
CAUTION
Do not attempt to use other manufacturers'
attachments on the JRB Quick Coupler unless
they are specifically designed to work on that
Coupler design. The attachment may fall off if not - Be sure all hoses are clear of the attachment
properly designed for this Quick Coupler causing area
death, injury or equipment damage.
- Be sure the coupler and attachment are parrallel
Be sure the attachment is of the correct size and and level
capacity for the loader. Attachments from larger
loaders may adapt to this Quick Coupler but - Be sure the coupler pins are fully retracted. The
exceed its rated load. Loss of stability may result pins can be seen from the operator's seat.
in death, injury, and/or equipment damage.
- Operate the Auxiliary attachment control lever
to retract the pins.
Component Identification
Note left hose (a) position. The pins will not
retract if the hose (a) is not attached as shown.
To attach
3
4 1 1. Use the Bucket Control Lever to tilt the Coupler
frame forward.
2. Lower the boom until the coupler frame bar

clears the coupler attachment hooks.
5 2
1. Coupler frame
2. Hydraulic hose - 3rd function
3. Hydraulic hose - attachment side
(only on some attachments)
751
70TMV-2
3. Slowly drive forward as shown to engage the 5. Operate the Auxiliary Attachment Control
coupler frame and attachment hooks. Lever to extend and lock the pins into the at-
tachment lock pin holes. Engagement of the
pins into the holes can be seen from the op-
erator's seat area inside cab.
If the pins do not extend the attachment may

not be properly aligned. Rock the attachment
using the bucket control lever while moving the
Auxiliary Attachment Control Lever. This
should align the holes allowing pin engage-
ment.
CAUTION
- A loose attachment may fall off causing death,
injury, or equipment damage.
4. Tilt the coupler frame back and slightly raise
- Be sure the coupler is locked to the attach-
the boom.
ment.
Test by reversing the Procedure 4~1. The
The attachment should be raised a few inches
attachment should not come off.
or centimeters above the ground.
When finished, verify that attachment is secure!
752
70TMV-2
! CAUTION
CAUTION
CRUSH HAZARD
- A loose attachment may fall off causing death,

injury, or equipment damage.
- Be sure the coupler is locked to the attach-

ment.
Test by reversing the Procedure 4~1. The
attachment should not come off.
6. If the attachment requires hydraulic power

(logforks, side dump bucket, broom, auger,
etc.) attach the hoses following these steps:
6a. Lower the attachment to the ground.
6b. Put the transmission in Neutral and apply

the parking brake.
6c. Stop the engine and release the trapped

hydraulic oil pressure by operating the
control levers several times in each direc-
tion.
6d. Move to the coupler area and remove any

protective caps from the hoses.
753
Lift kickout & lower kickout (70TMV-2/70~90ZV-2)

Location
A
5
3
Detail A
6
Lift kickout
1. Sensor assy
2. Rod When the boom control lever is placed at "Raise" posi-
3. Link tion and the boom reaches at the preset hight, the lift
4. Cover kickout automatically releases the detent and returns
5. Cover the boom control lever to "Hold" position. The detent
6. Boom function and the units are the same way as those of the
bucket leveler.
754
Rotary sensor hardware detail

Typical mounting for all 65~115ZV-2 models
Lower kickout
When the boom control lever is placed at "Float" posi-

tion and the boom reaches at the preset hight, the lower
kickout automatically releases the detent and returns
the boom control lever to "Hold" position. The detent
function and the units are the same way as those of the
bucket leveler.
Bolt
Right side cover
Left side cover

Front chassis
Bolt
Bolt
Boom arm
Pin
Lever
Shaft Block
Link assy
Bearings
Bolt
Bolt Seal Screw

&
Washers
Rotary sensor
755
Sensor assy (70TMV-2/70~90ZV-2)

4 4 2
2 3
5
1
A-A Detail of grease applying
1
1. Position sensor
2. Link
3. Plate
4. Shaft
5. Ball bearing
Rotary type potentiometer
A A
30
Position sensor detail
756
Detent solenoid Preset height adjustment

(70TMV-2/70~90ZV-2)
[For lower kickout] [For lift kickout]
Push rod Push rod

Switch
Detent Detent 1. Lift kickout preset hight

solenoid solenoid
Raise the boom to the desired position and press
Fixing Fixing
disc disc the left side of the kickout control switch located on
the console box to set the boom hight for the lift
kickout.
2. Lower kickout preset hight
Lower the boom to the desired position and press

the right side of the kickout control switch located
Two detent solenoids are installed in the pilot valve on the console box to set the boom hight for the
boom side. lower kickout.
One is for the lift kickout and another is for the lower
kickout.
Voltage DC 24 V
Coil resistance 62 ± 3 Ω
757
Diode (70TMV-2/70~90ZV-2)
Symbols Open circuit, failed in open position.
+24V
+ Switch
[Anode] [Cathode] Solenoid
(forward direction)
Current flow Diode
(backward direction)
Current flows while the diode is disconnected.
(The solenoid is energized, however the surge voltage
is not absorbed. This damages electrical parts.) 95ZV62130
Normal A diode is an electronic part which makes the current

flow in one direction.
Current flow
The + side is called "anode", and the - side is called
"cathode". The current can flow only in the direction
from the anode to the cathode.
+24V
Switch
Solenoid
When a diode is connected in the current flow direction,
it is called forward direction. When a diode is connected
in the current non-flow direction, it is called backward
direction.
Diode
Current flows while the diode is normal Some electrical parts, as solenoid valves, buzzers,
(The solenoid is energized.) relays, all equipped with electromagnetic coils may gen-
erate a surge voltage caused by counter electromotive
force when the power is turned off. This surge voltage
Short-circuit, failed in closed position.
may cause malfunction of equipment.
Diodes are provided to prevent such a malfunction.
+24V However, if a diode is damaged and short-circuited (or

Switch fails closed) in its inside, electronic parts may be
Solenoid harmed.
Therefore, if a malfunction occurs in electrical equip-

Diode ment, electrical connection diagrams should be referred
to first, to determine and repair the cause. If a diode is
Current flows through the diode with smaller resistance. provided in the electrical equipment, the diode should
The solenoid is not energized. be checked for damage.
758
Diode check method Caution for diode check method

(70TMV-2/70~90ZV-2)
Checking resistance with parallel diodes
A digital tester will not work to check the condition of diodes
in parallel-to-coil type configurations. (Digital meter doesn't "see" diode.)
Coil
An analog type meter must be used as it employs a real time
inductive load. Using the wrong tool will lead to misdiagnosis.
+
+
Analog type tester
12V 12V
Diode check mode (digital or analog meter)
30A
ECM Battery
(1)
R1 BR F15 (2) (3)
B AC
R2 C 5A
(2)(3): Diode unit
Suppression diode
R1
15A
F12
F14
F13
5A
5A
Charge From
circuit alternator
R terminal
B Neutral
relay
Forward check
Continuity is detected in the status shown in the figure.
Normal Continuity is not detected when tester terminals are con-
nected in opposite way.
Continuity is not detected in either way Disconnection
Abnormal
Continuity is detected in either way Short-circuit
Note
Using an analog type tester; diode condition can be checked.
To test, exchange the positions of terminals of the
tester. Solenoid coils that contain diodes inside the solen-
oid coil pack may be checked in this way. In good circuits
a change of resistance will be noted, indicating the diode
condition. Backward check
IMPORTANT
A diode may fail closed or open. This can lead to failure
Forward check Backward check Judgement
of the controller.
Continuity (voltage value) Over level Normal
Over level Over level Open circuit
0 volt 0 volt Short-circuit
759
Resistance check mode (70TMV-2/70~90ZV-2)
Analog type tester
R1>0 R2=
0 0
Forward check Backward check
Digital type tester
R1>0 R2=
R1
Forward check Backward check
Forward check Backward check Judgement

R Ω (0<R<∞) ∞Ω Normal
∞Ω ∞Ω Open circuit
0Ω 0Ω Short-circuit
760
Surge voltage and surge suppres- Fig. 3

sion diodes (70TMV-2/70~90ZV-2)
Surge suppression
Fig. 1 diode
Electromagnetic field
forms when switch closes. Coil
Current direction
Coil
Voltage
Battery
Current
Switch or
Current [A]
Voltage [V]
transistor
Time [sec]
Load When surge voltage is generated, it causes increased

wear on electronic parts, contacts and switch points.
Some electrical parts such as solenoid valves are When a coil is energized, and then de-energized, a volt-
equipped with a coil. age surge can cause breakdown of transistors or other
electrical components. (As already noted.)
When a coil is energized, an electromagnetic field is
formed. See figure 1. In order to absorb any surge voltage, a diode is connected
parallel to the coil in the reverse direction against the
power supply.
Fig. 2
Snap!
When the switch opens, the When power is turned off, the electric current follows the
field collapses across the path of lesser resistance and goes through the diode.
coil windings.
Coil
Voltage This electric current is lessened gradually and finally is
Battery
Current reduced to zero volts. This controls the surge voltage

that is generated in the circuit. See figure 3.
Current [A]
Voltage [V]
ON OFF
Time [sec]
Surge voltage
Load
When the solenoid coil is de-energized, the field col-

lapses across the coil. The collapse of this electromag-
netic field across the solenoid coil generates an
unregulated voltage surge. See figure 2.
This can damage transistors, contacts, and other elec-

tronic parts. (See connection diagram.)
761
For information on using the Maintenance Operation and Diagnostic Monitor, refer to the
training manual for this subject.
762

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KCM600-08/2006-00

Kawasaki Service Training Manual

This Manual covers Electrical Group Materials for Models 50~90ZV-2

• Layout of electrical pieces

• Line and address diagrams

This Training Manual supplements materials found in the Shop Manual.

Consult the Shop Manual for specific details on each machine.

Key to retaining information

If you share information with others, the following will happen:

- Remove the cables from batteries before starting

- Be sure to release the internal pressure before you

- Be sure to apply the articulation stopper before start-

- While supporting the bottom of the chassis using a

- When the boom or bucket is raised or when a unit is

- Do not start to work in an enclosed area if adequate

- To remove a heavy unit (20 kgf (40 lbs) or more), be

- Just after stopping operation, be careful not to

Safety ................................................................................ 603

Things to consider when repairing ..................................... 607

Dealer and customer call form ........................................... 608

How to Use Electrical Wiring Diagram .............................. 612

Way of looking at connectors ............................................. 613

Electrical wiring diagram abbreviation chart ...................... 615

Electrical Cable Color Codes ............................................ 616

Simple electrical terminology ............................................ 617

Electrical Circuit Symbols ................................................. 618

Sensor mount ................................................................... 619

Cab diagram (common for ZV-2) ...................................... 623

Diagrams .......................................................................... 624

Fuses ............................................................................... 674

Start circuits ..................................................................... 684

Relays .............................................................................. 687

Generators ....................................................................... 690

ECM ................................................................................. 691

MCU ................................................................................. 710

Diodes .............................................................................. 758

Important Points to Remember

3. Do not indiscriminately discard parts.

Kawasaki Loader Dealer / Customer call form Date: ________________________

Customer's address: ____________________________________________________

1. What system(s) is giving trouble? Hydraulic, Transmission, Electrical, etc.?

3. What is the machine application? Where is it working, and what is it doing?

4. Name of person that gave information _______________________________

Clear directions of how to arrive at the jobsite:

Required support publications or Service / Parts News documents:

Symbol Item Description

Shows the condition or procedure that will be useful

Shows the weight of a part or unit. The weight

Tightening Shows the tightening torque of a section that should

Shows the type of coating or adhesive and the coat-

Shows the oil or water drain port and the drain

E/G ........... Engine RH ............Right hand side 3rd ............3rd speed

Function & Structure

How to Use Electrical Wiring Diagram

A520 RB RB LgSb YV RL SbP RL LB GW GL B LgW

C205 F504 F704 F804

The address method is used for electrical wiring dia- Example 3

Electrical Wiring Diagram

Male pin connector

Female pin connector

40 pin connector 6 pin connector

Female pin connector

Male connector Female connector

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