CK35 1
CK35 1
CK35 1
Shop
Manual
CK35-1
COMPACT TRACK LOADER
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
CONTENTS
Page
10. STRUCTURE AND FUNCTION ....................................................................................... 10-1
00-2 CK35-1
REVISED PAGES
REVISED PAGES
The affected pages are indicated by the use of the
following marks. It is requested that necessary actions
be taken to these pages according to table below. Symbol Indication Action required
CK35-1 00-3
REVISED PAGES
30-40 40-1
30-41 40-2
30-42 40-3
30-43 40-4
30-44 40-5
30-45 40-6
30-46 40-7
30-47 40-8
30-48 40-9
30-49 40-10
30-50 40-11
30-51 40-12
30-52 40-13
30-53 40-14
30-54 40-15
30-55 40-16
30-56 40-17
30-57 40-18
30-58 40-19
30-59 40-20
30-60 40-21
30-61 40-22
30-62 40-23
30-63 40-24
30-64
40-25
30-65
40-26
30-66
40-27
30-67
30-68 40-28
30-69 40-29
30-70 40-30
30-71
30-72 90-1
30-73 90-2
30-74 90-3
30-75 90-4
30-76 90-5
30-77 90-6
30-78
30-79
30-80
30-81
30-82
30-83
30-84
30-85
30-86
30-87
30-88
30-89
30-90
30-91
30-92
30-93
30-94
30-95
30-96
30-97
30-98
00-4 CK35-1
k SAFETY
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be carefully followed. If any danger arises or may possibly arise,
first consider safety, and take necessary steps to face.
k SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. Read all the 7. Before adding or making any repairs, park the
Operation and Maintenance Manual carefully BEFORE machine on hard, level ground, and block the wheels
operating the machine. to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower outrigger, bucket or any
the precautions written on the decals which are suck other work equipment to the ground. If this is not
on the machine. possible, use blocks to prevent the work equipment
2. When carrying out any operation, always wear safety from falling down. In addition, be sure to lock all the
shoes and helmet. Do not wear loose work clothes, or control levers and hang warning sign on them.
clothes with buttons missing. 9. When disassembling or assembling, support the
• Always wear safety glasses when hitting parts machine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding parts 10. Remove all mud and oil from the steps or other places
with a grinder, etc. used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained, handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron, impossible to use the handrails, ladders or steps, use
glasses, cap and other clothes suited for welding a stand to provide safe footing.
work.
PRECAUTIONS DURING WORK
4. When carrying out any operation with two or more
workers, always agree on the operating procedure 11. When removing the oil filler cap, drain plug or
before starting. Always inform your fellow workers hydraulic pressure measuring plugs, loosen them
before starting any step of the operation. Before slowly to prevent the oil from spurting out.
starting work, hang UNDER REPAIR signs on the Before disconnecting or removing components of the
controls in the operator’s compartment. hydraulic circuit and engine cooling circuit, first
remove the pressure completely from the circuit.
5. Keep all tools in good condition and learn the correct
way to use them. 12. The water and oil in the circuits are not hot when the
engine in stopped, so be careful not to get burned.
6. Decide a place in the repair workshop to keep tools
Wait for the oil water to cool before carrying out any
and removed parts. Always keep the tools and parts in
work on the cooling water circuits.
their correct places. Always keep the work area clean
and make sure that there is no dirt or oil on the floor. 13. Before starting work, remove the leads from the
Smoke only in the areas provided for smoking. Never battery. Always remove the lead from the negative ( –
smoke while working. ) terminal first.
CK35-1 00-5
k SAFETY
14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample will not be damaged by contact with other parts
capacity. Install the lifting equipment at the correct when the machine is being operated.
places. Use a hoist or crane and operate slowly to
20. When installing high pressure hoses, make sure
prevent the component from hitting any other part.
that they are not twisted. Damaged tubes are
Do not work with any part still raised by the hoist or
dangerous, so be extremely careful when installing
crane.
tubes for high pressure circuits. Also, check that
15. When removing covers which are under internal connecting parts are correctly tightened.
pressure or under pressure from a spring, always
21. When assembling or installing parts, always use
leave two bolts in position on opposite sides. Slowly
specified tightening torques. When installing the
release the pressure, then slowly loosen the bolts to
parts which vibrate violently or rotate at high speed,
remove.
be particulary careful to check that they are correctly
16. When removing components, be careful not to installed.
break or damage the wiring.
22. When aligning two holes, never insert your fingers or
Damage wiring may cause electrical fires.
hand.
17. When removing piping, stop the fuel or oil from
23. When measuring hydraulic pressure, check that the
spilling out. If any fuel or oil drips on to the floor, wipe
measuring tool is correctly assembled before taking
it up immediately.
any measurement.
Fuel or oil on the floor can cause you to slip, or can
even start fires. 24. Take sure when removing or installing tracks. When
removing the track, the track separates suddenly, so
18. As a general rule, do not use gasoline to wash parts.
never let anyone stand at either end of the track.
In particular, use only the minimum of gasoline when
washing electrical parts.
00-6 CK35-1
FOREWORD
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.
NOTE
The specifications contained in this shop manual are subject to change at any time and without any
notice.
Contact your Komatsu Utility distributor for the latest information.
CK35-1 00-7
HOW TO READ THE SHOP MANUAL
k
date information before you start any work. work.
4
Item number (10. Structure and Caution necessary when selecting
Weight
Function) hoisting wire, or when working
posture is important, etc.
Consecutive page number for each
3
item Parts that require special attention
Tightening
for the tightening torque during
3. Additional pages: additional pages are indicated by torque
assembly.
a hyphen (–) and number after the page number. Fle
2
as in the example. Parts to be coated with adhesives
Coat
Example: and lubricants etc.
5
10-4 Places where oil, water or fuel
Oil, water
must be added, and their quantity.
10-4-1
Added pages
6
10-4-2 Places where oil or water must be
Drain drained, and quantity to be
10-5
drained.
REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.
00-8 CK35-1
HOISTING INSTRUCTIONS
4
HOISTING INSTRUCTIONS
CK35-1 00-9
STANDARD TIGHTENING TORQUE
3
STANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in section of «Disassembly and Assembly».
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
a Nm (newton meter): 1 Nm = 0.102 kgm
00-10 CK35-1
STANDARD TIGHTENING TORQUE
3
2. TIGHTENING TORQUE FOR NUTS OF FLARED
22 27 8±2 78.5±19.6
33 41 20±5 196.2±49
Sealing surface
1” - 14 30 8.2–9.2 80–90
2” - 12 57 20.4–24.4 200–240
CK35-1 00-11
COATING MATERIALS
2
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal
ASL800020
is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives
Loctite 270 Used for high resistant locking and for sealing threaded parts, bolts and stud bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573
dismantling is required.
Used for high resistant locking of mechanical components that can be removed only
Loctite 601
after heating
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
Loctite 675
and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw
ASL800060
fittings in hydraulic circuits of less than 50 mm in diameter.
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent sticking,
(Lubricant including ASL800040
burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
ASL800050
(Lithium grease) facilitation of assembling work.
Vaseline ----- Used for protecting battery electrode terminals from corrosion
00-12 CK35-1
ELECTRIC
ELECTRIC
ELECTRIC
In the wiring diagrams various colour and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R–N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Cross (mm) (A)
Numberstrands Ø of strands(mm)
section(mm)
0.5 16 0.20 0.35 1.55 3.5
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.35 14
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
CK35-1 00-13
WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Seat:
• Standard 10
• with suspension 16
Piston pump:
• Standard 82
• High-Flow 84
Control valve
• 3-spool (standard) 21
• 4-spool (High-Flow) 24
Final drive 65
Drive wheel 21
00-14 CK35-1
TABLE OF OIL AND COOLANT QUANTITIES
SAE 10W
SAE 30
OIL
Engine oil pan SAE 40 10.2 10.2
API CD
SAE 10W-30
SAE 5W-30
Hydraulic circuit
with
50 32
biodegradable oil
a
Fuel
DIESEL OIL 72 —
tank
ASTM D975 N. 2
PERMANENT
Engine cooling
LIQUID 15 —
system
(aa)
a ASTM D975 N. 1
aa Special red permanent antifreeze compatible with aluminium radiators. If pure, dilute with water
(50%).
CK35-1 00-15
TABLE OF OIL AND COOLANT QUANTITIES
IMPORTANT:
(1) When the diesel oil sulphur content is less then 0.5%, change the engine oil according to the periodic maintenance
intervals indicated in the operation and maintenance manual. In the diesel oil sulphur content exceeds 0.5% change
the engine oil according to the following table:
(2) When starting the engine at temperatures below 0ºC, use engine oil SAE 10W, 10W-30, 5W-30, even if during the
day the temperature increases by 10ºC.
(3) Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a
half.
(4) Use original products, which have characteristics specifically formulated and approved for the engine, the hydraulic
circuit of equipment and for reductions.
00-16 CK35-1
METHOD OF USING THE CONVERSION TABLE
EXAMPLE
• Method of using the conversion table to convert from millimeters to inches.
1. Convert 55 mm into inches.
1 - Locate the number 50 in the vertical column at the left side, take this as A , then drow a horizontal line from
A.
2 - Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from B .
3 - Take the point where the two lines cross as C . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm =2.165 in.
1 - The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to
convert it to 55 mm.
3 - The original value (550 mm) was divided by 10, so multiply 2.165 in. by 10 (move the decimal point one place to
the right) to return to the original value. This gives 550 mm = 21.65 in.
0 1 2 3 4 5 6 7 8 9
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
CK35-1 00-17
METHOD OF USING THE CONVERSION TABLE
From mm to in.
1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
From kg to lb.
1 kg = 2.2046 lb.
0 1 2 3 4 5 6 7 8 9
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.24 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-18 CK35-1
METHOD OF USING THE CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 12.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
CK35-1 00-19
METHOD OF USING THE CONVERSION TABLE
From Nm to lb.ft.
1 Nm = 0.737 lb.ft.
0 1 2 3 4 5 6 7 8 9
10 7.370 8.107 8.844 9.581 10.318 11.055 11.792 12.529 13.266 14.003
20 14.740 15.477 16.214 16.951 17.688 18.425 19.162 19.899 20.636 21.373
30 22.110 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743
40 29.480 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113
50 36.850 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483
60 44.220 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853
70 51.590 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223
80 58.960 59.697 60.434 61.171 61.908 82.645 63.382 64.119 64.856 65.593
90 66.330 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963
100 73.700 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333
110 81.070 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703
120 88.440 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073
130 95.810 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443
140 103.180 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150 110.550 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183
160 117.920 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170 125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180 132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190 140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
00-20 CK35-1
METHOD OF USING THE CONVERSION TABLE
From Nm to kgm
1 Nm = 0.102 kgm
0 1 2 3 4 5 6 7 8 9
10 1.020 1.222 1.224 1.326 1.428 1.530 1.632 1.734 1.836 1.938
20 2.040 2.142 2.244 2.346 2.448 2.550 2.652 2.754 2.856 2.958
30 3.060 3.162 3.264 3.366 3.468 3.570 3.672 3.774 3.876 3.978
40 4.080 4.182 4.284 4.386 4.488 4.590 4.692 4.794 4.896 4.998
50 5.100 5.202 5.304 5.406 5.508 5.610 5.712 5.814 5.916 6.018
60 6.120 6.222 6.324 6.426 6.528 6.630 6.732 6.834 6.936 7.038
70 7.140 7.242 7.344 7.446 7.548 7.650 7.752 7.854 7.956 8.058
80 8.160 8.262 8.364 8.466 8.568 8.670 8.772 8.874 8.976 9.078
90 9.180 9.282 9.384 9.486 9.588 9.690 9.792 9.894 9.996 10.098
100 10.200 10.302 10.404 10.506 10.608 10.710 10.812 10.914 11.016 11.118
110 11.220 11.322 11.424 11.526 11.628 11.730 11.832 11.934 12.036 12.138
120 12.240 12.342 12.444 12.546 12.648 12.750 12.852 12.954 13.056 13.158
130 13.260 13.362 13.464 13.566 13.668 13.770 13.872 13.974 14.076 14.178
140 14.280 14.382 14.484 14.586 14.688 14.790 14.892 14.994 15.096 15.198
150 15.300 15.402 15.504 15.606 15.708 15.810 15.912 16.014 16.116 16.218
160 16.320 16.422 16.524 16.626 16.728 16.830 16.932 17.034 17.136 17.238
170 17.340 17.442 17.544 17.646 17.748 17.850 17.952 18.054 18.156 18.258
180 18.360 18.462 18.564 18.666 18.768 18.870 18.972 19.074 19.176 19.278
190 19.380 19.482 19.584 19.686 19.788 19.890 19.992 20.094 20.196 20.298
CK35-1 00-21
METHOD OF USING THE CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.2 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 876.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-22 CK35-1
METHOD OF USING THE CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 145.0 159.5 174.0 188.5 203.0 217.5 232.0 246.5 261.0 275.6
20 290.0 304.6 319.1 333.6 348.1 362.6 377.1 391.6 406.1 420.6
30 435.1 449.6 464.1 478.6 493.1 507.6 522.1 536.6 551.1 565.6
40 580.1 594.6 609.1 623.6 638.1 652.6 667.1 681.6 696.1 710.6
50 725.1 739.6 754.1 768.6 783.2 797.7 812.2 826.7 841.2 855.7
60 870.2 884.7 899.2 913.7 928.2 942.7 957.2 971.7 986.2 1000.7
70 1015.2 1029.7 1044.2 1058.7 1073.2 1087.7 1102.2 1116.7 1131.2 1145.7
80 1160.2 1174.7 1189.2 1203.7 1218.2 1232.7 1247.2 1261.8 1276.3 1290.8
90 1305.3 1319.8 1334.3 1348.8 1363.3 1377.8 1392.3 1406.8 1421.3 1435.8
100 1450.3 1464.8 1479.3 1493.8 1508.3 1522.8 1537.3 1551.8 1566.3 1580.8
110 1595.3 1609.8 1624.3 1638.8 1653.3 1667.8 1682.3 1696.8 1711.3 1725.8
120 1740.4 1754.9 1769.4 1783.9 1798.4 1812.9 1827.4 1841.9 1856.4 1870.8
130 1885.4 1899.9 1914.4 1928.9 1943.4 1957.9 1972.4 1986.9 2001.4 2015.9
140 2030.4 2044.9 2059.4 2073.9 2088.4 2102.9 1217.4 2131.9 2146.4 2160.9
150 2175.4 2189.9 2204.4 2218.9 2233.5 2248.0 2262.5 2277.0 2291.5 2306.0
160 2320.5 2335.0 2349.5 2364.0 2378.5 2393.0 2407.5 2422.0 2436.5 2451.0
170 2465.5 2480.0 2494.5 2509.0 2523.5 2538.0 2552.5 2567.0 2581.5 2596.0
180 2610.5 2625.0 2639.5 2654.0 2668.5 2683.0 2697.7 2712.1 2726.6 2641.1
190 2755.6 2770.0 2784.6 2799.1 2813.6 2828.1 2842.6 2857.1 2871.6 2886.1
200 2900.6 2915.1 2929.6 2944.1 2958.6 2973.1 2987.6 3002.1 3016.6 3031.1
210 3045.6 3060.1 3074.6 3089.1 3103.6 3118.1 3132.6 3147.1 3161.6 3176.1
220 3190.7 3205.2 3219.7 3234.2 3248.7 3263.2 3277.7 3192.2 3306.7 3321.2
230 3335.7 3350.2 3364.7 3379.2 3393.7 3408.2 3422.7 3437.2 3451.7 3466.2
240 3480.7 3495.2 3509.7 3524.2 3538.7 3553.2 3567.7 3582.2 3596.7 3611.2
CK35-1 00-23
METHOD OF USING THE CONVERSION TABLE
TEMPERATURE
Fahrenheit-Centigrade conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade tem-
perature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tem-
peratures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade val-
ues and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
00-24 CK35-1
10 STRUCTURE AND FUNCTION
CK35-1 10-1
STRUCTURE AND FUNCTION P.T.O.
P.T.O.
5
4
1 2
RKS02070
1. Drive plate
2. Flywheel
3 Insert (4 pcs.)
4. Half sleeve
5. Pump
6. Flywheel cover
10-2 CK35-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
8 8
7
4
1
3 A BC 2
8 6 8
RKS05210
CK35-1 10-3
STRUCTURE AND FUNCTION FRAME
FRAME
3
2
4
7 8 6 7 6 7 5
RKS04910
10-4 CK35-1
STRUCTURE AND FUNCTION TRACK TENSIONER IDLER WHEEL
6 4 3
5
RKS04160
1. Roller
2. Shoulder
3. Bushing
4. Shaft
5. Gasket
6. Snap ring
CK35-1 10-5
STRUCTURE AND FUNCTION TRACK TENSIONER CYLINDER AND BUMPER SPRING
1 2 B 3 4
B
5
Section A - A
C
A A
6
7
9 8
Detail C
RKS04160
1. Piston 6. Valve
2. Cylinder 7. Grease fitting
3. Pin 8. Sealing ring
4. Spring retainer plate 9. Guard ring
5. Bumper spring
10-6 CK35-1
STRUCTURE AND FUNCTION LOWER IDLER ROLLER
2
6
5 4 3 RKS04180
1. Roller 4. Shaft
2. Shoulder 5. Gasket
3. Bushing 6. Snap ring
3-LIP TYPE
2
6
5 4 3 RKS04190
1. Roller 4. Shaft
2. Shoulder 5. Gasket
3. Bushing 6. Snap ring
CK35-1 10-7
STRUCTURE AND FUNCTION REAR IDLER ROLLER
3
5 4
RKS04200
1. Roller
2. Shoulder
3. Bushing
4. Shaft
5. Gasket
6. Snap ring
10-8 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (STANDARD)
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
B3
Pb3 ø6.5 l=400 (1/2-20 JIC)
ARM CYL. R.H. Pa3
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
ø9.5 l=1200 (13/16-16 ORFS)
A2
ø9.5 l=1850 (13/16-16 ORFS)
Pb2 B2
Pa2 ø6.4 l=1500 (1/2-20 JIC)
P 206 bar
ø0.5 Ts
Ps
B A A
ø1,4
steel pipe ø25 t=3 L=1015 ø15.9 l=1100 (1"13/16-12 ORFS) ø1,4
Db1 B A B A
A B C
steel pipe ø25 t=3 L=1020 ø15.9 l=1100 (1"13/16-12 ORFS) ø1,4 ø1,4
Da1
B
Pa1
Db2 Da2 Pa2 P4 SV1 SV2 SV3
P
ø7.9
E
Ps
ø19.1 l=900
ø6.5 l=1900 (9/16-18JIC)
(1"1/16-12 JIC)
Dr ø6.5 l=1900 (9/16-18JIC)
ø24.6~26.2 l=1000
TRAVEL MOTOR L.H.
R/G
RKS04691
ø9.5 l=2380 (9/16-18 JIC)
ø19 l=1650 ø16 ø19 l=1600
ø9.5 l=2380 (9/16-18 JIC) (1"1/16-12 JIC) t2 (1"5/16-12 JIC) ø25.4 l=430 ø32 l=580
(1"5/16-12 JIC) (1"5/8-12 JIC)
ø19.1 l=850
(1"1/16-12 JIC) ø42
CK35-1 10-9
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (FLOAT)
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
B3
ø6.5 l=400 (1/2-20 JIC)
ARM CYL. R.H. Pa3
Pb3
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
ø9.5 l=1200 (13/16-16 ORFS)
A2
ø9.5 l=1850 (13/16-16 ORFS)
Pb2 B2
Pa2 ø6.4 l=1500 (1/2-20 JIC)
P 206 bar
ø0.5 Ts
Ps
B A A
ø1,4
steel pipe ø25 t=3 L=1015 ø15.9 l=1100 (1"13/16-12 ORFS) ø1,4
Db1 B A B A
A B C
steel pipe ø25 t=3 L=1020 ø15.9 l=1100 (1"13/16-12 ORFS) ø1,4 ø1,4
Da1
B
Pa1
Db2 Da2 Pa2 P4 SV2 SV3
P SV1
ø7.9
E
Ps
ø19.1 l=900
ø6.5 l=1900 (9/16-18 JIC)
(1"1/16-12 JIC)
Dr ø6.5 l=1900 (9/16-18 JIC)
ø24.6~26.2 l=1000
TRAVEL MOTOR L.H.
R/G
RKS04701
ø9.5 l=2380 (9/16-18 JIC)
ø19 l=1650 ø16 ø19 l=1600
ø9.5 l=2380 (9/16-18 JIC) (1"1/16-12 JIC) t2 (1"5/16-12 JIC) ø25.4 l=430 ø32 l=580
(1"5/16-12 JIC) (1"5/8-12 JIC)
ø19.1 l=850
(1"1/16-12 JIC) ø42
10-10 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (FLOAT + PATTERN CHANGE)
206 bar
P
ø0.5 Ts
OUTPUT ISO PATTERN (KOMATSU) INPUT
HYDRAULIC CIRCUIT DIAGRAM T
ø6.4 l=650 (1/2-20 JIC) P4 OUT P4 IN
ø6.4 l=850 (1/2-20 JIC) P3 OUT P2 IN
ø6.4 l=650 (1/2-20 JIC) P2 OUT P1 IN
ø6.4 l=950 (1/2-20 JIC) P1 OUT P3 IN
ø6.4 l=1500 (1/2-20 JIC) P5 OUT P5 IN
R/G
ø7.9
E
A B C
ø19.1 l=900
ø6.5 l=1900 (9/16-18 JIC)
(1"1/16-12 JIC)
Dr ø6.5 l=1900 (9/16-18 JIC)
CK35-1 10-11
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (HIGH-FLOW)
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
B3
ø6.5 l=400 (1/2-20 JIC)
ARM CYL. R.H. Pb3 Pa3
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
ø9.5 l=1200 (13/16-16 ORFS)
A2
ø9.5 l=1850 (13/16-16 ORFS)
Pb2 B2
ø6.4 l=1500 (1/2-20JIC)
Pa2
P (206 bar)
ø0.5
Ts
T
Ps
ø19.1 l=1100 (1"3/16-12 ORFS)
B A A
ø1,4
steel pipe ø25 t=3 L=1015 ø15.9 l=1100 (1"13/16-12 ORFS) ø1,4
B A B A
Db1 A B C
steel pipe ø25 t=3 L=1020 ø15.9 l=1100 (1"13/16-12 ORFS) ø1,4 ø1,4
Da1
B
Pa1
Db2 Da2 Pa2 P4 P5 SV1 SV2 SV3
P
ø7.9
E
ø6.4 l=1550
(9/16-18 JIC) Pb1 T5 Pb2 S3 S4
E2
Ps
ø19.1 l=900
ø6.5 l=1900 (9/16-18JIC)
(1"1/16-12 JIC)
Dr ø6.5 l=1900 (9/16-18JIC)
ø24.6~26.2 l=1000
R/G
(1"5/8-12 JIC)
ø19 l=1650
(1"1/16-12 JIC) t2 (1"5/16-12 JIC)
ø32 l=580
ø25.4 l=430 ø25.4 l=800
(1"5/16-12 JIC) (1"5/16-12 JIC)
ø19.1 l=850
(1"1/16-12 JIC)
10-12 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (SUPER HIGH-FLOW)
female 1/2
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)
RIGHT
SIDE male 1/2
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
A3
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
ARM CYL. L.H. ø6.5 l=400 (1/2-20 JIC)
B3
ø6.5 l=400 (1/2-20 JIC)
ø9.5 l=1200 (13/16-16 ORFS)
Pb3
ø9.5 l=1850 (13/16-16 ORFS)
A2
ARM CYL. R.H. Pb2 B2
ø6.4 l=1500 (1/2-20 JIC) ø10 l=1050 ø10 l=1050
ø9.5 l=1200 (13/16-16 ORFS) (9/16-18 JIC) (9/16-18 JIC)
Pa2
Pb1 A1
BUCKET CYL. L.H. B1
ø9.5 l=530 (13/16-16 ORFS)
B A A
ø1,4
steel pipe ø25 t=3 L=1015 ø15.9 l=1100 (1"13/16-12 ORFS) ø1,4
B A B A
Db1 A B C
steel pipe ø25 t=3 L=1020 ø15.9 l=1100 (1"13/16-12 ORFS) ø1,4 ø1,4
Da1
B
Pa1
Sb2 Db2 Da2 Pa2 P4 P5
P SV1 SV2 SV3
ø7.9
E
Ps
ø19.1 l=900
ø6.5 l=1900 (9/16-18JIC)
(1"1/16-12 JIC)
Dr ø6.5 l=1900 (9/16-18JIC)
ø24.6~26.2 l=1000
R/G
(1"5/8-12 JIC)
ø19 l=1650 ø19 l=1600
(1"1/16-12 JIC) t2 (1"5/16-12 JIC)
ø32 l=580
ø25.4 l=430 ø25.4 l=800 RKS04731
(1"5/16-12 JIC) (1"5/16-12 JIC)
ø19.1 l=850
(1"1/16-12 JIC)
CK35-1 10-13
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (SUPER HIGH-FLOW / PATTERN CHANGE)
A2
ARM CYL. R.H. Pb2 B2
ø6.4 l=1500 (1/2-20 JIC)
ø9.5 l=1200 (13/16-16 ORFS) Pa2
ø6.4 l=950 (1/2-20 JIC)
ø9.5 l=1850 (13/16-16 ORFS)
Pb1 A1
BUCKET CYL. L.H.
B1
ø9.5 l=530 (13/16-16 ORFS)
ø7.9
E
A B C
P2 P1 Pp (brake)
ø6.4 l=1550
(9/16-18 JIC) P SV1 SV2 SV3
Pb1 E2 T5 PB2 S3 S4
ø24.6~26.2 l=1000
R/G
(1"5/8-12 JIC)
ø19 l=1650 ø19 l=1600
(1"1/16-12 JIC) t2 (1"5/16-12 JIC)
ø32 l=580
ø25.4 l=430 ø25.4 l=800
RKS04741
(1"5/16-12 JIC) (1"5/16-12 JIC)
ø19.1 l=850
(1"1/16-12 JIC)
10-14 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
HST PUMP LPV40 +45 (STANDARD FLOW)
10 1 8 7 2 8 7 5
6
Komatsu.Ltd.
11 12 3 11
8 9 9 8
1. Piston pump STRUCTURE
2. Control piston This pump is composed of variable swash plate type
3. Suction safety valve tandem piston pumps (1), control pistons (2), suction
safety valves (3), charge safety valve (4), charge pump (5),
4. Charge safety valve
work equipment gear pumps (6), and adjustment screws
5. Charge pump (7), (8), (9), AS valve (10), shuttle valve (11) and
6. Work equipment pump synchronization valve (12).
7. Adjustment screw (Neutral position)
8. Adjustment screw (Max. displacement)
9. Adjustment screw (Pump power control)
10. AS valve
11. Shuttle valve
12. Synchronization valve
CK35-1 10-15
STRUCTURE AND FUNCTION HYDRAULIC PUMP
10 1 8 7 2 8 7 5
6
JAPAN
Komatsu.Ltd.
11 12 3 11
8 9 9 8 RKS04760
10-16 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
4 2 5 6 14
3 15 (Standard version)
11
15 (High-flow version)
A 7 12 8 9 10 13
RKS04770
CK35-1 10-17
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
1. Operation of pump
• Cylinder block (9) rotates together with shaft (1),
and shoe (7) slides on flat surface "A".
When this happens, rocker cam (4) moves along
cylindrical surface “B”, so angle “α” between the
centre line of shaft (1) and centre line X of rocker
cam (4) changes, thereby varying the axial direction
of pistons in relation to the cylinder block.
Angle “k”is called "swash plate angle".
i) Central line X of rocker cam (4) maintains
swash plate angle “k” in relation to the axial 4 7 8 9 E PA PB
direction of cylinder block (9), and flat surface
“A” moves as a cam in relation to shoe (7).
In this way, piston (8) slides on the inside of X
cylinder block (9), so a difference between k PA
volumes E and F is created inside cylinder
block (9). The suction and delivery is carried
out by this difference F – E . PB
In other words, when cylinder block (7) rotates
and the volume of chamber F becomes 1 RKS00271
10-18 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
5
6
4
4
RKS00280
RKS00360
• Screw A restricts to the maximum stroke of control piston (i.e. maximum displacement of each pump). When screw
A is tightened, maximum displacement decreases, and when screw A is loosened, maximum displacement
increase. This screw should be adjusted when the machine doesn’t travel straight or machine maximum speed is
little bit wrong.
• Screw B is the fine adjuster of neutral position of control piston (5). That adjust prevent machine from creep.
A 5
A
6
RKS04500
CK35-1 10-19
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PPA =0 5 PPB=0
RKS04540
RKS04550
• When pressurised oil which has the pressure PPA>PPB is led from pilot line (PPC or AS valve), control piston (5)
moves to the right (o).
Control piston (5) moves the balanced position by spring force and pressure PPA.
• If the relation of pressure dimension of PPA, PPB is reversed, control piston moves to the left (i).
• The lowest between AS valve output pressure and PPC output pressure is selected by shuttle valve and sent to
control piston (5). (For details, see "SHUTTLE VALVE").
10-20 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
RKS00110
3
1
1. Charge pump
2. Charge safety valve 3A 3B 3C 3D 3E 3F
3. Suction safety valve
3A. Valve
3B. Rod
3C. Sleeve
3D. Spring
3E. Spring
3F. Plug
4. Piston pump
5. Travel motor RKS00090
FUNCTION
There are two suction safety valves installed to each HST pump, and they have the following functions:
CK35-1 10-21
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Actuation when acting as high pressure relief valve (Valve at piston pump delivery side)
• Port A is connected to the piston pump circuit and port B is connected to the charge circuit. The pressurised oil fills
port C through drill hole a of piston (3A). The pressurised oil at high pressure port A fills port D through groove b
between body and valve.
Poppet (3A) is in tight contact with valve seat (3C).
B 3A 3B 3C 3D 3E
a A b C D RKS00050
• If abnormal pressure is generated in the circuit and the oil pressure at ports A and D reaches the pressure set by
spring (3D), poppet (3A) is pushed to (o) direction, and oil at port A is relieved to port B to reduce the oil pressure
at port A.
B 3A
a A b 3D D
RKS00060
10-22 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Travel motor
Pump
PB PA
RKS00120
3
1
CK35-1 10-23
STRUCTURE AND FUNCTION HYDRAULIC PUMP
3C b D
PA
PB PA
A2 A1
4
RKS00070
PB PA
RKS00130
1
3C PB
A1 A2 B
RKS00080
10-24 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
RKS00140
3
1
1. Charge pump
2. Charge safety valve 2A 2B 2G 2C 2D 2E 2F
2A. Valve
2B. Spring
2C. Valve seat
2D. Poppet
2E. Spring
2F. Adjustment screw
2G. Filter
3. Suction safety valve RKS0004
FUNCTION
There is the charge safety valve installed to the HST pump.The charge safety valve restricts the maximum pressure
inside the charge circuit in order to protect the charge circuit.
CK35-1 10-25
STRUCTURE AND FUNCTION HYDRAULIC PUMP
FUNCTION
Port A is connected to the charge circuit.
Port B is connected to the tank drain circuit.
The pressurised oil fills port C through orifice a in valve (2A).
Poppet (2D) is in tight contact with valve seat (2C)
2A C 2C 2D 2E
1
a B RKS00010
• If abnormal pressure is generated in the circuit or the shuttle valve of HST motor is at neutral and the oil pressure at
ports A and C reaches the pressure set by spring (2E), poppet (2D) is pushed to right direction (o), and oil at C is
relieved to port B and pressure of the oil at C reduces.
2A C 2D 2E
RKS00020
B
• When pressure at port C reduces due to the shifting of poppet (2D), pressure at port A exceeds pressure at port B
due to the hole a in valve (2A).
This pressure gap shifts valve (2A) to right direction (o) and lets the pressurised oil at port A move to port B, thus
allowing charge circuit pressure to be adjusted.
2A C
RKS00030
a B
10-26 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
CHARGE PUMP
7
4
RKS00150
CK35-1 10-27
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
Delivery
7 6 B
A
2
Delivery side
A
Suction side
A RKS00160
Suction
• Charge pump is connected to HST pump shaft by coupling (2), so inner roter (6) and outer roter (7) rotate.
• During bucket (6) and impeller (7) rotation, oil is sucked in as quantity A increases and is discharged as quantity B
decreases.
• During rotation of inner roter (6) and outer roter (7), port A increases in volume as it performs oil suction, whereas
port B decreases in volume as it performs delivery.
10-28 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2 5
1A 1B 1C 1F 1D 1E
1G 1L 1H
RKS00170
1. AS valve FUNCTION
1A. Nut • The AS valve is attached on the main piston pump. It
1B. Screw reduces pressure for pump swash plate control from
1C. Spring charge circuit.
1D. Spring • The AS valve outputs pressure correspond with
engine revolution.
1E. Spring
1F. Valve
1G. Valve
1H. Nut
1L. Screw
2. Charge pump
3. Orifice
4. Charge safety valve
5. Engine
CK35-1 10-29
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
2 5
B A
1C 1D 1G
E
D
G
C RKS00180
• The oil from the charge pump (2) that rotates with the engine flows through a orifice (3) that is installed in the main
piston pump. And the oil always flows to pump charge circuit.
• Charge pump (2) is fixed capacity pump, so that discharge flow is proportionate to engine rotation speed. With the
oil from the charge pump (2) passed through the orifice, differential pressure is generated at port A and port B. This
differential pressure actuates the differential pressure sensing valve (1G) and makes hydraulic force F.
• By the hydraulic force F, the differential pressure sensing valve (1G) is moved direction.
That makes a change of spring (1D) load.
In port C, the AS valve output pressure that is balanced with spring (1C) and (1D) load is generated by reducing from
charge pressure of port G.
So the AS valve output pressure corresponds with charge flow (2) that is changed by engine (5) revolution.
10-30 CK35-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
SHUTTLE VALVE
1 3 2 RKS00200
1. Spool
2. Plug
3. Cover
FUNCTION
• The shuttle valves are installed in covers of pump swash plate control pistons. They select lower pressure either
travel PPC pressure or AS valve pressure, and output to pump swash plate control pressure.
D B A C
F2 F1
E RKS00210
Operation
• Port C is connected to port A (Travel PPC pressure inlet port). And hydraulic force F1 by travel PPC pressure
actuates the valve (1).
• And port D is connected to port B (AS pressure inlet port). Hydraulic force F2 by AS valve pressure actuates the
valve (1).
• By the hydraulic force F1 and F2, the shuttle valve selects lower pressure either PPC pressure or AS valve pressure.
It outputs lower pressure of them from port E to control pump swash plate.
CK35-1 10-31
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1A
1B
P1 1C
P2
3 2 2 3
1. Synchronization valve
1A. Spool
1B. Body
1C. Spring
2. Travel pump
3. Drive motor
FUNCTION
• Synchronization valve is mounted to main pump.
• Its purpose is to compensate for the difference in flow rate between right and left travel circuits in forward travel.
This way, the amount of oil circulating through the right and left circuits is almost equal and no deviation occurs
during travel.
• Synchronization is not dependent on differential pressure between P1 and P2 or flow rates.
• The difference in flow rate is compensated in forward travel, and the vehicle travels straight.
• On steering, the difference in flow rate rather than flow rate compensation is controlled, and then steering can be
performed.
OPERATION
• When pressure P1 is greater than pressure P2, oil flows through spools (1), (2).
• When a preset flow rate is reached, spool (2) shifts due to differential pressure between port a and b and passage
c reduces, thereby reducing the oil flow.
10-32 CK35-1
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
B
D A
B3 A3
B2 A2
PB3
PA3
G G
F F
PA2 PB2
E E
PA1 B1 A1
PB1
C C
T P
TS
B A
D
RKS00254
CK35-1 10-33
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
4 9
4
8
3
7
2
1
Section A - A Section B- B
AA
BB 10 12
13
AA 11
BB
Section C - C Section AA-AA Section BB-BB
RKS04800
10-34 CK35-1
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
9 8 9
4 5
3 7
2 10 2 7
Section E - E
1 Section D - D
12 11
15 14 15
13 3 6 4 5 RKS04810
Section F - F Section G - G
CK35-1 10-35
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
FLOAT VERSION
B
D A
B3 A3
B2 A2 PB3
PA3
G G
F F
PA2
E E PB2
PA1 B1 A1
PB1
C C
T P
TS
B A
D
RKS04390
10-36 CK35-1
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
3 8
3
2 7
1
Section A - A Section B- B
AA
BB 9 11
12
AA 10
BB
Section C - C Section AA-AA Section BB-BB
RKS04820
CK35-1 10-37
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
4 5
10 11
6 2 12
3 7
2
88 2 7 13
Section E - E
1 Section D - D
15 14
18 17 18
16 3 6 4 5
Section F - F Section G - G RKS04830
10-38 CK35-1
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
HIGH-FLOW VERSION
B C A
Pi2
B3 A3
PA3
H H
PB3
G G
F F
PA2 E PB2
B2 A2 E
B1 A1 PB1
PA1
D D
T P
TS
B A
C
RKS04420
P. from gear pump (P4 port) A2: to bucket cylinder (head side)
P2. from gear pump (P5 port) A3: to attachment port
T: to tank B1: to lift arm cylinder (bottom side)
TS. to tank B2: to bucket cylinder (bottom side)
Pi2. From solenoid valve group (B port) B3: to attachment port
A1: to lift arm cylinder (head side)
CK35-1 10-39
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
Section B- B
3 3
Section A - A
RKS04880
10-40 CK35-1
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
AA
BB
AA
BB
6 Section D - D
7 9
4 8
11 10
1 Section BB-BB
Section C - C
12
Section AA-AA
RKS04840
CK35-1 10-41
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
2 4
3 5
11 10
8 1 7 6
Section E - E
13 9 12
Section F - F
19
16 15 16
18
Section H - H
14 17
Section G - G
RKS04850
10-42 CK35-1
STRUCTURE AND FUNCTION CONTROL VALVE (4-SPOOL)
B C A
B4 A4
B3 A3 Pi
PA3
J J
H H
PB3
G G
F F
PA2 PB2
E B2 A2 E
PA1 PB1
B1 A1
D D
TS T P
B A
C
P2
RKS04460
P1. from gear pump (P4 port) A3: to attachment port (RH side)
P2. from gear pump (P5 port) A4: to HIGH FLOW attachment port (LH side)
T: to tank B1: to lift arm cylinder (bottom side)
TS. to tank B2: to bucket cylinder (bottom side)
Pi: From solenoid valve group (B port) B3: to attachment port (RH side)
A1: to lift arm cylinder (head side) B4: to HIGH-FLOW attachment port (LH side)
A2: to bucket cylinder (head side)
CK35-1 10-43
STRUCTURE AND FUNCTION CONTROL VALVE (4-SPOOL)
4 4
4 4
5
10
9
1
Section A - A
8
Section B - B
RKS04890
10-44 CK35-1
STRUCTURE AND FUNCTION CONTROL VALVE (4-SPOOL)
13
AA
BB
14
Section AA-AA
AA
BB
6
Section D - D
7
11
5
9
4 10
3 12
2 Section BB-BB
1 RKS04860
Section C - C
CK35-1 10-45
STRUCTURE AND FUNCTION CONTROL VALVE (4-SPOOL)
2 4
11 10
8 1 7 6
Section E - E
19
16 16
13 9 12
Section F - F
15
16 16
5 5
18 20
Section H - H
22
14 17
Section G - G
21 RKS04870
Section J - J
1. Pressure compensation valve (lift arm) 12. Pressure compensation valve (bucket)
2. Spool (lift arm) 13. Shuttle valve
3. Plug 14. Pressure compensation valve (attachment)
4. Float valve 15. Spool (attachment)
5. On - off solenoid 16. Plug
6. Spool (float) 17. Pressure compensation valve (attachment)
7. Pressure compensation valve (lift arm) 18. Pressure compensation valve (HIGH FLOW)
8. Shuttle valve 19. Spool (High - Flow)
9 Pressure compensation valve (bucket) 20 Pressure compensation valve (HIGH FLOW)
10. Spool (bucket) 21. Check valve (High - Flow joining circuit)
11. Suction valve 22. High - Flow joining spool
10-46 CK35-1
STRUCTURE AND FUNCTION CLSS
CLSS
1. OUTLINE
Features
CLSS stands for Closed centre Load Sensing System, and has the followings characteristics.
a. Controlability, not influenced by load;
b. Controllable digging force at fine control range;
c. Easy simultaneous operation by spool opening proportional flow dividing function.
Load Load
W W
Actuator Actuator
ÐP ÐP
S1 S2
Pressure Pressure
compensation compensation
valve valve
RKS00691
Pump
CK35-1 10-47
STRUCTURE AND FUNCTION CLSS
Features
• The small capacity gear pump keeps high speed movement because lift arm and the bucket circuit are connected
in a series circuit.
• The control valve has built in self leveling function.
• If loading pressure of bucket becomes beyond a certain value, the lift arm and the bucket circuits automatically
change to parallel circuit to keep strong digging force.
• The lift arm, attachment and High-flow section are connected in a parallel circuit and it has pressure
compensationing function each section.
• During individual operations, attachment High-flow keep individual demand flow rate.
However during compound operations, they are divided in the proportion of 1 to 9 and keep High-flow section flow
rate.
P2
Ls
13
A4
Optional equipment
B4 High-flow
P1
A3
Optional equipment
B3
Pa3 Pa3
Port
5
A2
B2 Bucket cylinder
Pa2 11 Pa2
Curl bucket
Dump bucket
4
11 A1
Pa1
Raise arm B1 Raise cylinder
9 8 3
12
10
Pa1
1 Lower arm
2
RKS04780
10-48 CK35-1
STRUCTURE AND FUNCTION CLSS
Function
• Return flow rate from the lift arm is recirculated to the bucket.
F
2 a 3
d
4
b
c
P1
Q1 P2
A B C
Q2
1
5
6
E RKS00720
Operation
When the lift arm raise and the bucket dump are operated at the same time.
• The lift arm spool (1) strokes fully and the bucket spool (2) stokes by half.
• When this happens, notch (a) doesn’t open, so all flow rate from pump supplies to the lift arm raise.
• The lift arm and the bucket PPC pressure are sent by passage E and F.
Then the leveling circulating valve (3) and the combination circulating valve (4) stroke fully.
• Return flow rate from the lift arm cylinder passes through passage A.
Then it is divided to passage B and C, by the leveling circulating valve (4) and the combination circulating valve (3).
• When this happens, the flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to passage B and C
in proportion to the area of opening as below expression.
Q1: Q2= (notch (b) + notch (d)): notch (C)
Q1= flow rate flows to B
Q2=flow rate flows to C
• Q1 passes through the check valve (6) and then supplies to the bucket cylinder.
CK35-1 10-49
STRUCTURE AND FUNCTION CLSS
Function
When the only lever of the lift arm raise is operated, the lift arm raise and the bucket dump are worked.
When this happens, the work equipment can raise with constant bucket bottom angle. (Only the lift arm raise).
F
2 a 3
d
4
b
c
P1
Q1 P2
A B C
Q2
1
5
6
E RKS00720
Operation
When the lift arm raise is operated individually.
• The lift arm spool (1) strokes fully and the bucket spool strokes by half.
• When this happens, notch (a) doesn’t open, so all flow rate from pump supplies to the lift arm raise.
• The lift arm raise PPC pressure is sent by passage E.
Then the leveling circulating valve strokes fully.
• Return flow rate from the lift arm cylinder passes through passage A.
Then it is divided to passage B and C, by the leveling circulating valve (3).
• When this happens, the flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to passage B and C
in proportion to the area of opening as below expression.
Q1: Q2= (notch (b) + notch (d)): notch (C)
Q1= flow rate flows to B
Q2=flow rate flows to C
Q1 passes through the check valve (6) and then supplies to the bucket cylinder.
10-50 CK35-1
STRUCTURE AND FUNCTION CLSS
Function
• (1) Low bucket load: Series circuit
• (2) High bucket load: Parallel circuit
• Depend on bucket load, a circuit can change automatically as above.
Then the machine gets high speed and strong digging power.
F
2 a 3
d
H 4
b
A c
P1
Q1 P2
B C
Q2
1
P3
5
6
E e
f G
7 RKS00730
CK35-1 10-51
STRUCTURE AND FUNCTION CLSS
Operation
When the lift arm raise and the bucket digging are operated at the same time.
• The lift arm spool (1) and the bucket spool (2) stroke fully.
• When this happens, the bucket digging PPC pressure is sent by passage H.
Then the combination circulating valve (3) strokes fully to the right and also the lift arm raise PPC pressure is sent
by passage E.
Then the leveling circulating valve (4) strokes fully to the left.
• Return flow rate from the lift arm cylinder passes through passage A.
Then it is divided to passage B and C, by the leveling circulating valve (4) and the combination circulating valve (3).
• When this happens, the flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to passage B and C
in proportion to the area of opening as below expression.
Q1: Q2= (notch (b) + notch (d)): notch (C)
Q1= flow rate flows to B
Q2=flow rate flows to C
• If the bucket load becomes beyond a certain valve by influences of digging, the series-parallel switching valve (7)
strokes to the right.
Then it passes thorough passage G by opening notch (e).
And then the spring chamber of flow divider (5) is connected to tank.
• As a result, flow divider (5) strokes fully to the right, and P2 = T.
Return flow rate from the lift arm is connected with tank totally, and Q1 = 0 l/min.
• When this happens, notch (f) of the lift arm spool and notch (a) of the bucket spool open, so the lift arm and the bucket
become parallel circuit (CLSS).
And flow rate of the lift arm raise (Q3) and the bucket digging flow rate are divided as below expression.
Q3: Q4 = notch f: notch (a )
10-52 CK35-1
STRUCTURE AND FUNCTION CLSS
Function
• During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to
increase, compensation is received. (When this happens, the other actuator being used for compound operation
(right side) is at a higher load than the actuator on this side (left side).
W W
A A
a a
PLS1 PPA PA
PPA
1
PA
2
PLS
PP
RKS00740
Operation
• If the load pressure of the other actuator (right side) becomes higher during compound operations, the oil flow in
actuator circuit A on this side (left side) tries to increase.
• If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLS1, and reducing valve (1) and
flow control valve (2) are pushed to the left (i).
• Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA, and pressure
loss is generated between PP and PPA.
• Flow control valve (2) and reducing valve (1) are balanced in position where the difference in pressure between PA
and PLS acting on both ends of reducing valve (2) and the pressure loss between PP andPPA on both sides of flow
control valve (1) are the same.
• In this way, the pressure difference between upstream pressure PPA and downstream pressure PA of both spools
used during compound operations is the same, so the pump flow is divided in proportion to the area of opening of
notch a of each spool.
CK35-1 10-53
STRUCTURE AND FUNCTION CLSS
Function
1. When each section is operated individually
Attachment: 60 l/min
HIGH-FLOW: 100 l/min
2. When standard attachment and high flow attachment are operated at the same time
1:9=attachment: HIGH-FLOW
1 2 3
RKS00711
Operation
1. When each section is operated individually
• Attachment spool (1) and High-Flow spool (3) stroke fully and individually, therefore they keep demand flow rate
individually.
Attachment: 60 l/min max.
HIGH-FLOW attachment: 100 l/min max.
2. When attachment and High-Flow are operated at the same time.
• High-Flow attachment PPC pressure passes through passage A, is sent to retainer (2) and makes retainer (2) stroke
to the left.
• When this happens, attachment spool (1) can stroke by half.
• As a result, flow rate of attachment and High-Flow are divided as below expression.
Attachment: High-Flow= 1:9
• Therefore flow rate of high flow is kept.
10-54 CK35-1
STRUCTURE AND FUNCTION SOLENOID VALVE
SOLENOID VALVE
SOLENOID VALVE GROUP ST1
(SERVOCONTROL - PARKING BRAKE - 2nd SPEED)
1 2 3
Z
T
A B C
View Z RKS01150
CK35-1 10-55
STRUCTURE AND FUNCTION SOLENOID VALVE
P1 P2
RKS01140
10-56 CK35-1
STRUCTURE AND FUNCTION SOLENOID VALVE
a c
RKS04490
a. T port - To transmission
b. Port 1 - From transmission
c. T1 port - Boom lockout cylinder
CK35-1 10-57
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
B
RKS01650
TECHNICAL DATA
Servocontrol feed unit
Nominal volume:0.35 l
Pre-loading: 8 bar
Working pressure: 25–27 bar
FUNCTION
• An elastic rubber bag (1) containing nitrogen is fitted inside the accumulator to maintain oil pressure in the circuit to
which the accumulator is connected.
OPERATION
• When the engine is running the chamber A of the rubber bag (1) (containing nitrogen) is compressed by oil under
pressure coming from line B.
• If the oil under in line B falls below the maximum calibration pressure (even after intensive use), the rubber bag (1)
will expand due to pressure from the nitrogen it.
10-58 CK35-1
STRUCTURE AND FUNCTION PATTERN CHANGE VALVE (OPTIONAL)
P out 4
P out 6
4 P out 3
6 3
T PO OS I
P out 1 1 5
2 P out 5
View Z
P out 2
Z
OPTIONAL
ISO PATTERN PATTERN
P out 4 P in 4
ISO PATTERN
P out 3 P in 3
P out 2 P in 2
P in 1
P out 1
P out 5
P in 1
P in 5
B
P out 6 P in 6
P in 5
1 5
Pout 4 P in 4
Pout 3 P in 3 P in 4
OPTIONAL
3
PATTERN
Pout 2 P in 2
Pout 1 P in 1
Pout 5
Pout 6
P in 5
P in 6
A A
4
P in 6 6 2 P in 3
P in 2 B
RKS00661
Pin 1. From L.H. PPC valve (P1 port) Pout 1. To hydraulic pump (DA1 port)
Pin 2. From L.H. PPC valve (P2 port) Pout 2. To hydraulic pump (DA2 port)
Pin 3. From L.H. PPC valve (P4 port) Pout 3. To hydraulic pump (DB1 port)
Pin 4. From L.H. PPC valve (P3 port) Pout 4. To hydraulic pump (DB2 port)
Pin 5. From R.H. PPC valve (P1 port) Pout 5. To control valve (PA1 port)
Pin 6. From R.H. PPC valve (P2 port) Pout 6. To control valve (PB1 port)
CK35-1 10-59
STRUCTURE AND FUNCTION PATTERN CHANGE VALVE (OPTIONAL)
C C
E E 3
F F
G G
D D
7
Section A - A Section H - H
5
7
4
3
1 H
2
6
RKS00650
10-60 CK35-1
STRUCTURE AND FUNCTION OPERATION
OPERATION
PATTERN ISO
P1
L.H. TRAVEL
P2
P out 4 P in 4
P out 3 P in 2 P3
REVERSE FORWARD
P out 2 P in 1
A1 B1 P out 1 P in 3
P out 5 P in 5
A2 B2 R.H. TRAVEL
P out 6 P in 6 P4
P T
PA1 FORWARD
P1
DUMP
BUCKET
PB1
P2
RAISE LOWER
P3 ARM ARM
CURL
BUCKET
P4
P T
RKS03070
PATTERN OPTIONAL
P1
RAISE
ARM
P2
REVERSE FORWARD
P3 L.H. L.H.
LOWER
ARM
P4
P out 4 P in 4
P out 3 P in 2 P T
P out 2 P in 1
FORWARD
P out 1 P in 3
P out 5 P in 5 P1
A1 B1 P out 6 P in 6
DUMP
A2 B2 BUCKET
P2
REVERSE FORWARD
PA1 P3 R.H.
R.H.
CURL
PB1 BUCKET
P4
PT
RKS03080
CK35-1 10-61
STRUCTURE AND FUNCTION R.H. PPC VALVE (STANDARD)
P2 P4
P3 P1
E E
D D
B T P
A C
C A
RKS00800
10-62 CK35-1
STRUCTURE AND FUNCTION R.H. PPC VALVE (STANDARD)
5 7
4
8
3
9
2 1
Section A - A Section B - B
Section D - D
Section C - C
Section E - E
RKS00810
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body
CK35-1 10-63
STRUCTURE AND FUNCTION R.H. PPC VALVE (STANDARD)
FUNCTION
D
f T
P
1
P1 P2
Fig. 1 RKS00820
2. During fine control (NEUTRAL o fine control)
When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed by
metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same time,
it is connected to pump pressure chamber PP, so
pilot pressure oil from the control pump passes
5
through fine control hole f and goes from port P1.
When the pressure at port P1 becomes higher, 4
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain 9
chamber D to release the pressure at port P1. 3
When this happens, spool (1) moves up or down so D
2
that the force of metering spring (2) is balanced with T
the pressure at port P1. f
The relationship in the position of spool (1) and
body (10) (fine control hole f is at a point midway P
between drain hole D and pump pressure chamber 1 PP
PP) does not change even if the pressure at port P1 10
becomes max. P1 P2
Therefore, metering spring (2) is compressed Fig. 2 RKS00830
10-64 CK35-1
STRUCTURE AND FUNCTION R.H. PPC VALVE (STANDARD)
CK35-1 10-65
STRUCTURE AND FUNCTION R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)
P2 P4
P3 P1
E E
D D
B T P
A C
C A
RKS00800
P1 port - To pattern change valve (Pin 5 port) FUNCTION
P2 port - To pattern change valve (Pin 6 port) ISO PATTERN:
P3 port - To control valve (PA2 port) P1 Lower arm
P4 port - To control valve (PB2 port) P2 Raise arm
P port - From solenoid valve group ST1 P3 Curl bucket
T port - To hydraulic tank P4 Dump bucket
OPTIONAL PATTERN:
P1 R.H. travel forward
P2 L.H. travel reverse
P3 Curl bucket
P4 Dump bucket
10-66 CK35-1
STRUCTURE AND FUNCTION R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)
5 7
4
8
3
9
2 1
Section A - A Section B - B
Section D - D
Section C - C
Section E - E
RKS00810
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body
CK35-1 10-67
STRUCTURE AND FUNCTION R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)
FUNCTION
D
f T
P
1
P1 P2
Fig. 1 RKS00820
2. During fine control (NEUTRAL o fine control)
When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed by
metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same time,
it is connected to pump pressure chamber PP, so
pilot pressure oil from the control pump passes
5
through fine control hole f and goes from port P1.
When the pressure at port P1 becomes higher, 4
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain 9
chamber D to release the pressure at port P1. 3
When this happens, spool (1) moves up or down so D
2
that the force of metering spring (2) is balanced with T
the pressure at port P1. f
The relationship in the position of spool (1) and
body (10) (fine control hole f is at a point midway P
between drain hole D and pump pressure chamber 1 PP
PP) does not change even if the pressure at port P1 10
becomes max. P1 P2
Therefore, metering spring (2) is compressed Fig. 2 RKS00830
10-68 CK35-1
STRUCTURE AND FUNCTION R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)
CK35-1 10-69
STRUCTURE AND FUNCTION L.H. PPC VALVE (STANDARD)
P2 P4
P3 P1
T P
E E
F F
D D
A C
RKS00860
C A
10-70 CK35-1
STRUCTURE AND FUNCTION L.H. PPC VALVE (STANDARD)
5 7
4
8
3
9
2 10
Section A - A Section B - B
Section D - D
11
12
Section C - C
13
G G
14
Section F - F
Section E - E
Section G - G
RKS00870
1. Spool 8. Cover
2. Metering spring 9. Stopper
3. Centering spring 10. Body
4. Piston 11. Plug
5. Disc 12. Ball
6. Nut 13. Seat
7. Joint 14. Body (for shuttle valve)
CK35-1 10-71
STRUCTURE AND FUNCTION L.H. PPC VALVE (STANDARD)
FUNCTION
1. NEUTRAL
Ports P1 and P2 of the PPC valve are connected to
drain chamber D through fine control hole f in spool
(1). (Fig. 1).
D
f T
P
10-72 CK35-1
STRUCTURE AND FUNCTION L.H. PPC VALVE (STANDARD)
CK35-1 10-73
STRUCTURE AND FUNCTION L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL)
P2 P4
P3 P1
E E
D D
B T P
A C
C A
RKS00800
10-74 CK35-1
STRUCTURE AND FUNCTION L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL)
5 7
4
8
3
9
2 1
Section A - A Section B - B
Section D - D
Section C - C
Section E - E
RKS00810
1. Spool 5. Disc
2. Metering spring 6. Nut
3. Centering spring 7. Joint
4. Piston 8. Cover
9. Stopper
10. Body
CK35-1 10-75
STRUCTURE AND FUNCTION L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL)
FUNCTION
D
f T
P
10-76 CK35-1
STRUCTURE AND FUNCTION L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL)
3).
CK35-1 10-77
STRUCTURE AND FUNCTION EQUIPMENT CONTROL PPC VALVE
5
4
c d 6
3 7
2
8
1
9
Section A - A
RKP00960
10-78 CK35-1
STRUCTURE AND FUNCTION EQUIPMENT CONTROL PPC VALVE
D
T
f P
RKP00980
Fig. 2
CK35-1 10-79
STRUCTURE AND FUNCTION EQUIPMENT CONTROL PPC VALVE
A Control valve B
RKP00990
Fig. 3
T
2
8
P
f
f'
1 P1 P2 PP
A Control valve B
Fig. 4 RKP01000
10-80 CK35-1
STRUCTURE AND FUNCTION CYLINDERS
CYLINDERS
BUCKET RAISE
7
2 3 4 5 6 9 8
1
13 12 11 10 7 RKS02000
BUCKET DUMP
6 7
2 3 4 5 9 8
1
13 12 11 10 7 RKS02210
1. Bushing 8. Bushing
2. Dust 9. Nut
3. Gasket 10. Piston
4. Gasket 11. Cylinder
5. Rod 12. Gasket
6. Gasket 13. Head
7. Ring
Unit: mm
CK35-1 10-81
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (ENGINE LINE) (1/3)
FILTRO ARIA
AIR FILTER SWITCH PRERISCALDO POOL-STOP SOLENOIDE CARBURANTE SENSORE LIVELLO COMBUSTIBILE
PREHEATING FUEL POOL-STOP SOLENOID FUEL LEVEL SENDER
S25
R1 X13 X17 SIRENA BACK-UP
BACK-UP ALARM
RELE' SICUREZZA
SAFETY RELAY
X29
X08
RELE' SICUREZZA
SAFETY RELAY
PRESSOSTATO OLIO MOTORE
XS1 ENGINE OIL PRESSURE SWITCH
S31
ISOLATORE
INSULATOR
XS
X18
8
2
9
3
10
4
5
6
12
TO FRAME CABLE
X10 X23
A LINEA TELAIO
TO FRAME CABLE
X01
PRESSOSTATO 2 LUCI STOP
A LINEA TELAIO STOP LIGHT PRESSURE SWITCH 2
TO FRAME CABLE MASSE START(+50)
GROUND POMPA GASOLIO X21
START(+50) PRESSOSTATO 1 BACK-UP
X02 FUEL PUMP
GND5 XM BACK-UP PRESSURE SWITCH 1
X14
X22
ALTERNATORE
GENERATOR
v
X11
INT. FILTRO OLIO IDR.
HYDR. OIL FILTER SW. x
S26 ALTERNATORE
GENERATOR
G2 +30 IMPIANTO
POWER (+30) CONNECT WITH XS
XS*
MOTORINO AVV.
STARTER MOTOR
XB
FUSIBILE GENERALE(50A)
FG1
CK35-1 10-83
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (ENGINE LINE) (2/3)
V1 K02 K03
SAFETY
POWER
K01 86 87 R-N2.5
BOX
X01
RELAY 4
M2.5
X01
R-B1
85 30 3
R4
R1
N1
G1
X01
2
X07
X07
X07
X07
X03 X03 X03 X03 X06 X06 XS1 XS1 X08 X08 X08 X08 X01
1
86 85 30 87 l - 4 3 2 1 A B 1 3 5 6
N4
XS
R-N1.5
R-N1.5
R-N2.5
R-N1.5
M-V1
R-G1
S-N1
L/B1
L/B1
B2.5
R4
GND5
M-V1
N1
N1
N1
B2
B1
X02
R10
l
L-R1
R-N1.5
X10
13
X10
12
R2.5
X10
11
R-V1
X10
10
B1
X10
9
S1
X10
8
C-N1
X10
7
C-L1
X10
6
S-G1
X10
5
X10
4
B-N1
GND X10
3
R10
R-G1
X10
2
B-G1
1 X10
1
XF
1
X28
FG1
80A
HA3
S31
XF p
2
X29 X29
2 1
Z-N1
R10
N1
R10
R50
B2.5
R-G1
S-N1
S1
R-N1.5
R-G1
C-N1
G1
B-N1
S-G1
M2.5
C-L1
N2
N1
N1
N1
N1
B2
1 2 1 3
R-V1
Z-N1
L-R1
L-R1
L-R1
12Vcc 3 1 2 - + 1 2 1 C A - + 1
X09
X11
X11
X11
X13
1 1
X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 1 2 1 2 1 2 1 2
R1.5
B2.5
D+
30 50 30
G
W M2
M S25 S26 S27 S28 S29 S30
N50
3 Y0 M p p p p p p
U
t
31
RKS03220
10-84 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (ENGINE LINE) (3/3)
CK35-1 10-85
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (1/3)
A LINEA MOTORE
A LINEA CABINA TO ENGINE CABLE
TO CABIN CABLE X01.1
X46 A LINEA MOTORE
TO ENGINE CABLE
X02.1
8 9
1 2
A LINEA MOTORE
10
TO ENGINE CABLE
4 3
X10.1
11 12
5 6
13
A LINEA CABINA
7
TO CABIN CABLE
X47
MASSA
GROUND
GND5
8 9 10
1 2 3
GND2
11 12 13
5 6 7
X45
TO CABIN CABLE
5
X32
X48
PRESSOSTATO FRENO
BRAKE PRESSURE SWITCH
E/V SERV. PPC X37
PPC SERV. VALVE
X33 E/V SECONDA VELOCITA' ELETTROVALVOLA FRENO
2nd SPEED VALVE BRAKE VALVE
X32A X36 X35
E/V FLOTTANTE
FLOAT VALVE
X34
RKS03230
10-86 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (2/3)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
X01.1 R-N2.5
4
X01.1 M2.5
3
X01.1 R4 M1
2 X48
1
X01.1 R4 M-V1
1 X48
2
R-V1
X48
3
GND5 L-G1
X48
4
R-N2.5
X46
FROM ENGINE LINE STD/OPT
X02.1 4
l M2.5
X02.1 L-R1.5
X46
3
- R4
X46
2
R4
X46
N4
X47
2
N4
X47
1
N2.5
M-N1
M-B1
M-V1
V-N1
L-G1
M1
R1
N1
N1
N1
N1
1 1 1 2 1 2 1 2 1 2 1
X32 X32A X33 X33 X34 X34 X35 X35 X36 X36 X37
S32 Y1 Y2 Y6 Y3 S33
p p
GND2
RKS03240
CK35-1 10-87
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (3/3)
COMPONENTS
GND2 C8 ground terminal
GND5 C6 ground terminal
S32 PPC safety pressure switch
S33 Brake valve pressure switch
X01.1 Engine line 4 way connector
X02.1 Engine line 2 way connector
X10.1 Engine line 13 way connector
X32 PPC safety pressure switch 1 way connector
X32A PPC safety pressure switch 1 way connector
X33 PPC valve 2 way connector
X34 Float valve 2 way connector
X35 Brake valve 2 way connector
X36 Second speed valve 2 way connector
X37 Brake pressure switch 1 way connector
X45 Cabin line 13 way connector
X46 Cabin line 4 way connector
X47 Ground 2 way connector
X48 Cabin line 5 way connector
Y1 PPC valve
Y2 Float valve
Y3 Second speed valve
Y6 Brake valve
10-88 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (1/3)
8 9
A LINEA MOTORE
1 2
A LINEA MOTORE X43
TO ENGINE CABLE
10
TO ENGINE CABLE
3
X10.1
4
X41
11 1
5 6
2 13
7
A LINEA CABINA
TO CABIN CABLE
X47
MASSA
GROUND
GND 5
8 9 10
1 2 3
GND 2
5 6 7
X45
MASSA
GROUND
GND 1
1
TO CABIN CABLE
5
X32
X48
PRESSOSTATO
FRENO
E/V SERV. PPC BRAKE PRESSURE
PPC SERV. VALVE SWITCH
E/V SECONDA
X33 VELOCITA' ELETTROVALVOLA X37
2nd SPEED E/V HI-FLOW E/V HI-FLOW FRENO
VALVE MOMENTARY DETENT BRAKE VALVE
HI-FLOW MOMENTARY HI-FLOW DETENT X35
7
1
2
3
X32A X36 VALVE VALVE
8 4
9
10
5
6 X40 X39
11
A LINEA CABINA
TO CABIN CABLE
E/V FLOTTANTE
X49 FLOAT VALVE
X34
RKS03250
CK35-1 10-89
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (2/3)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
X01.1 R-N2.5
4
X01.1 M2.5 M1
X48
3 1
X01.1 R4 M-V1
X48
2 2
X01.1 R4 R-V1
X48
1 3
L-G1
GND5 N4 X48
4
R-N2.5
X02.1 X46
FROM ENGINE LINE STD/OPT
4
l M2.5
X02.1 L-R1.5 X46
3
- R4
X46
2
R4
X10.1 R-N1.5 X46
1
13
X10.1
12 R-N1.5
X10.1 R2.5 X45
13
11 V-N1
X10.1 R-V1 X45
12
10 M-B1
X10.1 B1 X45
C-B1
X49
11
C1
X49
10
V-B1
X49
9
V1
X49
8
A-N1
X49
7
A-B1
X49
6
A-G1
X49
5
Z-N1
X49
4
A-V1
X49
3
S-N1.5
X49
2
L-R1.5
X49
1
N2.5
M-B1
M-N1
Z-N1
M-V1
V-N1
L-G1
A-V1
R2.5
M1
N1
N1
N1
N1
N1
N1
GND1
GND2
N4
X47
1 1 1 2 1 2 1 2 1 2 1 2 1 2 1 2
N4
X47
X32 X32A X33 X33 X34 X34 X39 X39 X40 X40 X35 X35 X36 X36 X37 1
S-N1.5
L-R1.5
A-G1
A-N1
C-B1
A-B1
V-B1
N1.5
C1
V1
S32 Y1 Y2 Y5 Y4 Y6 Y3 S33
p p
4 3 2 1 5 4 3 2 1 1
X41
X41
X41
X41
X42
X42
X42
X42
X42
X43
RKS03260
10-90 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (3/3)
COMPONENTS
GND1 C8 ground terminal
GND2 C8 ground terminal
GND5 C6 ground terminal
S32 PPC safety pressure switch
S33 Brake valve pressure switch
X01.1 Engine line 4 way connector
X02.1 Engine line 2 way connector
X10.1 Engine line 13 way connector
X32 PPC safety pressure switch 1 way connector
X32A PPC safety pressure switch 1 way connector
X33 PPC valve 2 way connector
X34 Float valve 2 way connector
X35 Brake valve 2 way connector
X36 Second speed valve 2 way connector
X37 Brake pressure switch 1 way connector
X39 High-flow detent valve 2 way connector
X40 High-flow momentary valve 2 way connector
X41 Stabilizer 5 way connector
X42 Attachment 5 way connector
X43 ENPI valve 1 way connector
X45 Cabin line 13 way connector
X46 Cabin line 4 way connector
X47 Ground cabin line 2 way connector
X48 Cabin line 5 way connector
X49 Cabin line 11 way connector
Y1 PPC valve
Y2 Float valve
Y3 Second speed valve
Y4 Reverse hi-flow momentary valve
Y5 Super-flow detent valve
Y6 Brake valve
CK35-1 10-91
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (1/5)
4
3
X78-79 ZOCCOLO RELE' FLOAT
11
1
10
FLOAT RELAY SOCKET
8
K04
7
6
5
DA LINEA TELAIO
FROM FRAME LINE
X48.1
4
1
2
5
3
SENSORE BRACCIOLO
PROXIMITY BAR 3 WAY
DA LINEA TELAIO
FROM FRAME LINE X54
X46.1
MANIPOLATORE DX
1
RIGHT LEVER
8
2
9
3
10
X84
4
DA LINEA TELAIO
5
11
X45.1
SWITCH SEDILE
SAFETY SEAT SWITCH
GND X55
GROUND
X47.1
CABINA
CABIN LINE
X82 1
7 2
8 3
9 4
5
MASSE
10
11
6
GROUND
GND3
INT. LUCI
FRONT LIGHTS SWITCH
X86
INT. FARO LAVORO POST. PANNELLO
REAR WORK LIGHTS SWITCH DI CONTROLLO
X85 CONTROL PANEL
X80
PANNELLO
DI CONTROLLO
CONTROL PANEL PULSANTE FRENO INT. GIROFARO
BRAKE BUTTON BEACON LIGHT SWITCH
X81 X87 X88
RKS03270
10-92 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (2/5)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
BRAKE P.B. IN
X50 L/B1 H-R1
23
HA1
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
HI-SPEED P. B. IN
X50 A/B1 R-N2.5 G1.5
R2.5
22
FLOAT P. B. IN
X50 L/G1
21
SAF. BAR. SW IN
X50 C/N1
H-R2.5
20 1 1 1 1 1 1 1 1 1 1 1
M2.5
X50 X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76
B1
C-B1 X52 X53
SEAT SWITCH IN
19 1 1
POW. SUPP. +12V
X50 H-R1
Z-B1
18 R1 ACC BR R2 C
X50 H-L1
FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01
EV BRAKE OUT OFF ACC
R1
17 R/N1 ST
1 1 1 1 1 1 1 1 1 1 1
X50 B/N1
SAF. BAR.LED OUT
14 S12
SEAT LED OUT
X50 G/N1 S11
R4
13
G-N1
X50 M/B1 G-N1
R-N2.5
R-G1
L-R1.5
H-R1
H/R1
B-R1
A-R1.5
G/R1
WARNING LED OUT
12
FLOAT OUT
X50 B-N1 X54 X54 X54 G1
11
C A B X55 X55
BUZZER OUT (-)
X50 Z-B1 2 1
H-R1.5
10
HI-SPEED OUT
X50 M-B1 G/R1
C/N1
N1
H-R1
C-B1
H-R1
9
GNDGND
X50 N1.5 A-R1.5
8
HORN OUT
X50 C1 H/R1
7
START SIGN. IN
X50 B1 L/B1
6
+12V HORN
X50 H-R1.5 A/B1
5
HORN PUSH B. IN
X50 B/R1 L/G1
4
EV PPC OUT
X50 V-N1 C1
2
M-N1
G-N1
M-V1
M-B1
C-N1
H-R1
S-G1
B-G1
M/B1
G/N1
B-N1
B/N1
Z-B1
C-L1
H0.5
M1
8
N1
B1
S1
X45.1 R-G1
7
X45.1 S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
6
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
X45.1 C-N1
5
X45.1 C-L1
4
X45.1 S-G1 P1
3
X45.1 B-N1
2
X45.1 B-G1 CONTROL PANEL (UNIDECK)
X47.1 1
2
X47.1 N4
1
RKS03280
CK35-1 10-93
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (3/5)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
H-R1
G1.5
S13 S14 S15
R-N0.5
R-N0.5
V/B0.5
L/G0.5
L/G0.5
RIGHT LEVER
K04 85 87
LEFT LEVER
86 30
X83 X83 X83 X83 X84 X84 X84
1 2 3 11 1 3 11
B-R1
B/R1
A/B1
N1
B-R1
L/G1
N1
H/R1
N1
B-N1
B-R1
B-R1
M-N1
G-N1
G1 G/R1 X85
9
H-R1.5 A-R1.5 X85
1
G/R1
1 9
1 0
A-R1.5
H/R1
5 10
S01
L/B1
C1
H-R1
3 2 10
M-N1 H-R1.5 X86
3
H-R1 X86
N4 2
N1 X86
10
A-G1.5
G-N1
H-G1
H-N1
H-N1
N1.5
S/N1 X87
C1
6
H-R1 X87
GND3 3
1 2 3 4 5 6 7 8 9 10 11
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
5 10
H-G1
S07
X88
5
N1 X88
10
RKS03290
10-94 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (4/5)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
X80-15
X80-16
X80-12
X80-14
X80-11
X80-8
+
L1 L2 L3 L4 L5 C2 C3
P1
C1 C2
00000 00 h
C E
C1
C3
HOUR COUNTER
X80-6
-
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
L6 L7 L8 L9 L10 DL2 DL1 DL3
X80-9 X80-2 X80-3
POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR
C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1
C3 X80-3 WATER TEMPERAT. INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1
GND X80-6 GROUND GND N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1
POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5
L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1
RKS03300
CK35-1 10-95
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (5/5)
COMPONENTS
X63 Fuse 1 way connector
GND3 C6 ground terminal X64 Fuse 1 way connector
FU01 Fuse 3A left side lights X65 Fuse 1 way connector
FU02 Fuse 3A control panel lights X66 Fuse 1 way connector
FU03 Fuse 15A horn, front work lights X67 Fuse 1 way connector
FU04 Fuse 7.5A switch lights X68 Fuse 1 way connector
FU05 Fuse 15A rear work light X69 Fuse 1 way connector
FU06 Fuse 10A lever switch power supply, float X70 Fuse 1 way connector
FU07 Fuse 10A current intake 12V, beacon light X71 Fuse 1 way connector
FU08 Fuse 10A control panel, electronic unit, fuel shut off, safety bar proximity, seat safety switch, brake switch X72 Fuse 1 way connector
FU09 Fuse 7.5A back-up alarm X73 Fuse 1 way connector
FU10 Fuse 7.5A fuel pump, safety engine relay, generator X74 Fuse 1 way connector
FU11 Fuse 30A pull solenoid, PPC safety pressure switch X75 Fuse 1 way connector
HA1 Warning buzzer X76 Fuse 1 way connector
K04 Float relay X77 Fuse 1 way connector
K06 Elettronic unit X78 Current intake 1 way connector
K14 Brake relay X79 Current intake 1 way connector
P1 Control panel X80 Control panel 16 way connector
S01 Rear work lights switch X81 Control panel 8 way connector
S02 Panel lights and low beam lights switch X82 Lights line 11 way connector
S07 Beacon light switch X83 Left lever 12 way connector
S08 Brake switch X84 Right lever 12 way connector
S10 Starting switch X85 Rear work lights SWF switch
S11 Safety seat switch X86 Panel and front lights SWF switch connector
S12 Bar PNP safety sensor X87 Brake push button connector
S13 Horn push button X88 Beacon light switch connector
S14 Second speed push button X89 Float relay connector
S15 Float push button
X44 Brake relay connector
X45.1 From frame line mark 13 way connector
X46.1 From frame line 4 way connector
X47.1 From frame line 2 way ground connector
X48.1 From frame line mark 5 way connector
X50 Electronic unit 23 way connector
X52 Buzzer 1 way connector
X53 Buzzer 1 way connector
X54 Proximity bar 3 way connector
X55 Safety seat switch 2 way connector
X56 Fuse 1 way connector
X57 Fuse 1 way connector
X58 Fuse 1 way connector
X59 Fuse 1 way connector
X60 Fuse 1 way connector
X61 Fuse 1 way connector
X62 Fuse 1 way connector
10-96 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (1/7)
SAL 11
10 4
3
2
SCATOLA FUSIBILI K14 ZOC. RELE' FLOAT K95
6
5
FUSES BOX FLOAT RELAY S.
PRESA DI CORRENTE X56-X77 K04 CENTRALINA
CURRENT INTAKE COMANDO RELE'
4
10
3
X78-X79 15
RELAY COMAND UNIT
11
3
10
3 30
7.5
INT. E.V. ENPI X90
9
10 10
8
10
ENPI VALVE SWITCH
21 20 19 18 17
11 10 9 8 7
DA LINEA TELAIO
7
10
6
15
X91
5
FROM FRAME LINE
4
1
X48.1
2
5
6
3
16 15 14 13 12
5 4 3 2 1
SENSORE BRACCIOLO
DA LINEA TELAIO PROXIMITY BAR 3 WAY
FROM FRAME LINE
X46.1 X54
MANIPOLATORE SX
QUADRO AVVIAMENTO MANIPOLATORE DX LEFT LEVER
STARTING SWITCH RIGHT LEVER X83
DA LINEA TELAIO S10 X84
FROM FRAME LINE
X45.1
1
8
2
9
3
10
4
5
11
6
12
7
13
INT. STAB SX
LEFT STAB. SWITCH
X106
SWITCH SEDILE SWITCH HAZARD
SAFETY SEAT SWITCH SWITCH HAZARD
X55 X105
GND
GROUND
X47.1
INT. STAB. DX
X107
1
7 2
8 3
9 4
5
MASSE
CABINA
10
11
6
GROUND
CABIN LINE GND3
X82
INT. LUCI
FRONT LIGHTS SWITCH
X86
PANNELLO DI CONTROLLO
INT. FARO LAVORO POST. CONTROL PANEL
REAR WORK LIGHTS SWITCH X80 INT. GIROFARO
X85 BEACON LIGHT SWITCH
X88
INT. LUCI DIREZIONE
DIRECTION LIGHTS SWITCH
X104
PANNELLO DI CONTROLLO
CONTROL PANEL PULSANTE FRENO
X81 BRAKE BUTTON
X87
RKS03310
CK35-1 10-97
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (2/7)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
BRAKE P.B. IN
X50 23 L/B1 H-R1
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
HI-SPEED P. B. IN 22
R2.5
FLOAT P. B. IN
X50 21 L/G1
X50 20 C/N1
H-R2.5
SAF. BAR. SW IN 1 1 1 1 1 1 1 1 1 1 1
M2.5
X50 X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76
B1
SEAT SWITCH IN 19 C-B1 X52 X53
1 1
POW. SUPP. +12V
X50 18 H-R1
FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01
Z-B1
R1 ACC BR R2 C
X50 H-L1 30A 7.5A 10A 10A 10A 10A 15A 10A 15A 3A 3A
EV BRAKE OUT 17 R1
OFF ACC
R/N1 ST
B/N1
SAF. BAR.LED OUT 14 S12
X50
S11
SEAT LED OUT 13 G/N1
R4
X50
R-N2.5
R-G1
L-R1.5
H-R1
H/R1
B-R1
A-R1.5
G/R1
G-N1
WARNING LED OUT 12 M/B1 G-N1
FLOAT OUT
X50 11 B-N1 X54 X54 X54 G1
C A B X55 X55
BUZZER OUT (-)
X50 10 Z-B1 2 1 H-R1.5
HI-SPEED OUT
X50 9 M-B1 G/R1
C/N1
N1
H-R1
C-B1
H-R1
GND
X50 8 N1.5 A-R1.5
HORN OUT
X50 7 C1 H/R1
START SIGN. IN
X50 6 B1 L/B1
+12V HORN
X50 5 H-R1.5 A/B1
HORN PUSH B. IN
X50 4 B/R1 L/G1
EV PPC OUT
X50 2 V-N1 C1
X48.1 M1 B-N1
K06 1
X48.1 M-V1 H0.5
2
X48.1 R-V1 B-R1
3
X48.1 L-G1 B-R1
4
H-R1
X46.1 R-N2.5
4 M-N1
X46.1 M2.5
3 R-V1
X46.1 R4 86 X44 K14 86 87a 87
2 L-N1
FROM FRAME LINE OPT
M-N1
G-N1
M-V1
M-B1
C-N1
H-R1
S-G1
B-G1
M/B1
G/N1
B-N1
B/N1
Z-B1
C-L1
L-N1
H0.5
8
M1
N1
B1
S1
X45.1 R-G1
7
X45.1 S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
6
X45.1 C-N1
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
5
X45.1 C-L1
X45.1
4 P1
S-G1
3
X45.1 B-N1
2
X45.1 B-G1 CONTROL PANEL (UNIDECK)
X47.1 1
2
X47.1 N4
1
RKS03320
10-98 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (3/7)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
H-R1
1 2 3 4 5 6 7 8 9 10 11
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
K04 85 87
K95 86 87a 87
A1
L1
G1
G-N1
R/N1
H-N1
H-N1
A-G1.5
C1
N1.5
H-G1
86 30 85 30
X79
X89 X89 X89 X89 86 85 30 87a
1 1 85 86 30 87
M1
N1
L-R1
R-V1
B-N1
B-R1
B-R1
M-N1
H/R1
N1
G-N1
9
G1 G/R1 X85
1
H-R1.5 A-R1.5 X85
G/R1 S01 1 9
1 0
A-R1.5
H/R1
5 10
L/B1
5
A/B1 G-N1.5 X85
L/G1
10
N1 X85
S/N1
C1
9
B/R1 G/R1 X86
8
B-N1 G1.5 X86
1
H0.5 H-N1 X86
B-R1 S02
1 2
1 6 8 9
0
B-R1
H-R1
3 2 10
3
M-N1 H-R1.5 X86
2
R-V1 H-R1 X86
10
L-N1 N1 X86
L-R1.5
6
S/N1 X87
L-R1.5
3
H-R1 X87
M1. S08 15/1 30/3 L/6
0 1
N4
49/4 30b/2 R/7
2
L/B1 X87
7
H-R1 X87
9
G/R1 X88
1
GND3 H/R1 X88
S07 1 9
1 0
A-R1.5
L-R1.5
L-R1.5
G/R1
H/R1
B-R1
R-V1
R/N1
B/R1
L-N1
L/G1
A/B1
N1.5
N1
A1
L1
5 10
= Parts not included in the wiring H-G1
5
X88
10
N1 X88
RKS03330
CK35-1 10-99
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (4/7)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
H/R1
L-N1
B-R1
L1
A1
R-V1
L/G1
L-R1.5
A/B1
L-R1.5
B/R1
R/N1
N1
N1.5
A-R1.5
G/R1
RELAYS UNIT
K05
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
A-V1
C/B1
L-R1.5
A/N1
L-N1
A/V1
R/N1
R-V1
L/N1
Z-N1
N1.5
A-N1
V/B1
L/R1
A-G1
Z/N1
A-B1
A-R1.5
A1 X104
2
L1 X104
1
S03 1 2
1 0 2
54
A/N1 X104
54
N1 X105
10
A/N1 X105
5
G/R1 X105
8
H/R1 X105
2
S09 2 8 5 10
1 0
X49.1 C-B1
11
X49.1 C1
4 6 3 1 7
FROM FRAME LINE OPT
10
X49.1 V-B1 L/R1 X105
9
4
X49.1 V1 A1 X105
8
3
X49.1 A-N1 L1 X105
7
1
X49.1 A-B1 G/R1 X105
L-R1.5
6
G/R1
S-N1
7
X49.1 A-G1
N1
5 G/R1 X106
X49.1 Z-N1 9
4
5 1 9 10
V-B1 X106
X91
X91
X91
X91
X49.1 A-V1 7
3 V1 X106
X49.1 S-N1 1
A-G1
SWITCH EV ENPI
B-R1
B-R1
A-N1
B/R1
C/B1
Z-N1
2 A-B1
A/B1
V/B1
L/G1
A/V1
Z/N1
L/N1
1 7 9
N1
N1
X49.1 L-R1.5 1 0 2
1
1 2 3 4 5 6 11 1 2 3 4 5 6 7 8 9 11
3 10
X83
X83
X83
X83
X83
X83
X83
X84
X84
X84
X84
X84
X84
X84
X84
X84
X84
L-R1.5 X106S05
3
X106
RIGHT LEVER N1
R-N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
A-B0.5
N0.8
R-N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
A-B0.5
A-G0.5
A-N0.5
Z-N0.5
N0.8
10
G/R1 X107
9
C-B1 X107
7
C1 X107
LEFT LEVER
1
S06 1 7 9
1 0 2
S13 S14 S36 S37 HL1 S15 S38 HL2 S39 HL3 S40 HL4
3 10
RKS3340
10-100 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (5/7)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
RELAYS UNIT
85 30 86 87 86 87 85 30
K07 85 30 K13 +
K10
53M
53S
R CL(T)
31
15
T
86 87
-(53S)
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
K05
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
RKS03350
CK35-1 10-101
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (6/7)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
X80-15
X80-16
X80-12
X80-14
X80-11
X80-8
P1 L1 L2 L3 L4 L5 C2 C3 +
C E
C1 C3
HOUR COUNTER
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
L6 L7 L8 L9 L10 DL2 DL1 DL3
X80-9 X80-2 X80-3
POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR
C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1
C3 X80-3 WATER TEMPERAT. INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1
GND X80-6 GROUND GND N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1
POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5
L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1
RKS03360
10-102 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (7/7)
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (7/7) S40 “B” way push button
X44 Parking brake relay connector
COMPONENTS X45.1 From frame line mark 13 way connector
X46.1 From frame line 4 way connector
GND3 C6 ground terminal
X47.1 Ground 2 way connector
FU01 Fuse 3A left side lights, plate light
X48.1 From frame line mark 5 way connector
FU02 Fuse 3A control panel lights, right side lights
X49.1 From frame line mark 11 way connector
FU03 Fuse 15A horn, low beam or front work lights
X50 Safety control box 23 way connector
FU04 Fuse 10A switch lights, direction lights
X52 Buzzer 1 way connector
FU05 Fuse 15A rear work light, stop light
X53 Buzzer 1 way connector
FU06 Fuse 10A lever switch power supply, float
X54 Proximity bar 3 way connector
FU07 Fuse 10A current intake 12V, hazard, beacon light
X55 Safety seat switch 2 way connector
FU08 Fuse 10A control panel, electronic unit, fuel shut off, safety bar proximity, seat safety switch, brake switch
X56 Fuse 1 way connector
FU09 Fuse 10A back-up alarm, attachement 3 way, hi-flow, stabilizer, ENPI valve
X57 Fuse 1 way connector
FU10 Fuse 7.5A fuel pump, safety engine relay, generator
X58 Fuse 1 way connector
FU11 Fuse 30A pull solenoid, PPC safety pressure switch
X59 Fuse 1 way connector
HA1 Warning buzzer
X60 Fuse 1 way connector
HL1 Super-flow led diode
X61 Fuse 1 way connector
HL2 “C” way led diode
X62 Fuse 1 way connector
HL3 “A” way led diode
X63 Fuse 1 way connector
HL4 “B” way led diode
X64 Fuse 1 way connector
HL5 Optional led diode
X65 Fuse 1 way connector
K04 Float relay
X66 Fuse 1 way connector
K05 Relays box (without relays)
X67 Fuse 1 way connector
K06 Elettronic unit
X68 Fuse 1 way connector
K07 “B” way relay
X69 Fuse 1 way connector
K08 “A” way relay
X70 Fuse 1 way connector
K09 “C” way relay
X71 Fuse 1 way connector
K10 Super-flow detent step by step relay
X72 Fuse 1 way connector
K11 Reverse hi-flow momentary relay
X73 Fuse 1 way connector
K12 Stop lights relay
X74 Fuse 1 way connector
K13 Flasher unit
X75 Fuse 1 way connector
K14 Brake relay
X76 Fuse 1 way connector
K95 Stop light relay
X77 Fuse 1 way connector
P1 Control panel
X78 Current intake 1 way connector
S01 Rear work lights switch
X79 Current intake 1 way connector
S02 Panel lights and low beam lights switch
X80 Control panel 16 way connector
S03 Direction lights switch
X81 Control panel 8 way connector
S05 Up-down left stabilizer button
X82 Lights line 11 way connector
S06 Up-down right stabilizer button
X83 Left lever 12 way connector
S07 Beacon light switch
X84 Right lever 12 way connector
S08 Brake switch
X85 Rear work lights SWF switch
S09 Hazard switch
X86 Panel and front lights SWF switch connector
S10 Starting switch
X87 Brake push button connector
S11 Safety seat switch
X88 Beacon light switch connector
S12 Bar PNP safety sensor
X89 Float relay connector
S13 Horn push button
X90 Relays box 21 way connector
S14 Second speed push button
X91 Enpi valve SWF connector
S15 Float push button
X104 Direction lights switch connector
S36 Reverse hi-flow momentary push button
X105 SWF hazard connector
S37 Super-flow detent push button
X106 Stabilizer push button connector
S38 “C” way push button X107 Stabilizer push button connector
S39 “A” way push button
CK35-1 10-103
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (1/2)
A B
LINEA CRUSCOTTO
FROM DASHBOARD CABLE H4
A
B
4
X82.1
11 10
6 5
AVV. ACUSTICO
PRESA 12V HORN
CURRENT INTAKE(12V) HA2
XP1
B A
FARO DI LAVORO ANTERIORE DX
MASSE FRONT RIGHT WORKING LIGHT
GROUND H6
GND4
MASSA CLAXON
HORN GROUND
GND6
14 13 12 11 10 9 8 7 6 5 4 3 2 1
10-104 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (2/2)
1 2 3 4 5 6 7 8 9 10
COMPONENTS
GND4 C6 ground terminal
GND6 C8 horn ground terminal
H1 Beacon light
H4 Left front work lamp
H6 Right front work lamp
H10 Left rear work light
= Parts not included in the wiring H11 Right rear work light
HA2 Horn
X82.1 From cabin line 11 way connector
X108 Left front light 2 way connector
X109 Right front light 2 way connector
X82.1
11
H-G1
X110 Left rear work lights 2 way connector
X82.1
10
N1.5
X111 Right rear work lights 2 way connector
X82.1
9
C1
X113 Horn 1 way connector
X82.1
XP1
FROM CABIN LINE
8
A-G1
12V socket, beacon light 1 way connector
X82.1
7
H-N1 XP1A 12V socket, beacon light 1 way connector
X82.1 H-N1 GND4
6
X82.1
5
X82.1
4
X82.1
3
X82.1
2
X82.1
1
1 2 1 2 A B A B 2 1
X108 X108 X109 X109 X110 X110 X111 X111 XP1 XP1A
H-N1
N1
H-N1
N1
A-G1
N1
A-G1
N1
N1
H-G1
GND6
1
H1
X113
M
H4 H6 H10 H11
HA2
RKS03390
CK35-1 10-105
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION) (1/2)
A B
LUCE TARGA
NUMBER PLATE LIGHT
FARO DI LAVORO POSTERIORE SX
H12 REAR LEFT WORKING LIGHT
FANALE POSTERIORE SX
H10 REAR LEFT LIGHT
H8 FANALE ANTERIORE SX
FANALE POSTERIORE DX FRONT LEFT LIGHT
REAR RIGHT LIGHT
B
A
H5
H9
FARO ANABBAGLIANTE SX
3 2 1
9 8 7
A
FROM DASHBOARD CABLE H4
B
4
11 10
X82.1
6 5
AVV. ACUSTICO
PRESA 12V HORN
CURRENT INTAKE(12V) HA2
XP1
ł6 B A
ł6
MASSE
GROUND
FARO ANABBAGLIANTE DX
GND4 FANALINO ANTERIORE DX
ł8
FRONT RIGHT MAIN BEAM
FRONT RIGHT LIGHT
MASSA CLAXON H6
HORN GROUND
H7
GND6
RKS03540
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
10-106 CK35-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X82.1 H-G1
11
X82.1 N1.5
10
X82.1 C1
FROM CABIN LINE
9
X82.1 A-G1
8
X82.1 H-N1
7
X82.1 H-N1
6
X82.1 R/N1
5
X82.1 G-N1
4
X82.1 G1
3 GND4
X82.1 L1
2
X82.1 A1
1
A B 1 1 1 A B 1 1 1 1 1 1 1 1 1 1 1 1 1 A B A B 1 1
X108 X108 X115 X116 X117 X109 X109 X118 X119 X120 X121 X122 X123 X124 X125 X126 X127 X128 X129 X130 X110 X110 X111 X111 XP1 XP1A
H-N1
N1
L1
G1
N1
N1
H-N1
G-N1
A1
N1
N1
L1
G1
R/N1
R/N1
G-N1
A1
N1
G1
N1
A-G1
N1
A-G1
N1
N1
H-G1
1
X113
GND6
HA2 H4 H5 H6 H7 H8 H9 H12 H10 H11 H1
58R
58R
58L
58L
54
54
R
R
L
L
31
31
31
31
RKS03550
COMPONENTS X109 Front low beam 2 way connector X127 Rear traffic lights 1 way connector
X110 Rear work lights 2 way connector X128 Rear traffic lights 1 way connector
GND4 Ground ø6 terminal
X111 Rear work lights 2 way connector X129 Plate light connector
GND6 Ground ø8 terminal
X115 Front traffic lights 1 way connector X130 Plate light connector
H1 Beacon light
X116 Front traffic lights 1 way connector XP1 Current intake 12v, beacon light
H4 Left low beam
X117 Front traffic lights 1 way connector XP1A Current intake 12v, beacon light
H5 Left side light
X118 Front traffic lights 1 way connector
H6 Right low beam
X119 Front traffic lights 1 way connector
H7 Right side light
X120 Front traffic lights 1 way connector
H8 Left rear lamp
X121 Rear traffic lights 1 way connector
H9 Right rear lamp
X122 Rear traffic lights 1 way connector
H10 Left rear work light
X123 Rear traffic lights 1 way connector
H11 Right rear work light
X124 Rear traffic lights 1 way connector
H12 Plate light
X125 Rear traffic lights 1 way connector
HA2 Horn
X126 Rear traffic lights 1 way connector
X108 Front low beam 2 way connector
CK35-1 10-107
PAGE INTENTIONALLY
LEFT BLANK
20 TESTING AND ADJUSTMENTS
k When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level ground.
Apply all the machine safety devices and use blocks to prevent any machine movement.
k When more than one person is engaged in the work, use the prescribed notices that indicate that the machine is un-
dergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
k When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed while the
liquid is still hot and under pressure, it may cause severe burns.
k Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).
CK30-1 20-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Compression
Oil temperature 40–60 °C kg/cm² 35±1 28±1
pressure
(Engine speed) (rpm) (250) (250)
(SAE30 oil)
Blow - by
Water temperature in operating range
pressure mm H2O – –
At high idling speed
(oil SAE30)
Oil temperature: 80 °C
Engine oil
At high idling kg/cm² 3.0–4.0 –
pressure
At low idling kg/cm² > 0.6 –
Oil
Entire speed range °C Max. 250 120 Max. 250 120
temperature
CK35-1 20-3
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Neutral o R.H.
Attachment pedal 20 15–25
Neutral o L.H.
20-4 CK35-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Pilot system travel • Engine speed: 2500±10 rpm 16.5± 0.5 16–17
reverse (maximum) • Oil temperature: 45–55 °C
• Machine raised from grouns bar
Pilot system travel
*Pressure of wheels starting rotation
to right or left – –
(start-up) *
CK35-1 20-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Front bucket
Bucket cylinder
Max. 8 Max. 8
(Extension)
20-6 CK35-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Raise
4.6 4.14–5.06
Arm
• Control position:
Arm on the ground see Fig.B in this section.
• Average value over 3 tests.
I • Engine speed: max.
Cylinders fully • Oil temperature: 45–55 °C
extended
Lower
3.8 3.42–4.18
Standard
Bucket
Curl
2.2 1.98–2.42
• Control position:
Cylinders fully see Fig.C in this section.
extended • Average value over 3 tests.
I • Engine speed: max.
• Oil temperature: 45–55 °C
Work equipment speed
Cylinders fully
Curl
sec.
Raise
4,8 4.32–5.28
Arm
• Control position:
see Fig.D in this section.
Arm on the ground
• Average value over 3 tests.
Pattern change version (optional)
3.90 3.51–4.29
Bucket
Curl
2.3 2.07–2.53
• Control position:
Cylinders fully see Fig.E in this section.
extended • Average value over 3 tests.
I • Engine speed: max.
• Oil temperature: 45–55 °C
Cylinders fully
Curl
CK35-1 20-7
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Normal
86 83–89
• Control position:
see Fig.F in this section.
Wheel swing • Engine speed: max.
drive wheel • Oil temperature: 45–55 °C rpm
• Machine raised from grouns
With increment
(without load)
• Track tensioning arrow
15-20 mm on central roller
138 134–142
Normal
12 11.43–12.63
• Control position:
(7.5 km/h) (7.12–7.87 km/h)
see Fig.G in this section.
• Engine speed: max.
• Oil temperature: 45–55 °C
Travel speed sec.
• Track tensioning arrow
15-20 mm on central roller
With increment
• Control position:
see Fig.H in this section.
• Oil temperature: 45–55 °C Max. 250 Max. 250
• Track tensioning arrow (Max. 250) (Max. 250)
15–20 mm on central roller
• Travel 20 metres on flat ground and measure
the deviation.
• Check all the direction
a The surface must be firm and horizontal.
Travel deviation mm
20m
Engine speed 1900±100 rpm
10m
RKS01710 Max. 250 Max. 250
(Max. 250) (Max. 250)
[Max 400] [Max 400]
( ): Value with speed increment
[ ]: Value in reverse gear
20-8 CK35-1
PAGE INTENTIONALLY
LEFT BLANK
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. A Fig. B
RKS05090
RKS05100
Fig. C Fig. D
RKS05110
RKS05100
20-10 CK35-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. E Fig. F
RKS05110
RKS05120
Fig. G Fig. H
RKS05140 RKS05140
CK35-1 20-11
TESTING AND ADJUSTMENTS SPECIAL TOOLS
SPECIAL TOOLS
Commercially
1 Pressure adapter 1 Thread 1/8”
available
Engine oil pressure D
Commercially
2 Compression gauge 1 Scale 10 bar
available
Commercially
1 Compression gauge 2 Scale 60 bar
available
20-12 CK35-1
TESTING AND ADJUSTMENTS CHECKING THE ENGINE SPEED
CK35-1 20-13
TESTING AND ADJUSTMENTS ADJUSTMENT OF VALVE CLEARANCE
1
RKSA1270
4 - Loosen the nut (1) and the block (3) adjustment screw
(2).
YES NO
RKS02280
5
2. Adjustment
1 - Turn the drive shaft in the normal direction of rotation
until the line (1) marked as no. 1 on the flywheel is in
alignment with the reference notch (2) on the flywheel 2
1
housing.
RKSA1290
20-14 CK35-1
TESTING AND ADJUSTMENTS ADJUSTMENT OF VALVE CLEARANCE
5 3 4
B1
RKSA1300
a Ignition sequence: 1 - 3 - 4 - 2.
CK35-1 20-15
TESTING AND ADJUSTMENTS MEASUREMENT OF THE COMPRESSION PRESSURE
a Test conditions:
• Engine: at working temperature.
• Hydraulic oil: 45–55°C.
• Battery: fully charged
• Valve clearance: adjusted
(See "ADJUSTMENT OF VALVE CLEARANCE")
RKSA1310
6 - Turn the engine using the starting motor and read the
compression value.
40
35
30
25
20
20-16 CK35-1
TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE FAN BELT TENSION
RKSA1330
2 - Rotate the alternator (2) to give the belt (1) the correct 3
tension and tighten the screw (4).
2
3 - Check the belt (1) tension.
CK35-1 20-17
TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE INJECTION TIMING
RKSA1340
3 - Take off the clamp (3) and disconnect all the fuel
delivery tubes (4) from the injection pump.
RKSA1350
Mark
2
RKSA1360
20-18 CK35-1
TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE INJECTION TIMING
6 - After you have loosened the check nuts for the pump (6)
and the screws (7), rotate the injection pump (5) 8
outwards or towards the engine.
• To ADVANCE injection, rotate pump (4) outwards.
• To DELAY injection rotate the pump (4) towards the
cylinder block.
CK35-1 20-19
TESTING AND ADJUSTMENTS CHECKING ENGINE OIL PRESSURE
2 - Stop the engine and remove the oil pressure sensor (1).
RKSA1430
D1
RKSA0110
20-20 CK35-1
TESTING AND ADJUSTMENTS ADJUSTING THE STROKE OF THE ACCELERATOR CABLES
RKSA1400
4 - Use the nuts (7) and (8) to reset the position of the
injection pump lever (5) to approx. 0.5 mm from the high
idling adjustment screw (6). 3
RKSA1410
RKSA1420
CK35-1 20-21
TESTING AND ADJUSTMENTS REGULATION OF PPC VALVES’ DRIVE PRESSURE
RKSA2360
3 - Loosen the screw (4), remove the washer (5) and pull
out the complete handle (6). [*1]
4
RKSA2370
10
RKSA2380
20-22 CK35-1
TESTING AND ADJUSTMENTS REGULATION OF PPC VALVES’ DRIVE PRESSURE
12
RKSA2390
Assembly
• To assemble, perform the disassembly procedure in the
reverse order. 15 16
17
a Thoroughly clean all parts.
2 Cleaner: Loctite 7063
14
[*1]
3 Screw: 64-74 Nm
[*2]
3 Joint: 112.8±14.7 Nm
[*3]
3 Screws: 13.2±1.5 Nm
[*4]
a Lubricate the stoppers (13).
CK35-1 20-23
TESTING AND ADJUSTMENTS ADJUSTMENT OF THE PPC VALVE CLEARANCES
3 - Tighten the disc (3) until it makes light contact with the 4
push-rods (4).
20-24 CK35-1
TESTING AND ADJUSTMENTS ADJUSTING THE POSITION OF THE SERVO-CONTROL
RKSA0140
1 -Lower the LH safety bar (1) and adjust the position of the
sensor (2) by loosening and tightening the adjustment
nuts (3).
2 3
RKS01260
CK35-1 20-25
TESTING AND ADJUSTMENTS CONTROL AND REGULATION OF THE PRESSURES IN THE
ENGINE
P1 P2 P3 P4 P5
CONTROL VALVE
Command Ports
Arm (Lower - Raise) A1 - B1 3
Bucket (Dump - Curled) A2 - B2 2
Equipment (R.H. - L.H.) A3 - B3 B 1 A
RKS01130
20-26 CK35-1
TESTING AND ADJUSTMENTS TESTING THE HYDRAULIC PUMP
1 - Remove the plugs (1) and (2) and mount the two
pressure adapters E5.
RKS04610
2 -Connect two pressure gauges E1 (60 bar), start the
engine and accelerate to high idling.
3 Plugs: 19.6–27.4 Nm
RKS04620
3 Plugs: 19.8-27.4 Nm
CK35-1 20-27
TESTING AND ADJUSTMENTS VALVE CALIBRATION
VALVE CALIBRATION
1. HST valve calibration
1 - Loosen the nut (1), taking care not to move the
adjustment screw (2).
a Rotating the screw by one turn (2) will vary pressure TOP VIEW RKS01330
by 15.5 bar.
3 - Tighten the nut (1) and check that the working pressure
remains within permissible limits. 2 1
3 Nut: 58.8–78.5 Nm
Section A - A
RKS01340
2. AS valve calibration A
• Pressure adjustment at low idling
3 - Tighten the nut (1) and check that the working pressure
remains within permissible limits.
1 2
3 Nut: 34.3–58.8 Nm
Section A - A
RKS01360
20-28 CK35-1
TESTING AND ADJUSTMENTS VALVE CALIBRATION
3 - Tighten the nut (3) and check that the working pressure
remains within permissible limits.
3 Nut: 34.3–58.8 Nm
CK35-1 20-29
TESTING AND ADJUSTMENTS CHECKING THE TRAVEL DEVIATION
RKS05150
Deviation
m
10
m
10
RKS04600
20-30 CK35-1
TESTING AND ADJUSTMENTS CHECKING THE TRAVEL DEVIATION
3 Nut: 26.5–32.4 Nm
A1 A2
RKS04580
B1 B2
CK35-1 20-31
TESTING AND ADJUSTMENTS CONTROL VALVE
CONTROL VALVE
1. Control of operating pressure (unloading valve)
1 - Remove the plug (1) and mount a pressure adapter.
2 - Connect a pressure gauge E3 (10 bar). E3
3 - Start the engine and bring it up to high idling with all
levers in neutral position. 1
4 - Check the pressure.
a Normal pressure: 4.8 bar
Valve adjustment
a The unloading valve cannot be re-adjusted, only
substituted.
3 Nut: 69±10 Nm
3
a After adjustment, check the adjustment of the main relief
valve with the same procedures as used for the
measurements. Section A - A RKS01400
20-32 CK35-1
TESTING AND ADJUSTMENTS CONTROL AND REGULATION OF THE SERVO-CONTROLPOWER
Action
DA1 DA2 DB1 DB2
FORWARD Q Q
REVERSE Q Q
RIGHT Q Q
LEFT Q Q
CK35-1 20-33
TESTING AND ADJUSTMENTS CONTROL AND REGULATION OF THE SERVO-CONTROLPOWER
20-34 CK35-1
TESTING AND ADJUSTMENTS ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF
2 - Stop the engine, loosen the tank cap (1) and then close
it again.
a This operation lets air into the tank when the level of
the remaining oil is at minimum. RKS05160
CK35-1 20-35
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE HYDRAULIC CIRCUITS
1 2 3 4 5
• Substitution filter Q Q Q Q
• Repair - substitution pump
Q Q Q Q Q
• Removal of suction tube
2 - Pour hydraulic oil through the hole until the entire casing 2
is full.
1
3 - Replace the cap (1).
RKSA1050
20-36 CK35-1
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE HYDRAULIC CIRCUITS
low idling and pout the piston through its entire stroke
until it reaches max. pressure in both directions.
CK35-1 20-37
TESTING AND ADJUSTMENTS TRACK TENSION TEST AND ADJUSTMENT
a Test conditions:
• Firm level ground.
• Working equipment: resting on the ground
2 -Force the blade of the bucket into the ground until track
tensioner idler wheel lifts by approx 300 mm off the
ground.
RKSA5000
2 RKSA3890
2 -Adjustment
RKSA3910
20-38 CK35-1
30 REMOVAL AND INSTALLATION
CK35-1 30-1
TRACK ......................................................................... 65
• Removal.................................................................. 65
• Installation............................................................... 66
LOWER IDLER ROLLER............................................. 67
• Removal.................................................................. 67
• Installation............................................................... 67
IDLER WHEELS .......................................................... 68
• Removal.................................................................. 68
• Installation............................................................... 68
DRIVE WHEEL............................................................. 69
• Removal.................................................................. 69
• Installation............................................................... 69
TRACK TENSIONER CYLINDER................................ 70
• Removal.................................................................. 70
• Installation............................................................... 70
FINAL DRIVE ............................................................... 71
• Removal.................................................................. 71
• Installation............................................................... 73
FINAL DRIVE ............................................................... 74
• Disassembly............................................................ 74
• Assembly ................................................................ 86
30-2 CK35-1
REMOVAL AND INSTALLATION HOW TO READ THE MANUAL
(2) Each special method that only applies to the installation procedure is marked with [*1]; the same symbol will
appear at the end of each important step in the removal procedure to indicate which part for installation the
information refers to.
(Example)
REMOVAL GROUP qqq:.........................................................Title of operation
2. To the precautions to be taken during the removal or installation of the groups, must be added the specific
«PRECAUTIONS TO BE TAKEN DURING THE OPERATIONS».
Always make sure that these precautions are taken.
4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill tanks
and containers
(1) In the operating procedures, you will find the symbols 3, 4 , 5, 2, 6; In the following
order, these represent the values for «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS»,
«QUANTITIES OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS
AND LUBRICATION» - «LUBRICATING GREASE» and «QUANTITIES OF OIL OR LIQUIDS TO BE
DRAINED».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
CK35-1 30-3
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING
30-4 CK35-1
REMOVAL AND INSTALLATION ENGINE HOOD
ENGINE HOOD
Removal
5
k Completely lower the working equipment to the ground
and stop the engine. 1 1
1 - Remove the retainer screws (1) from hinges (2) and (3). 4
RKSA1490
Installation
• To install, reverse removal procedure.
[*1]
a Check the centre and the lock engagement
adjustment.
CK35-1 30-5
REMOVAL AND INSTALLATION CAB
CAB
Dump
1 - Remove the lower idler roller.
(See "LOWER IDLER ROLLER" for details). 1
2 - Completely raise the working equipment and secure
them in their safety positions. 2
3 - Loosen the four screws (1) and remove the foot-rest (2).
RKSA1500
6 - Loosen the screws (5) (two to each side) and raise the
cab as far as the safety cables allow.
[*1]
RKSA1510
30-6 CK35-1
REMOVAL AND INSTALLATION CAB
12
11
RKSA1520
RKSA1530
16
RKSA1540
18
23
RKSA5011
CK35-1 30-7
REMOVAL AND INSTALLATION CAB
14 - Remove the safety cotter pin (19) and the washers (20).
RKSA0282
17 - Tilt the cab (18) slowly until the distance between the
centres of the dumper fixing hooks (23) is 1100 mm.
23
RKSA5011
A
RKSA5020
30-8 CK35-1
REMOVAL AND INSTALLATION CAB
Lower
• To lower the cab back into position, reverse the tilting
procedure.
[*1]
3 Screws: 98±7.3 Nm
[*2]
• Connect the hoses by pushing them fully home into
their seatings. Test for proper connection by
attempting to pull the hoses out of their seats.
[*3]
• Adjust accelerator lever cable travel.
(See "20 TESTING AND ADJUSTMENTS" for
details).
CK35-1 30-9
REMOVAL AND INSTALLATION CAB
Removal
1 2 1
1 -Remove the complete attachments.
(For details, see "WORKING EQUIPMENT SUPPORT
FRAME").
2 -Loosen the nuts (1) and tilt the rear panel (2) towards the
front of the machine.
1 1
RKSA0520
RKSA0530
10
9
5
6
RKSA0550
30-10 CK35-1
REMOVAL AND INSTALLATION CAB
RKSA1531
14
RKSA1541
17
18
RKSA2230
20
19
RKSA1521
CK35-1 30-11
REMOVAL AND INSTALLATION CAB
21
RKSA5031
16 -Remove the pins (25) from the dumper fixing hooks (26).
17- Loosen the nuts (27) and remove the screws (28) and
29
washers (29).
27 28
RKSA5071
30-12 CK35-1
REMOVAL AND INSTALLATION CAB
Installation
• To install, reverse removal procedure.
[*1]
9
a Mount the retainers (9) on the hoses and connect
the pipes by pushing them fully home in their
seatings.
Check for proper connection by attempting to pull
the hoses out of their seatings.
[*2]
a Adjust accelerator lever cable travel. RKSA1241
CK35-1 30-13
REMOVAL AND INSTALLATION BATTERY
BATTERY
Removal
1 -Loosen the screws (1) and remove the carter (2).
1
2
1
RKSA2730
2 -Disconnect the negative cable (--) (3) and the positive ca-
ble (+) (4) from the battery (5) in that sequence. 4
RKSA2740
3 -Loosen the nuts (6) that secure the battery clamp (7) a re-
lease the tie-rods (8) of the battery support.
8
6
RKSA2750
4 - Tilt the battery clamp (7) towards the front of the ma-
chine and lift out the battery.
Installation
• To install, reverse removal procedure.
RKSA2760
30-14 CK35-1
REMOVAL AND INSTALLATION STARTING MOTOR
STARTING MOTOR
Removal
1 - Tilt the cab and secure it in its safety position.
RKSA2770
4 -Loosen the screws (4) and take out the starting motor 4
(5).
2
5
3
RKSA2780
Installation
• To install, reverse removal procedure.
CK35-1 30-15
REMOVAL AND INSTALLATION ALTERNATOR
ALTERNATOR
Removal
1 - Remove the battery. 1
(For details, see "BATTERY")
RKSA1570
5 RKSA1331
Installation
• To install, reverse the removal procedure.
[*1]
30-16 CK35-1
REMOVAL AND INSTALLATION AIR INTAKE FILTER
RKSA2560
5
3
RKSA2571
Installation
• To install, reverse the removal procedure.
CK35-1 30-17
REMOVAL AND INSTALLATION MUFFLER
MUFFLER
Removal
1 - Loosen the clamp (1) and remove the suction manifold
(2).
1
RKSA2560
3 4 RKSA2580
4 - Loosen and remove the screws (7) fixing the muffler (8).
RKSA2590
5 - Remove the four nuts (9) that secure the muffler (8) to
the turbocharger (10). 8
10
9
RKSA2600
30-18 CK35-1
REMOVAL AND INSTALLATION MUFFLER
RKS02970
Installation
• To install, reverse the removal procedure.
CK35-1 30-19
REMOVAL AND INSTALLATION VALVE COVER
VALVE COVER
Removal
k Disconnect the negative terminal cable (–) from the 1
battery.
RKSA2800
3
5
4
6
2
RKSA1640
5 -Remove the clamp (9) screw (8) and move the pipes.
RKSA1650
[*1]
10
10
RKSA1660
30-20 CK35-1
REMOVAL AND INSTALLATION VALVE COVER
[*2]
11
13
12
RKSA1670
Installation
• To install, reverse the removal procedure.
[*1]
3 Pipe union: 19.6-24.5 Nm
[*2]
a Check the state of valve cover seal and replace if
necessary.
CK35-1 30-21
REMOVAL AND INSTALLATION INJECTORS
INJECTORS
Removal
1 - Remove air suction filter (1).
(For details, see "AIR INTAKE FILTER".)
3 - Loosen the five screws (1) and remove the fuel pipe (2)..
1
a Take care to not damage the five gasket (3).
[*1] 2
1 3
RKSA1680
4 - Loosen the screws (4) and remove the four bracket (5).
[*2]
4
5 - Remove the nozzle (6). 4
5
6 6
RKSA1690
Installation
• To install, reverse the removal procedure.
[*1]
3 Screw: 7.8-9.8 Nm
[*2]
3 Screws: 22.6-28.4 Nm
30-22 CK35-1
REMOVAL AND INSTALLATION INJECTION PUMP
INJECTION PUMP
Removal
k 1 -Disconnect the negative terminal cable (–) from the
battery.
RKSA1700
RKSA2810
4 - Disconnect fuel feed (5) and fuel return (6) hoses, fuel
feedback pipe (7) and coolant hoses (8) and (9) from
injection pump (4).
5
9
4
RKSA2170
11
RKSA1710
CK35-1 30-23
REMOVAL AND INSTALLATION INJECTION PUMP
[*3]
13
12
RKSA1720
8 - Loosen and remove the nut (14) and the lock washer
retaining the pump driving gear (15).
[*4]
a Be extremely careful not let nut (14) and lock washer
drop into the housing.
14
RKS02350
15 X2
RKS01731
17
RKSA1711
30-24 CK35-1
REMOVAL AND INSTALLATION INJECTION PUMP
[*6]
18
18
RKSA1730
Installation
• To install, reverse the removal procedure.
[*1]
[*2]
[*4]
3 Nut: 113-123 Nm
[*5]
[*6]
3 Pump screws: 22.6-28.4 Nm
CK35-1 30-25
REMOVAL AND INSTALLATION CYLINDER HEAD
CYLINDER HEAD
Removal
k
3
Disconnect accumulator negative terminal cable (–). 1
a Drain the engine coolant liquid.
[*1] 2
6 Coolant liquid: max. 15 l
1 - Remove the coolant liquid pump.
(For details, see "COOLANT LIQUID PUMP")
5
RKSA1740
7 7
RKSA1691
RKSA1750
30-26 CK35-1
REMOVAL AND INSTALLATION CYLINDER HEAD
RKS03030
12
RKS03020
Exhaust side
Flywheel side
7 16 14 6
1 9 18 12 4
3 11 17 10 2
5 13 15 8
Suction side
RKS01630
CK35-1 30-27
REMOVAL AND INSTALLATION CYLINDER HEAD
Installation
• To install, reverse the removal procedure.
[*1]
1 - Fill up the coolant liquid circuit.
[*2]
3 Screws: 22.6-28.4 Nm
[*3]
a Adjust valve clearance.
(For details, see "20 TESTING AND ADJUSTMENTS" -
"ADJUSTMENT OF VALVE CLEARANCE").
[*4]
a Raise the cylinder head, keeping it horizontal, and place
it on the gasket without shifting anything.
Exhaust side
Flywheel side
3 Screws:
14 6 4 11
Suction side
1st tightening: 49.0–58.8 Nm
2nd tightening: 103.1-112.9 Nm
RKS01640
30-28 CK35-1
REMOVAL AND INSTALLATION TURBOCHARGER
TURBOCHARGER
Removal
1 -Remove the muffler. 5
(For details, see "MUFFLER") 2
RKSA2610
RKSA2620
9
10
RKSA2481
12
Installation
11
• To install, reverse the removal procedure.
RKSA2630
CK35-1 30-29
REMOVAL AND INSTALLATION COOLANT LIQUID PUMP
RKSA1760
2 - Loosen the screws (2), remove the fan (3) and the
spacer (4). 3
Loosen the alternator drive belt and disengage the
circulation pump pulley.
[*2]
3 - Loosen the screws (5) and remove the complete pump
(6) and the seal (7).
[*3] 2
4
RKS02380
Installation
7
• To install, reverse the removal procedure. 6
[*1]
5
RKS02390
[*2]
a Adjust the belt tension. (For details, see "20 TESTING
AND ADJUSTMENTS" - "CONTROL AND
ADJUSTMENT OF THE FAN BELT TENSION").
30-30 CK35-1
REMOVAL AND INSTALLATION RADIATOR GROUP
RADIATOR GROUP
Removal
k Completely raise the attachment and tilt the cab.
(For details, see "CAB"). 1 3
a Drain the hydraulic oil.
[*1]
RKSA2180
7
RKSA0480
11
12
RKSA0490
CK35-1 30-31
REMOVAL AND INSTALLATION RADIATOR GROUP
Installation
• To install, reverse removal procedure.
[*1]
1 - Fill up the hydraulic oil to maximum level.
3 - Start the engine to circulate the oil and the coolant, and
check that there are no leaks.
[*2]
3 Screws: 190 Nm
5 - Pressurise the tank and bleed the air from all circuits.
(For details, see "20 TESTING AND ADJUSTMENTS").
30-32 CK35-1
REMOVAL AND INSTALLATION FUEL TANK
FUEL TANK
Removal
a Drain the fuel. 1
6 Fuel: max 72 l
1
2
2
RKSA3420
5 3
3 RKSA2190
4 -Disconnect the return (7) pipe from filter (6) and the
delivery pipe (9) from decanter (8). 7
9
6
8
RKSA2200
10
11
RKSA4990
CK35-1 30-33
REMOVAL AND INSTALLATION FUEL TANK
8 -Raise the tank (15) and move it towards the front of the
machine.
12
13 RKSA2220
Installation
• To install, reverse removal procedure.
30-34 CK35-1
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
ENGINE-PUMP GROUP
Removal
1 - Tilt the cab until it is resting on a support. (For details,
see"CAB"). [*1]
6 Oil: max. 50 l
RKSA5021
6 Fuel: max. 72 l
2 3
1
[*2]
4 -Remove the cover of the control unit (1), loosen the nuts
(2) and disconnect the control unit (3) from frame.
2 RKSA2240
5 - Disconnect the connectors X10 (4), X01 (5), X42 (6) and
X02 (7) that connect the control unit (1) to the engine
and frame wiring harness.
4 7
6 5
RKSA2250
8
9
RKSA2260
CK35-1 30-35
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
11
RKSA2650
RKSA1532
15
RKSA1542
18
19
RKSA2231
30-36 CK35-1
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
22 22
RKSA3701
27 26
25
RKSA3652
15 -Disconnect the pipes (30), (31) and (32) from the pump
(29).
30
32 31
RKSA3712
16 -Disconnect the pipes (33), (34), (35), and (36) from the
pump.
34
35
33
RKSA3722
CK35-1 30-37
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
18 -Loosen the four nuts (37) that secure the engine and
remove the complete group. [*3]
37
RKSA5041
Installation
• To install, reverse removal procedure.
[*1]
a Adjust accelerator cable travel.
(See "20 TESTING AND ADJUSTMENTS" for details).
[*2]
k While filling the tank, bleed the air from the pump. (For
details, see "20 TESTING AND ADJUSTMENTS").
3 - Fill the fuel tank and bleed the air from the system. (For
details, see "20 TESTING AND ADJUSTMENTS").
5 Fuel: max. 72 l
4 - Start the engine to circulate the oil and the coolant, and
check that there are no leaks.
[*3]
3 Engine nuts: 60-75 Nm
30-38 CK35-1
REMOVAL AND INSTALLATION COMPLETE HYDRAULIC PUMP
1 - Disconnect the pipes (2), (3) and (4) from the pump (1).
4
2 3
RKSA3711
2 - Disconnect the pipes (5), (6), (7), and (8) from the pump.
5
6
RKSA3721
10
9
RKSA3840
CK35-1 30-39
REMOVAL AND INSTALLATION COMPLETE HYDRAULIC PUMP
RKSA3740
5 -Loosen the eleven screws (12) and remove the pump (1)
complete with the flange (13). 14
[*1]
13
4 Pump: 88 kg
RKSA2680
30-40 CK35-1
REMOVAL AND INSTALLATION COMPLETE HYDRAULIC PUMP
Installation
• To install, reverse removal procedure.
[*1]
3 Flange screws: 80 Nm
2 Flange screws: Loctite 262
2 Pump shaft: Lithium EP MS2 NLGI 2
[*2]
3 Pump screws: 195 Nm
2 Pump screws: Loctite 262
2 - Start the engine to circulate the oil and check that there
are no leaks.
CK35-1 30-41
REMOVAL AND INSTALLATION GEAR PUMP
GEAR PUMP
Removal
k Completely raise the attachment and tilt the cab. 1
(For details, see "CAB").
1 - Disconnect from the pump (1) the suction pipe (2) and
the pipe (3) (one for the normal version, two for the
HIGHFLOW version.
3 RKSA2270
2 - Loosen the two screws (4) and remove the pump (1)
complete with the O-ring (5).
[*1] 5
1
4 RKS02400
Installation
a To install, reverse removal procedure.
[*1]
3 Screws: 59–74 Nm
30-42 CK35-1
REMOVAL AND INSTALLATION ENGINE-PUMP COUPLING
ENGINE-PUMP COUPLING
Removal
k Completely raise the attachment and tilt the cab. 3
(For details, see "CAB").
1
1 - Remove the pump.
(For details, see "COMPLETE HYDRAULIC PUMP")
Installation
• To install, reverse the removal procedure.
[*1]
2 Pump half-sleeve clamping screw: Loctite.....
3 Pump half-sleeve clamping screw:...........Nm
[*2]
2 Drive flange screw: Loctite 262
3 Drive flange screw: 50 Nm
k Bleed the air from the piston pump while filling the
tank.
(For details, see "20 TESTING AND
ADJUSTMENTS").
2 - Start the engine to circulate the oil and check that there
are no leaks.
CK35-1 30-43
REMOVAL AND INSTALLATION CONTROL VALVE
CONTROL VALVE
Removal
k Fully raise the working equipment and tilt the cab. (For
1
details, see "CAB").
2
RKS01880
Installation
a To install, reverse removal procedure.
[*1]
3 Control valve screws: 35 Nm
3 - Pressurise the tank and bleed the air from all circuits.
(For details, see "20 TESTING AND ADJUSTMENTS").
30-44 CK35-1
REMOVAL AND INSTALLATION PPC VALVES
PPC VALVES
Removal
2
k Lower the working equipment until it is resting on the
ground, stop the engine and remove the ignition key. 1
6
k Release residual pressures from all circuits and from
the tank. (For details, see "20 TESTING AND
ADJUSTMENTS").
3
With front door
4
1 - Remove the heater group.
(For details see: "TRACK" until point 6.)
5
2 - Raise the switch-box cover (1) disconnect the RKSA0690
[*1]
a Check very carefully the positions for the pipe
connections. P2
P T
L.H. PPC VALVE
Position P4
P T P1 P2 P3 P4
P3
M S A R L R P1
RKSA0710
White White Yellow Yellow Blue Blue
CK35-1 30-45
REMOVAL AND INSTALLATION HEATING SYSTEM BLOWER FAN
RKSA3671
RKSA1548
3 - Loosen the screws (4) and remove the front part of the
inlet hose (5).
4
RKSA1971
RKSA1981
30-46 CK35-1
REMOVAL AND INSTALLATION HEATING SYSTEM BLOWER FAN
RKSA1991
8
RKSA2001
11
RKSA2011
Installation
• To install, reverse the removal procedure.
CK35-1 30-47
REMOVAL AND INSTALLATION HEATING SYSTEM BLOWER FAN
RAISING CYLINDER
Removal
k Lower the working equipment until it is resting on the
ground.
3 - Loosen the screws (1) and remove the front bracket (2)
1
retaining the plate (3).
2
3
RKSA2020
3
RKSA2030
5 - Loosen the 4 screws (7) and remove the lower lock (8).
7
7
RKSA5050
30-48 CK35-1
REMOVAL AND INSTALLATION HEATING SYSTEM BLOWER FAN
10
9 RKSA2050
10
RKSA2060
Installation
• To install, reverse removal procedure.
[*1]
2 Bushing inner side: Lithium EP MS2 NLGI2
3 Pin retaining screws: 49 Nm
[*2]
k When the positions of hole and pin line up, idle the
engine.
Do not introduce your fingers into the holes to check
alignment.
CK35-1 30-49
REMOVAL AND INSTALLATION BUCKET CYLINDER
BUCKET CYLINDER
Removal
k Lower the working equipment and rest the equipment
support frame on the ground.
RKSA3770
1 - Remove the pin (1) and fully retract the piston rod (2).
[*1] [*2]
a Check and make a note of the positions of the
2
adjustments to a given clearance.
RKSA3800
2 - Disconnect the pipes (4) and (5) from the cylinder (3).
RKSA3780
3 - Remove the pin (6) and take away the cylinder (3).
[*1] [*3]
a Check and make a note of the positions of the
adjustments to a given clearance.
6
3
RKSA3790
30-50 CK35-1
REMOVAL AND INSTALLATION BUCKET CYLINDER
Installation
• To install, reverse removal procedure.
[*1]
[*2]
MAX 1mm
a Insert the removed shims and, if necessary, add
more until the residual clearance is about 1 mm.
RKS01780
[*3]
a Insert the removed shims and, if necessary, add
more until the residual clearance is about 1 mm.
1 - Start the engine and bleed the air from the cylinder. (For
details, see "20 TESTING AND ADJUSTMENTS").
CK35-1 30-51
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
1
RKS01660
2 A
RKSA1060
RKSA1070
2 3
RKSA1080
30-52 CK35-1
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
5 - Raise the cylinder and hook the piston rod to the mobile
group of the tool A.
RKSA1090
10 - Take all the groups to pieces and remove all the seals,
guard rings and guide rings.
5
E D
k The seals, guard rings, and guide rings cannot be
used again.
RKSA1100
CK35-1 30-53
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
Assembly
a Take great care not to damage the seal and the sliding
surfaces.
RKSA1120
7 9
RKS01800
30-54 CK35-1
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
2. Piston assembly
1 - Using the tool H, mount the piston seal. Mount in H
sequence the rubber ring (13), the outer seal (14) and
the anti-extrusion rings (15).
13 14 15
RKSA1130
13
RKSA1140
B
K
RKSA1150
RKSA1160
CK35-1 30-55
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
RKSA1170
7 - Mount the nut (5) that secures the piston and tighten it
with the socket wrench E and the dynamometric tool
with a multiplier D.
5
E D
RKSA1101
4. Cylinder assembly
1 - Mount the tools A onto the apparatus B.
B
2 - Position the bushing (20) and mount it onto the cylinder
(2). 2 A
a Leave the cylinder in position, ready for the next
assembly operation.
19
RKSA1061
RKSA1180
30-56 CK35-1
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
5 - Mount the piston rod group (4) onto the tool A and raise
the mobile part up to the end of its stroke.
6 - Put the cylinder (2) into a vertical position and guide the
piston into the tool M.
4
7 - Lower the apparatus supporting the piston rod (4) in
order to insert the piston into the cylinder liner (2).
A
8 - Remove the tool M from the cylinder and then lower the
apparatus A even further, until the head (3) and the
piston rod approach the cylinder.
M
9 - Place the cylinder (2) in position for screwing in the head
(3).
10 - Insert the head into the cylinder and screw it in by hand
for a few turns. 2
RKSA1091
3 Head: 490±49 Nm
D
C
12 - Mount the guard rings (1) on both sides of the cylinder 3
and the piston rod. 2
RKSA1071
CK35-1 30-57
REMOVAL AND INSTALLATION COMPLETE WORKING EQUIPMENT
RKSA2090
RKSA2100
RKSA5110
30-58 CK35-1
REMOVAL AND INSTALLATION COMPLETE WORKING EQUIPMENT
13
15
RKSA2290
16 17
RKSA2120
9 - Lift the arm until the tool holder frame fulcrum pin and
the arm fulcrum pin line up.
RKS05170
10 -Loosen the screw (18), remove the pin (19) and remove
the working equipment.
RKSA2300
CK35-1 30-59
REMOVAL AND INSTALLATION COMPLETE WORKING EQUIPMENT
Installation
• To install, reverse removal procedure. MAX 1mm MAX 1mm
[*1]
1 - Start the engine and bleed the air from the cylinder.
(For details, see "20 TESTING AND ADJUSTMENTS").
30-60 CK35-1
REMOVAL AND INSTALLATION FULCRUM LEVER
FULCRUM LEVER
Removal
k Completely lower the working equipment to the ground.
3
2
1
k Release any residual hydraulic pressure.
(For details see "20 TESTING AND ADJUSTMENTS").
RKSA2130
RKS02500
Installation
• To install, reverse removal procedure.
[*1]
[*2]
MAX 1mm MAX 1mm
a Introduce shims between lever and frame until the
residual clearance is less than 1 mm.
RKS02490
CK35-1 30-61
REMOVAL AND INSTALLATION LIFT LEVER
LIFT LEVER
Removal
k Completely lower the working equipment to the ground.
2- Introduce a pin into the centre hole on the lever (1), con-
nect a hoist and slightly tension the cables.
1
RKSA2140
[*1]
2
3
RKSA2150
4- Lift the lever (1) until the centre hole on the lever and the
fulcrum hole on the frame line up.
RKS05180
30-62 CK35-1
REMOVAL AND INSTALLATION LIFT LEVER
5- Loosen the screw (4), remove the pin (5) and remove
the lever (1). 1
a Check for any damaged seals (6) and replace if
necessary.
6
a Check and note down the position of shims.
[*1][*2]
5 4
RKSA2310
Installation
• To install, reverse removal procedure.
[*1]
[*2]
a Introduce shims between lever and frame until
residual clearance is less than 1 mm.
CK35-1 30-63
REMOVAL AND INSTALLATION WORKING EQUIPMENT SUPPORT FRAME
RKSA3771
2 - Remove the pins (1) and retract the cylinder piston rods
(2). 2
a Check and make a note of the positions of the
adjustments to a given clearance.
[*1] [*2]
RKSA0990
3 - Remove the pins (3) and take off the complete working
equipment support frame (4). [*3]
Installation 4
• To install, reverse removal procedure. RKSA3830
[*1]
a Insert the removed shims and if necessary add
more until the residual clearance is less than 3 mm.
[*2]
30-64 CK35-1
REMOVAL AND INSTALLATION TRACK
TRACK
Removal
k Disconnect the negative (–) battery terminal cable.
1 -Lift machine off the ground by 10 cm approx.
RKSA5060
RKSA3930
RKSA5090
RKSA5080
CK35-1 30-65
REMOVAL AND INSTALLATION TRACK
Installation
• To install, reverse removal procedure.
[*1]
30-66 CK35-1
REMOVAL AND INSTALLATION LOWER IDLER ROLLER
RKSA3970
Installation
• To install, reverse removal procedure.
[*1]
CK35-1 30-67
REMOVAL AND INSTALLATION IDLER WHEELS
IDLER WHEELS
Removal
k Disconnect the cable from the accumulator negative (–
) terminal.
RKSA3980
RKSA3990
Installation
• To install, reverse removal procedure.
[*1]
30-68 CK35-1
REMOVAL AND INSTALLATION DRIVE WHEEL
DRIVE WHEEL
Removal
1
k Disconnect the cable from the accumulator negative (– 2
) terminal.
RKSA4000
Installation
• To install, reverse removal procedure.
[*1]
CK35-1 30-69
REMOVAL AND INSTALLATION TRACK TENSIONER CYLINDER
RKSA4010
RKSA4020
RKSA4030
Installation
• To install, reverse removal procedure.
[*1]
a Ensure the track tensioner cylinder fits snugly in A
hole “A” on the frame.
RKS04680
30-70 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
FINAL DRIVE
Removal
2
1 -Remove track on removal side. (For details, see
"TRACK").
2- Fully raise the working equipment and tilt the cab. (For 1
details, see "CAB").
1
RKSA4040
4 -Remove all nuts (4) and move bulkhead (5) to one side.
4
RKSA4050
RKSA4060
RKSA4070
CK35-1 30-71
REMOVAL AND INSTALLATION FINAL DRIVE
10
11
RKSA4080
12
RKSA4090
9 -Remove all nuts (13) (6+6 pcs.) and screws (14) (4+4
pcs.). 13
[*1]
14
RKSA4100
RKSA4110
30-72 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
12
RKSA4090
RKSA4130
4 Final drive: 92 kg
17
16
RKSA4120
Installation
• To install, reverse removal procedure.
[*1]
3 Nuts: 185-225 Nm
3 Screws: 285-325 Nm
[*2]
3 Screws: 230-270 Nm
2 Screws: Loctite 242
CK35-1 30-73
REMOVAL AND INSTALLATION FINAL DRIVE
FINAL DRIVE
Disassembly
1 2
1 -Remove the plugs (1) and their seals (2) and completely
drain the oil.
RKSA4140
RKSA4150
RKSA4160
RKSA4170
30-74 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
RKSA4180
RKSA4190
RKSA4230
RKSA4200
CK35-1 30-75
REMOVAL AND INSTALLATION FINAL DRIVE
10
RKSA4210
12
RKSA4220
13
14
RKSA4240
12– Remove the first ring of packing (15) from drive motor
(14).
15
14
RKSA4250
30-76 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
15
RKSA4260
16
RKSA4270
17
13
RKSA4280
RKSA4290
CK35-1 30-77
REMOVAL AND INSTALLATION FINAL DRIVE
20
RKSA4300
21
RKSA4310
RKSA4320
25
24
RKSA4330
30-78 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
26
RKSA4340
27
28
RKSA4350
29
30
RKSA4360
33
31
32
RKSA4370
CK35-1 30-79
REMOVAL AND INSTALLATION FINAL DRIVE
34
RKSA4380
RKSA4390
35
35
RKSA4400
RKSA4410
30-80 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
38
RKSA4420
39
RKSA4430
RKSA4440
32 -Remove all springs (42) and (43) from brake piston (44).
42
44
43
RKSA4450
CK35-1 30-81
REMOVAL AND INSTALLATION FINAL DRIVE
44
RKSA4460
46
44
RKSA4470
RKSA4480
49
RKSA4490
30-82 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
RKSA4500
38 -Extract the cylinder block (51) from the flanged hub (41).
51
41
RKSA4510
53
RKSA4520
55
RKSA4530
CK35-1 30-83
REMOVAL AND INSTALLATION FINAL DRIVE
56
RKSA4540
57
41
RKSA4550
57
58
RKSA4560
59
RKSA4570
30-84 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
60
61
RKSA4580
61
RKSA4590
62
RKSA4600
CK35-1 30-85
REMOVAL AND INSTALLATION FINAL DRIVE
Assembly
1 -Install grommet (62) to flanged hub (41) so it is flush with 41
the hub.
RKSA4610
61
60
41
RKSA4620
60
RKSA4630
57
58
RKSA4560
30-86 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
57
41 RKSA4640
56
RKSA4540
51
53
RKSA4521
54
RKSA4650
CK35-1 30-87
REMOVAL AND INSTALLATION FINAL DRIVE
54
55
RKSA4660
54
51
RKSA4670
51
41
RKSA4680
12 -Install one friction disc (47) first, and then one steel disc
(50), and continue in this sequence until brake pack is
complete. The brake pack consists of 3 friction discs and
2 steel discs.
47 50
RKSA4690
30-88 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
48
RKSA4700
44
48
RKSA4710
48
44
RKSA4720
44
RKSA4730
CK35-1 30-89
REMOVAL AND INSTALLATION FINAL DRIVE
RKSA4740
43
44
42
RKSA4750
39
RKSA4760
38
RKSA4770
30-90 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
RKSA4410
35
35
RKSA4400
22
41
RKSA4780
3 Screws: 145 Nm
34
RKSA4790
CK35-1 30-91
REMOVAL AND INSTALLATION FINAL DRIVE
31
32
RKSA4800
22
25
24
RKSA4810
3 Plug 54±5 Nm
23
RKSA4820
RKSA4830
30-92 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
3 Plug 92±4 Nm
22
26
RKSA4840
21
RKSA4310
19
20
RKSA4850
3 Plug 157±8 Nm
33 -Repeat the procedure on the opposite side of spool.
18
RKSA4860
CK35-1 30-93
REMOVAL AND INSTALLATION FINAL DRIVE
13
RKSA4870
17
RKSA4880
RKSA4890
RKSA4900
30-94 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
15
13
RKSA4910
RKSA4920
13
RKSA4930
14
13
RKSA4940
CK35-1 30-95
REMOVAL AND INSTALLATION FINAL DRIVE
13
RKSA4950
12
RKSA4960
10
RKSA4970
10
RKSA4201
30-96 CK35-1
REMOVAL AND INSTALLATION FINAL DRIVE
RKSA4230
RKSA4190
RKSA4180
RKSA4170
CK35-1 30-97
REMOVAL AND INSTALLATION FINAL DRIVE
50 -Install cover (4) and lock in place using snap ring (3).
3
RKSA4151
51 -Install the plugs (1) and their seals (2) without tightening.
52 -Mount the final drive on frame and fill up with final drive
oil.
1 2
RKSA4980
30-98 CK35-1
40 STANDARD MAINTENANCE
P.T.O. ........................................................................................ 2
FRAME AND BUMPER SPRING .............................................. 3
TRACK TENSIONER IDLER WHEEL ....................................... 4
DRIVE WHEEL.......................................................................... 5
LOWER IDLER ROLLERS ........................................................ 6
REAR IDLER WHEEL ............................................................... 7
HYDRAULIC PUMP .................................................................. 8
CONTROL VALVE .................................................................. 10
R.H. PPC VALVE .................................................................... 23
L.H. PPC VALVE ..................................................................... 24
PATTERN CHANGE VALVE (OPTIONAL) ............................. 26
CYLINDERS ............................................................................ 27
WORKING EQUIPMENT......................................................... 28
CK35-1 40-1
STANDARD MAINTENANCE P.T.O.
P.T.O.
3 50 Nm
3 195 Nm
3 82 Nm
RKS02071
40-2 CK35-1
STANDARD MAINTENANCE FRAME AND BUMPER SPRING
2
RKS04911
Unit: mm
CK35-1 40-3
STANDARD MAINTENANCE TRACK TENSIONER IDLER WHEEL
1 2
3 574 Nm
with Loctite 242
8 4 3 RKS04161
Unit: mm
Criteria
No. Check item Remedy
Standard size Repair limit
1 Track guide outer diameter
Reconstru
2 Track rest outer diameter ct by
3 Track rest width welding or
replace
4 Track guide width
Tolerance Minimum Clearance
Standard
size Shaft Hole clearance limit
5 Clearance between shaft and bushings
–0 + 0.183 0.044–
25 1.5
– 0.013 + 0.144 0.196
– 0.073 + 0.030 0.018–
6 Interference between bushing and roller 32 –
– 0.048 +0 0.073 Replace
Standard size Clearancelimit
7 Roller float
0.20 0.74
Standard size Repair limit
8 Metal shim at roller rest
26.25 22.25
40-4 CK35-1
STANDARD MAINTENANCE DRIVE WHEEL
DRIVE WHEEL
4
3
2 1
3 230-270 Nm
RKS04210
Unit: mm
Criteria
No. Check item Remedy
Standard size Tolerance Repair limit
1 Wear at bottom of drive wheel tooth
2 Wear of tooth tip Repair by
welding or
3 Tooth tip width replace
4 Tooth base width
CK35-1 40-5
STANDARD MAINTENANCE LOWER IDLER ROLLERS
3 574 Nm
with Loctite 242
2 1
4 3
7 RKS04191
Unit: mm
Criteria
No. Check item Remedy
Standard size Repair limit
1 Track guide outer diameter
Reconstru
2 Track rest outer diameter ct by
3 Track rest width welding or
replace
4 Track guide width
Tolerance Minimum Clearance Remedy
Standard
size Shaft Hole clearance limit
5 Clearance between shaft and bushings
Replace
6 Interference between bushing and roller
40-6 CK35-1
STANDARD MAINTENANCE REAR IDLER WHEEL
3 574 Nm
with Loctite 242
2
RKS04201
Unit: mm
Criteria Remedy
No. Check item
Standard size Repair limit Reconstru
ct by
1 Outer diameter 350 –
welding or
2 Track guide width 44 20 replace
CK35-1 40-7
STANDARD MAINTENANCE HYDRAULIC PUMP
HYDRAULIC PUMP
3 147-186.2 Nm
3 19.6-27.4 Nm
3 58.8-73.5 Nm
3 49-58.8 Nm
Komatsu.Ltd.
3 19.6-27.4 Nm
3 19.6-27.4 Nm 3 147-186.2 Nm
3 58.8-73.5 Nm
RKS04920
40-8 CK35-1
STANDARD MAINTENANCE HYDRAULIC PUMP
AS VALVE
3 34.3-58.8 Nm 3 34.3-58.8 Nm
1 2 3
3 44.1-53.9 Nm Section
Sezione AA- -AA 3 58.8–78.4 Nm
RKS01450
Unit: mm
Criteria
Standard size Repair limit
No. Check item Remedy
Free Installed Installed Free Installed
length length load length load
CK35-1 40-9
STANDARD MAINTENANCE CONTROL VALVE
CONTROL VALVE
STANDARD VERSION
3 11.3±1.5 Nm
3 31.9±2.5 Nm
3 11.3±1.5 Nm
3 11.3±1.5 Nm
B
A C
D D
B
3 31.9±2.5 Nm
C
3 31.9±2.5 Nm
A
3 23.5±3.9 Nm
3 11.3±1.5 Nm
RKS04270
View Z
40-10 CK35-1
STANDARD MAINTENANCE CONTROL VALVE
2
2
3
3
3 8.3±1.5 Nm
3 23.5±4 Nm
1
3 23.5±4 Nm
8
9
5 Section B- B
8
3 53.0±5.9 Nm
9
6 7
3 139.7±22.1 Nm 3 22.5±2.9 Nm
Section A - A RKS04980
Unit: mm
Criteria
Standard size Repair limit
No. Check item Remedy
Free
Installed Installed Free Installed
installed
length load length load
x Øe
1 Spool return spring (lift arm) 28.8x17.1 26.8 38.2 N – 30.6 N
2 Spool return spring (bucket) 26.3x17.7 18.5 176.5 N – 141.2 N
3 Spool return spring (bucket) 21.6x14.8 10 38.7 N – 31.0 N
4 Spool return spring (ATT) 28x11.5 24.5 137.3 N – 109.8 N Replace
Spring of series - parallel circuit springs.
5 switching valve 38.3x15.2 24 161.8 N – 129.5 N If there are
damage
6 Spring of unload valve 32.9x18.2 18 74.0 N – 59.2 N or
7 Spring of unload valve 18.7x9.3 16 3.4 N – 2.7 N deformation
Spring of pressurecompensation
8 valve 15.4x6 13 2.5 N – 2.0 N
Spring of pressurecompensation
9 valve 20x8.4 12 6.9 N – 5.5 N
CK35-1 40-11
STANDARD MAINTENANCE CONTROL VALVE
3 53.0±5.9 Nm
3 AA
BB
3 53.0±5.9 Nm
4
Section AA-AA AA
BB
Section D - D
3 44.1±4.9 Nm
3 44.1±4.9 Nm
3 8.3±1.5 Nm
1
Section BB-BB
Section C - C RKS04970
Unit: mm
Criteria
Spring of combination
1 circulating valve 37.5x16.6 22.5 177.0 N – 142.0 N
Replace
springs.
2 Spring of leveling circulating valve 37.5x15.4 22.5 66.7 N – 53.4 N If there are
damage
3 Spring of flow divider 30.2x9.4 23 2.9 N – 2.4 N or
deformation
4 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N
40-12 CK35-1
STANDARD MAINTENANCE CONTROL VALVE
FLOAT VERSION
3 11.3±1.5 Nm
3 31.9±2.5 Nm
3 11.3±1.5 Nm
3 11.3±1.5 Nm
B
A C
D D
3 31.9±2.5 Nm
B C
A
3 31.9±2.5 Nm
3 23.5±3.9 Nm
3 11.3±1.5 Nm
View Z
RKS04240
CK35-1 40-13
STANDARD MAINTENANCE CONTROL VALVE
2
2
3 8.3±1.5 Nm 1 3
3 23.5±4 Nm
8
9
5 Section B- B
8
3 53.0±5.9 Nm
9
6 7
3 139.7±22.1 Nm Section A - A 3 22.5±2.9 Nm
RKS04990
Unit: mm
Criteria
Standard size Repair limit
No. Check item Remedy
Free
Installed Installed Free Installed
installed
length load length load
x Øe
1 Spool return spring (lift arm) 28.8x17.1 26.8 38.2 N – 30.6 N
2 Spool return spring (bucket) 26.3x17.7 18.5 176.5 N – 141.2 N
3 Spool return spring (bucket) 21.6x14.8 10 38.7 N – 31.0 N
4 Spool return spring (ATT) 28x11.5 24.5 137.3 N – 109.8 N Replace
Spring of series - parallel circuit springs.
5 switching valve 38.3x15.2 24 161.8 N – 129.5 N If there are
damage
6 Spring of unload valve 32.9x18.2 18 74.0 N – 59.2 N or
7 Spring of unload valve 18.7x9.3 16 3.4 N – 2.7 N deformation
Spring of pressurecompensation
8 valve 15.4x6 13 2.5 N – 2.0 N
Spring of pressurecompensation
9 valve 20x8.4 12 6.9 N – 5.5 N
40-14 CK35-1
STANDARD MAINTENANCE CONTROL VALVE
3 53.0±5.9 Nm
3 AA
BB
3 53.0±5.9 Nm
4
Section AA-AA AA
BB
Section D - D
3 44.1±4.9 Nm
3 44.1±4.9 Nm
3 8.3±1.5 Nm
1
Section BB-BB
Section C - C RKS04970
Unit: mm
Criteria
Standard size Repair limit
No. Check item Remedy
Free
Installed Installed Free Installed
installed x
length load length load
Øe
Spring of combination
1 circulating valve 37.5x16.6 22.5 177.0 N – 142.0 N Replace
springs.
2 Spring of leveling circulating valve 37.5x15.4 22.5 66.7 N – 53.4 N If there are
damage
3 Spring of flow divider 30.2x9.4 23 2.9 N – 2.4 N or
4 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N deformation
CK35-1 40-15
STANDARD MAINTENANCE CONTROL VALVE
HIGH-FLOW VERSION
3 11.3±1.5 Nm 3 11.3±1.5 Nm
3 31.9±2.5 Nm
B 3 11.3±1.5 Nm
A C
D D
3 31.9±2.5 Nm
B C
A
3 31.9±2.5 Nm
3 23.5±3.9 Nm
3 11.3±1.5 Nm
RKS04280
View Z
40-16 CK35-1
STANDARD MAINTENANCE CONTROL VALVE
2
2
3 8.3±1.5 Nm 1 3
3 23.5±4 Nm 8
9
Section B- B
5
8
3 53.0±5.9 Nm
9
3 139.7±22.1 Nm
6 7
3 22.5±2.9 Nm
RKS04960
Section A - A
Unit: mm
Criteria
Standard size Repair limit
No. Check item Remedy
Free
Installed Installed Free Installed
installed
length load length load
x Øe
1 Spool return spring (lift arm) 28.8x17.1 26.8 38.2 N – 30.6 N
2 Spool return spring (bucket) 26.3x17.7 18.5 176.5 N – 141.2 N
3 Spool return spring (bucket) 21.6x14.8 10 38.7 N – 31.0 N
4 Spool return spring (ATT) 28x11.5 24.5 137.3 N – 109.8 N Replace
Spring of series - parallel circuit springs.
5 switching valve 38.3x15.2 24 161.8 N – 129.5 N If there are
damage
6 Spring of unload valve 32.9x18.2 18 74.0 N – 59.2 N or
7 Spring of unload valve 18.7x9.3 16 3.4 N – 2.7 N deformation
Spring of pressurecompensation
8 valve 15.4x6 13 2.5 N – 2.0 N
Spring of pressurecompensation
9 valve 20x8.4 12 6.9 N – 5.5 N
CK35-1 40-17
STANDARD MAINTENANCE CONTROL VALVE
3
3 53.0±5.9 Nm AA
BB
3 53.0±5.9 Nm
4
Section AA-AA
AA
BB
3 44.1±4.9 Nm
Section D - D
3 44.1±4.9 Nm
1 3 8.3±1.5 Nm
Section BB-BB
RKS04950
Section C - C
Unit: mm
Criteria
Standard size Repair limit
No. Check item Remedy
Free
Installed Installed Free Installed
installed x
length load length load
Øe
Spring of combination
1 circulating valve 37.5x16.6 22.5 177.0 N – 142.0 N Replace
springs.
2 Spring of leveling circulating valve 37.5x15.4 22.5 66.7 N – 53.4 N If there are
damage
3 Spring of flow divider 30.2x9.4 23 2.9 N – 2.4 N or
4 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N deformation
40-18 CK35-1
STANDARD MAINTENANCE CONTROL VALVE
3 11.3±1.5 Nm
3 31.9±2.5 Nm 3 11.3±1.5 Nm
B 3 11.3±1.5 Nm
C A
F F
E E
D D
3 31.9±2.5 Nm
B A
C
3 31.9±2.5 Nm
3 23.5±3.9 Nm
3 11.3±1.5 Nm
RKS04310
View Z
CK35-1 40-19
STANDARD MAINTENANCE CONTROL VALVE
3 44.1±4.9 Nm
3 90.7±2.3 Nm
3 44.1±4.9 Nm
3 44.1±4.9 Nm
4
3
Section A - A
2 2
3 8.3±1.5 Nm
1 6
7
Section B - B RKS04940
Unit: mm
Criteria
Standard size Repair limit
No. Check item Remedy
Free
Installed Installed Free Installed
installed x
length load length load
Øe
1 Spool return spring (lift arm) 28.8x17.1 26.8 38.2 N – 30.6 N
2 Spool return spring (bucket) 26.3x17.7 18.5 176.5 N – 141.1N
3 Spool return spring (bucket) 21.6x14.8 10 38.7 N – 31.0 N Replace
springs.
4 Spool return spring (ATT) 28x11.5 24.5 137.3 N – 109.8 N If there are
damage
5 Spool return spring (High-Flow) 29x17.6 25.5 131.4 N – 105.1 N or
6 Spool return spring (float) 14.7x4.4 9.5 4.9 N – 3.9 N deformation
Spring of series - parallel circuit
7 switching valve 38.3x15.2 24 161.8 N – 129.5 N
40-20 CK35-1
STANDARD MAINTENANCE CONTROL VALVE
3 53.0±5.9 Nm
7
AA
BB
3 53.0±5.9 Nm
8
Section AA-AA
AA
BB
4
Section D - D
3
4
4 5 3 8.3±1.5 Nm
3
4
6
3 53.0±5.9 Nm
Section BB-BB
3 139.7±22.1 Nm
1 2 3 22.1±2.5 Nm
RKS04930
Section C - C
Unit: mm
Criteria
Standard size Repair limit
No. Check item Remedy
Free
Installed Installed Free Installed
installed x
length load length load
Øe
1 Spring of unload valve 23.9x18.2 18 74.0 N – 59.2 N
2 Spring of unload valve 18.7x9.3 16 3.4 N – 2.7 N
Spring of pressure compensation
3 valve 15.4x6 13 2.5 N – 2.0 N
Replace
Spring of pressure compensation springs.
4 valve 20x8.4 12 6.9 N – 5.5 N If there are
damage
Spring of combination or
5 circulating valve 37.5x16.6 22.5 177.5 N – 142.0 N
deformation
6 Spring of leveling circulating valve 37.5x15.4 22.5 66.7 N – 53.4 N
7 Spring of flow divider 30.2x9.4 23 2.9 N – 2.4 N
8 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N
CK35-1 40-21
STANDARD MAINTENANCE CONTROL VALVE
3 22.1±2.5 Nm
3 11.3±1.5 Nm
2
3 31.9±2.5 Nm
3 77.9±12.3 Nm 3 34.3±4.9 Nm
1
Section H - H 3 11.3±1.5 Nm
Section J - J
RKS04480
Unit: mm
Criteria
Standard size Repair limit
No. Check item Remedy
Free
Installed Installed Free Installed
installed x
length load length load
Øe
1 Spring of check valve 13x6.5 9.5 2.0 N – 1.6 N Replace
springs.
If there are
Spool return spring damage
2 (High-Flow joining circuit) 25.7x11.1 22 66.7 N – 53.4 N
or
deformation
40-22 CK35-1
STANDARD MAINTENANCE R.H. PPC VALVE
3 112.8±14.7 Nm
3 13.2±1.5 Nm
2
3 44.1±4.9 Nm
4
5
P2 P1
Section A - A Section B - B
3 39.2±4.9 Nm
1
Section D - D
P3 P4
Section C - C
Section E - E RKS00854
Unit: mm
Criteria Remedy
Standard size Repair limit
No. Check item
Free
Installed Installed Free Installed
installed x
length load length load
Øe Replace
springs.
1 Centering spring (for P3 and P4) 44.6x15.5 34 22.1 N – 17.7 N If there are
damage
2 Centering spring (for P1 and P2) 38.56x15.5 34 30.4 N – 24.3 N or
3 Metering spring (for P3 and P4) 32.65x8.15 25.6 40.8 N – 32.6 N deformation
CK35-1 40-23
STANDARD MAINTENANCE L.H. PPC VALVE
2 4
3 13.7±1 Nm
3
P2 P1
Section A - A Section B - B
1
Section D - D
P3 P4
Section C - C G G
Section F - F
Unit: mm
Criteria Remedy
Standard size Repair limit
No. Check item
Free
Installed Installed Free Installed
installed x
length load length load Replace
Øe
springs.
1 Centering spring (for P3 and P4) 35.5x15.5 34 9.8 N – 7.8 N If there are
damage
2 Centering spring (for P1 and P2) 38.56x15.5 34 30.4 N – 24.3 N or
deformation
Metering spring
3 (for P2, P3 and P4) 26.2x8.15 25.3 5.27 N – 4.2 N
40-24 CK35-1
STANDARD MAINTENANCE L.H. PPC VALVE
3 112.8±14.7 Nm
3 13.2±1.5 Nm
1
3 44.1±4.9 Nm
Section A - A Section B - B
3 39.2±4.9 Nm
2
Section D - D
Section C - C
Section E - E RKS00851
Unit: mm
Criteria Remedy
Standard size Repair limit
No. Check item
Free
Installed Installed Free Installed
installed x
length load length load Replace
Øe
springs.
1 Centering spring (for P3 and P4) 35.5x15.5 34 9.8 N – 7.8 N If there are
damage
2 Centering spring (for P1 and P2) 38.56x15.5 34 30.4 N – 24.3 N or
deformation
Metering spring
3 (for P2, P3 and P4) 26.2x8.15 25.3 5.27 N – 4.2 N
CK35-1 40-25
STANDARD MAINTENANCE PATTERN CHANGE VALVE (OPTIONAL)
3 27.5-34.3 Nm
3 11.8-14.7 Nm
Section A - A Section B - B
4
6 3
1 5
2
3 27.5-34.3 Nm RKS00940
40-26 CK35-1
STANDARD MAINTENANCE CYLINDERS
CYLINDERS
1 2
490±49 Nm 1127±112Nm
3
RKS01990
Unit: mm
Criteria
Lifting bucket 40
-- 0.025 +0 0.025–
0.426
Tolerance between -- 0.087 + 0.039 0.126 Replace
3 piston rod and
cylinder head -- 0.025 +0 0.025– head
Tilt bucket 35 0.426
-- 0.087 + 0.039 0.126
CK35-1 40-27
STANDARD MAINTENANCE WORKING EQUIPMENT
WORKING EQUIPMENT
D
F F
E
A G
A
B
E G
B
H
C
H
Sezione A - A
Sezione B - B
2
3
Sezione D - D
RKS05190
Sezione C - C
40-28 CK35-1
STANDARD MAINTENANCE WORKING EQUIPMENT
4 8
Sezione F- F
Sezione E- E
5 9
Sezione G- G
Sezione H- H
RKS01980
Unit: mm
Criteria
N° Check item Standard Tolerance Minimum Clearance Remedy
size Shaft Hole clearance limit
Clearance between bushing and – 0.012 + 0.012 0.024–
1 45 1.0
mounting pin of lift lever – 0.065 +0.056 0.121
Clearance between bushing and
– 0.01 + 0.072 0.082–
2 mounting pin of work equipment 35 1.0
– 0.05 +0.134 0.184
support frame
Clearance between bushing and – 0.012 + 0.012 0.024–
3 45 1.0
mounting pin of fulcrum lever – 0.065 +0.056 0.121
Clearance between bushing and – 0.012 + 0.012 0.024–
4 45 1.0
mounting pin of lift lever – 0.065 +0.056 0.121
Clearance between bushing and – 0.012 + 0.012 0.024– Replace
5 45 1.0 bushing
mounting pin of fulcrum lever – 0.065 +0.056 0.121
CK35-1 40-29
PAGE INTENTIONALLY
LEFT BLANK
90 OTHER
CK35-1 90-1
OTHER ELECTRICAL DIAGRAM (STANDARD)
C
S13
ON
S14
CN
C
ON
X13
X14, X18
CN
1 2 K06
H-R1
+ - BRAKE P.B. IN
X50 L/B1
3
RIGHT LEVER
S13 S14 S15
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
23
X50 A/B1 HA1 R-N2.5 G1.5
LEFT LEVER
HI-SPEED P. B. IN
R2.5
22
FLOAT P. B. IN
X50 L/G1
X08
R-N0.5
R-N0.5
21
H-R2.5
R-N2.5
V/B0.5
L/G0.5
L/G0.5
X07 SAF. BAR. SW IN
X50 C/N1
M2.5
20
1 1 1 1 1 1 1 1 1 1 1
K04 85 87
X50
B1
SEAT SWITCH IN
C-B1 X52 X53 X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76
1 2 3 1 2 19
X50 1 1
POW. SUPP. +12V
H-R1 FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01 86 30
Z-B1
18 R1 ACC BR R2 C X83 X83 X83 X83 X84 X84 X84
4 5 6 EV BRAKE OUT
X50 H-L1 OFF ACC 30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A
3 4
X89
X89
X89
X89
17 R/N1 R1
ST 1 2 3 11 1 3 11
X78
X79
STOP ENGINE OUT
X50 R-N1.5
B-R1
B/R1
A/B1
N1
B-R1
L/G1
N1
16
ELECTRONIC UNIT
X50 85 86 30 87
BRAKE LIGHT OUT
S/N1 S10 B X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77 1 1
15
X50 B/N1 S12 1 1 1 1 1 1 1 1 1 1 1
M-N1
B-N1
B-R1
B-R1
H/R1
N1
SAF. BAR.LED OUT
14
SEAT LED OUT
X50 G/N1 S11
R4
WIRE POSITIONING
H-R1.5
A-R1.5
13
G/N1
R2.5
X50
G1
M/B1
R-N2.5
L-R1.5
R-G1
H-R1
G/R1
H/R1
B-R1
WARNING LED OUT
ON CONNECTOR X50
12
FLOAT OUT
B-N1 X54 X54 X54 G/R1 X85 9
( WIRE SIDE WIEW WIRING ) X50
11
Z-B1 C A B X55 X55
A-R1.5 X85 1
BUZZER OUT (-) 2 1
= Parts not included in the wiring X50
10
M-B1
C/N1
N1
H-R1
C-B1
H-R1
HI-SPEED OUT 1 9
9 1 0
GND
X50 N1.5
KUE 37C-06-11312 8
HORN OUT
X50 C1
5 10
X50
7
B1 S01
START SIGN. IN
6
0A005893 +12V HORN
X50 H-R1.5 A-G1.5 X85 5
5
HORN PUSH B. IN
X50 B/R1
4 N1 X85 10
PPC SAF. SW. IN
X50 L-G1
3
EV PPC OUT
X50 V-N1
V1 K02 X50
2
R/N1 G/R1 X86
POWER
8
86 87 R-N2.5 X01 X01.1 R-N2.5
M1 X48 X48.1 M1 H-N1 X86
RELAY M2.5 4 4
X01.1 M2.5
1
R-B1
X01 1
H0.5
M-V1 1 M-V1
X48 X48.1
X07 G1
X07 R1
X07 N1
85 30 3 1 6 8 9
K03 R4 X01 3
X01.1 R4 2 0 1 2
R-V1 2
2 X48 X48.1
X07
X01 2
X01.1 R4 3 3
X03 X03 X03 X03 X06 X06 XS1 XS1 X08 X08 X08 X08 1 L-G1 X48 X48.1 L-G1
86 85 30 87 l - 4 3 2 1 A B 1 3 5 6 GND5 1
4 4 S02 3 2 10
N4 N4 H-R1.5 X86 3
XS R4 R-N2.5 R-N2.5 H-R1 X86
X46 X46.1 K14 2
X02.1GND5
B2.5
R-G1
B1
N1
S-N1
L/B1
R-N2.5
B2
R-N1.5
R-N1.5
N1
M-V1
L/B1
R-N1.5
N1
M2.5 4 M2.5 N1
l X46 X46.1 X86 10
L-R1 l
X02.1 L-R1.5
R10
A-G1.5
1 1
B-G1 X44 85
G-N1
H-G1
H-N1
H-N1
13
N1.5
13
X10 X10.1 15/1 30/3 L/6
G1
C1
12 R-N1.5 X45 X45.1 R-N1.5 0 1
R2.5 X10 12
X10.1 R2.5 13 GND3
11 V-N1 X45 13 X45.1 V-N1
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
R-V1 X10 11
X10.1 R-V1 12
10 M-B1 X45 12 X45.1 M-B1 S08 49/4 30b/2 R/7
B1X10 10 X10.1 B1 11
1 2 3 4 5 6 7 8 9 10 11 L/B1 X87 2
L-R1.5 X45 11 X45.1 L-R1.5
B-N1
C-N1
B1
N1
H-R1
G/N1
Z-B1
S-G1
M1
C-L1
S1
B-G1
B/N1
M-N1
M-V1
M-B1
H0.5
M/B1
G/N1
9
S1X10 9 X10.1 S1 10 1 2 3 4 5 6 7 8 9 10 11
H-R1 X87 7
8 B1 X45 10 X45.1 B1
C-N1 X10 8
X10.1 C-N1 G/R1 X88
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
9 9
M-N1 9 M-N1
7 X45 X45.1
C-L1 X10 7
X10.1 C-L1 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 H/R1 X88 1
R-G1 8 R-G1
6 X45 X45.1
S-G1 6
X10.1 S-G1
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
X10 7 7 1 9
5 S1 X45 X45.1 S1 P1 1 0
R10
H-G1
H-N1
H-N1
A-G1
N1.5
X10 X10.1
C1
6 6
4 C-N1 X45 X45.1 C-N1
B-N1 X10 4
X10.1 B-N1
GND 3 C-L1 X45 5 5
X45.1 C-L1 S07 5 10
R-G1 X10 3
X10.1 R-G1 H-G1 X88
B-G1 X10 2 2
X10.1 B-G1
S-G1 X45 4 4
3
X45.1 S-G1 CONTROL PANEL (UNIDECK) N1 X88
5
10
1 3
1 B-N1 X45 X45.1 B-N1
1
XF 2 2
1
B-G1 X45 X45.1 B-G1
FG1 1 1
50A X28
HA3
N4 X47 X47.1 N4 = Parts not included in the wiring
S31 N4 X47 1 1
X47.1 N4
XF p 2 2 H-G1 KUE 37A-06-11343
2
N1.5
X29
X29
C1
2 1
0A007930
A-G1
R10 INTERNAL CONNECTION CONTROL PANEL
P1 CONTROL PANEL (UNIDECK) H-N1
X80-15
X80-16
X80-12
X80-14
X80-11
N1
Z-N1
R10
H-N1
R50 X80-8
R-G1
+
S-N1
B2.5
S1
R-N1.5
R-G1
C-N1
S-G1
B-N1
M2.5
C-L1
L1 L2 L3 L4 L5 C2 C3
N2
N1
N1
N1
N1
B2
G1 GND4
M-N1
M-B1
M-V1
L-G1
V-N1
L1 L2 L3 L4 L5
R2.5
Z-N1
L-R1
L-R1
L-R1
M1
1 2 1 3
N1
N1
N1
N1
LEVEL INDICATOR
X09
X11
X11
X11
12Vcc
N2.5
3 1 2 - + 1 2 1 C A - + 1
X13
1 1 X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 1 2 1 2 1 2 1 2 1 1 1 2 1 2 1 2 1 2 1 H F
XB XM C2
M1 G2 R1 R2 R3 X20 X20 X21 X21 X22 X22 X23 X23 X32 X32A X33 X33 X34 X34 X35 X35 X36 X36 X37
N2.5
B2.5
50
D+ M2 C1
30 30
G W
S25 S26 S27 S28 S29 S30 S32 S33 00000 00 h 1 2 1 2 A B A B 2 1
N50
M Y0
3 M p p p p p p p p
XP1A
X108
X108
X109
X109
X110
X110
X111
X111
XP1
U C E
t GND2 C1
31 HOUR COUNTER C3
Y1 Y2 Y6 Y3
H-G1
H-N1
H-N1
A-G1
A-G1
N1
N1
N1
N1
N1
L6 L7 L8 L9 L10 DL1 DL2 DL3
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
- KUE 37A-06-11471
HA2
POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR
= Parts not included in the wiring 0A005935 C3 X80-3 WATER TEMPERAT. INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1
GND X80-6 GROUND GND N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1
NOME DESCRIZIONE COSTRUTTORE TIPO QTA
X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1 H1 GIROFARO /BEACON LIGHT CIAM (KUE) 110450 (885111118) 1
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 H4 FARO DI LAVORO ANT. SX / LEFT FRONT WORK LAMP COBO (KUE) 05-531-000 (885111132) 1
H6 FARO DI LAVORO ANT. DX / RIGHT FRONT WORK LAMP COBO (KUE) 05-531-000 (885111132) 1
H10 FARO DI LAVORO POSTERIORE SX / LEFT REAR WORK LAMP COBO (KUE) 05-531-000 (885111132) 1
H11 FARO DI LAVORO POSTERIORE DX / RIGHT REAR WORK LAMP COBO (KUE) 05-531-000 (885111132) 1
POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR HA2 AVVISATORE ACUSTICO /HORN CIAM (KUE) 112001 (885100005) 1
X82.1 CONNETTORE MARK 11 VIE DA LINEA CABINA / FROM CABIN LINE 11 WAY CONN. AMP * 1
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1 X108 CONNETTORE 2 VIE LUCE ANTERIORE SX / LEFT FRONT LIGHT 2 WAY CONN. PACKARD * 1
NOME/NAME DESCRIZIONE/DESCRIPTION COSTRUT./SUPPL. TIPO/TYPE QTA L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5 X109 CONNETTORE 2 VIE LUCE ANTERIORE DX / RIGHT FRONT LIGHT 2 WAY CONN. PACKARD * 1
X110 CONN. 2 VIE FARO LAVORO POST. SX / LEFT REAR WORK LIGHTS 2 WAY CONN. DEUTSCH * 1
FG1 FUSIBILE GENERALE 80A /GENERAL FUSE 50A CIAM 163028 1 L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1 X111 CONN. 2 VIE FARO LAVORO POST. DX / RIGHT REAR WORK LIGHTS 2 WAY CONN. DEUTSCH * 1
G1 BATTERIA /BATTERY 100Ah FIAMM (KUE) L5 600 103 085 (37C-06-11110) 1
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1 XP1, XP1A CONN. 1 VIA PRESA 12V, GIROFARO / 12V SOCKET, BEACON LIGHT 1 WAY CONN. AMP * 1
G2 ALTERNATORE /GENERATOR YANMAR (DENSO) 129423-77200 1
X113 CONNETTORE 1 VIA CLAXON / HORN 1 WAY CONN. AMP * 1
K01 RELE' SOLENOIDE CARBURANTE /FUEL SOLENID VALVE RELAY MATSUSHITA (KUE) CB1aH (885071022) 1
GND4 OCCHIELLLO C6 MASSA / C6 GROUND TERMIMAL AMP * 1
K02 TIMER 1 SECONDO PULL SOLENOIDE / FUEL PULL SOLENID VALVE TIMER 1 SECOND 1
GND6 OCCHIELLLO C8 MASSA CLAXON/ C8 HORN GROUND TERMIMAL AMP * 1
K03 SAFETY RELAY YANMAR (KUE) 119802-77200 1
M1 MOTORINO AVVIAMENTO / STARTER MOTOR YANMAR 123900-77010 1
M2 POMPA GASOLIO / FUEL PUMP YANMAR 129612-52100 1
R1 RESISTENZA PRERISCALDO /PREHEATING STARTER YANMAR 129100-77500 1
R2 SENSORE LIVELLO CARBURANTE /FUEL LEVEL SENDER COBO (KUE) 29-0419-0000 (37A-04-11140) 1
NOME/ NAME DESCRIZIONE/ DESCRIPTION COSTRUT./ SUPP. TIPO/ TYPE QTA
R3 TRASDUTTORE DI TEMP. ACQUA MOTORE /ENGINE WATER TEMPERATURE SENDER YANMAR (KUE) (7861-92-3320) 1
FU01 FUSE 3A (LEFT SIDE LIGHTS) 1 NOME/ NAME DESCRIZIONE/ DESCRIPTION COSTRUTT./ SUPP. TIPO/ TYPE QTA
S25 SENSORE INTASAMENTO FILTRO ARIA /AIR FILTER BLOCKED SWITCH DONALDSON (KUE) X770317 (37A-06-11960) 1
S26 PRESSOSTATO INTASAMENTO OLIO IDRAULICO /HYDRAULIC OIL FILTER BLOCKED SWITCH FMDI (KUE) 11716/1 (885261034) 1 FU02 FUSE 3A CONTROL PANEL LIGHTS 1 X54 CONNETTORE 3 VIE SENSORE BARRA / PROXIMITY BAR 3 WAY CONN. DEUTSCH * 1
S27 PRESSOSTATO LUCI STOP /STOP LIGHTS PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1 FU03 FUSE 15A HORN, FRONT WORK LIGHTS 1 X55 CONNETTORE 2 VIE SENSORE SICUREZZA SEDILE /SAFETY SEAT SWITCH 3 WAY CONN. DEUTSCH * 1
S28 PRESSOSTATO STOP /STOP LIGHTS PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1 FU04 FUSE 7.5A SWITCH LIGHTS 1 X56 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
S29 PRESSOSTATO BACK-UP /BACK-UP ALARM PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1 FU05 FUSE 15A REAR WORK LIGHT 1 X57 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
S30 PRESSOSTATO BACK-UP /BACK-UP ALARM PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1 FU06 FUSE 10A LEVER SWITCH POWER SUPPLY, FLOAT X58 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 WIRING COLOURS
S31 PRESSOSTATO MINIMA PRESSIONE OLIO MOTORE /ENGINE OIL MIN. PRESSURE SWITCH YANMAR * 1 FU07 FUSE 10A CURRENT INTAKE 12V, BEACON LIGHT 1 X59 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
V1 DIODO 1A / DIODE 1A CIAM 1A 1N4007 1 FU08 FUSE 10A CONTROL PANEL, ELECTRONIC UNIT, FUEL SHUT OFF, SAFETY BAR PROXIMITY, SEAT SAFETY SWITCH, BRAKE SWITCH 1 X60 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 A LIGHTBLUE
Y0 ELETTROVALVOLA STOP SOLENOIDE CARBURANTE /STOP FUEL SOLENOID VALVE YANMAR 129005-77950 1 FU09 FUSE 7.5A BACK-UP ALARM 1 X61 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 B WHITE
X01 CONNETTORE 3 VIE LINEA TELAIO /FRAME LINE 3 WAY CONNECTOR * * 1 FU10 FUSE 7.5A FUEL PUMP, SAFETY ENGINE RELAY, GENERATOR 1 X62 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 C ORANGE
X02 CONNETTORE 2 VIE / 2 WAY CONN. * * 1 FU11 FUSE 30A PULL SOLENOID, PPC SAFETY PRESSURE SWITCH 1 X63 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 G YELLOW
X03 CONNETTORE RELE SOLENOIDE CARBURANTE / FUEL SOLENOID RELAY CONN. * * 1 1 X64 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 H GREY
1 1 X65 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 L BLUE
1 1 X66 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 M BROWN
X06 CONNETTORE 2 VIE DIODO ANTIDISTURBO / DIODE 2 WAY CONN. * * 1 HA1 BUZZER SEGNALAZIONE ANOMALIE / WARNING BUZZER 1 X67 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 N BLACK
X07 CONNETTORE 4 VIE TIMER PULL SOLENOIDE/PULL SOLENOID TIMER 4 WAY CONN. * * 1 1 X68 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 R RED
X08 CONNETTORE 6 VIE SAFETY RELAY /SAFETY RELAY 6 WAY CONN. SUMITOMO 6195-0021 1 X69 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 S PINK
X09 OCCHIELLO C6 ALTERNATORE / C6 GENERATOR TERMINAL * * 11 K04 RELE' FLOAT / FLOAT RELAY CIAM 157061 (KUE 885071043) 1 X70 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 V GREEN
X10 CONNETTORE MARK 13 VIE LINEA TELAIO /FRAME LINE MARK 13 WAY CONN. * * 1 X71 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 Z VIOLET
X11 CONNETTORE 3 VIE ALTERNATORE /GENERATOR 3 WAY CONN. SUMITOMO 6189-0442 1 K06 CENTRALINA ELETTRONICA / ELECTRONIC UNIT CIAM 01171077 (KUE 885070046) 1 X72 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
1 K14 RELE' FRENO / BRAKE RELAY CIAM * 1 X73 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 EXAMPLE:
X13 CONNETTORE 3 VIE POOL-STOP SOLENOIDE CARBURANTE /FUEL POOL-STOP SOLENOID 3 WAY CONN. DEUTSCH DT06-3S 1 NOME/NAME DESCRIZIONE/DESCRIPTION COSTRUT. / SUPPL. TIPO/ TYPE QTA P1 PANNELLO STRUMENTI /CONTROL PANEL UNIDECK 04610027 (KUE 37A-54-14291) 1 X74 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 G/V ->YELLOW/GREEN (TRANSVERSE MARKED)
X14 CONNETTORE 2 VIE POMPA GASOLIO / FUEL PUMP 2 WAY CONN. * * 1 S32 PRESSOSTATO PPC SAFETY / PPC SAFETY PRESSURE SWITCH FMDI (KUE) 11717.75 (37A-06-11670) 1 X75 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
X15 OCCHIELLO C6 RESISTENZA PRERISCALDO / PREHEATING START C6 TERMINAL * * 1 S33 PRESSOSTATO FRENO STAZIONAMENTO /BRAKE VALVE PRESSURE SWITCH FMDI (KUE) * 1 X76 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 YELLOW GREEN
X16 CONNETTORE 2 VIE SENSORE INTASAMENTO FITRO ARIA / AIR FILTER BLOCKED SWITCH 2 WAY CONN. AMP MINITIMER 1 Y1 ELETTROVALVOLA SERVOCOMANDI /PPC VALVE HYDRAFORCE * 1 S01 INTERRUTTORE SWF 1 POS. STABILE FARI LAVORO POST /REAR WORK LIGHTS SWITCH CIAM 106AA008 (KUE 885081160) 1 X77 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
Y2 ELETTROVALVOLA FLOAT /FLOAT VALVE HYDRAFORCE * 1 S02 INTERRUTTORE SWF 2 POSIZIONI STABILI LUCI STRUMENTO E ANAB. /PANEL LIGHTS AND LOW BEAM LIGHTSCIAM
SWITCH 106AA018 (KUE 885081159 ) 1 X78 CONNETTORE 1 VIA PRESA DI CORRENTE /CURRENT INTAKE 1 WAY CONN. AMP * 1
X17 CONNETTORE 3 VIE SENSORE LIVELLO CARBURANTE /FUEL LEVEL SENDER 3 WAY CONN. * * 1 Y3 ELETTROVALVOLA SECONDA VELOCITA' /SECOND SPEED VALVE HYDRAFORCE * 1 S07 INTERRUTTORE SWF LAMPADA ROTANTE /BEACON LIGHT SWITCH CIAM 106AA008 (KUE 885081160) 1 X79 CONNETTORE 1 VIA PRESA DI CORRENTE /CURRENT INTAKE 1 WAY CONN. AMP * 1 G-V ->YELLOW-GREEN(LONGITUDINAL COLOURS)
X18 CONNETTORE 2 VIE TRASDUTTORE TEMP. ACQUA /ENGINE WATER TEMPERATURE SENDER 2 WAY CONN. * * 1 Y6 ELETTROVALVOLA FRENO /BRAKE VALVE HYDRAFORCE * 1 S08 PULSANTE FRENO / BRAKE SWITCH CIAM 0A003455 (KUE 37A-06-11410) 1 X80 CONNETTORE 16 VIE PANNELLO DI CONTROLLO / CONTROL PANEL 16 WAY CONN. AMP * 1
X19 OCCH. C5 SENSORE INTASA. FILTRO OLIO IDRAULICO / IDRAULIC OIL FILTER BLOCKED SWITCH C5 TERMINAL* * 1 X01.1 CONNETTORE 4 VIE LINEA MOTORE / ENGINE LINE 4 WAY CONN. DEUTSCH DTP04-4P 1 S10 QUADRO AVVIAMENTO /STARTING SWITCH 1 X81 CONNETTORE 8 VIE PANNELLO DI CONTROLLO /CONTROL PANEL 8 WAY CONN. AMP * 1 YELLOW GREEN
X20 CONNETTORE 2 VIE PRESSOSTATO 1 LUCI STOP / STOP LIGHT PRESSURE 1 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 X02.1 CONNETTORE 2 VIE LINEA MOTORE /ENGINE LINE 2 WAY CONN. * * 1 S11 FINECORSA SICUREZZA SEDILE /SAFETY SEAT SWITCH 1 X82 CONNETTORE MARK 11 VIE LINEA FARI /LIGHTS LINE 11 WAY CONN. AMP * 1
X21 CONNETTORE 2 VIE PRESSOSTATO 2 LUCI STOP / STOP LIGHT PRESSURE 2 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 X10.1 CONNETTORE MARK 13 VIE LINEA MOTORE /ENGINE LINE 13 WAY CONN. * * 1 S12 PROXIMITY DI SICUREZZA PNP BRACCIOLO /BAR PNP SAFETY SENSOR SAIET E-A1TMU/3AP (KUE 37A-06-11250) 1 X83 CONNETTORE MARK 12 VIE MANIPOLATORE SX / LEFT LEVER 12 WAY CONN. DEUTSCH DT04-12P,DT06-12-S 1
X22 CONNETTORE 2 VIE PRESSOSTATO 1 BACK-UP / BACK-UP PRESSURE 1 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 X32 CONNETTORE 1 VIA PRESSOSTATO PPC SAFETY / PPC SAFETY PRESSURE SWITCH 1 WAY CONN. AMP SUPERSEAL 1 S13 PULSANTE CLAXON /HORN PUSH BUTTON 1 X84 CONNETTORE MARK 12 VIE MANIPOLATORE DX / RIGHT LEVER 12 WAY CONN. DEUTSCH DT04-12P,DT06-12-S 1
X23 CONNETTORE 2 VIE PRESSOSTATO 2 BACK-UP /BACK-UP PRESSURE 2 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 X32A CONNETTORE 1 VIA PRESSOSTATO PPC SAFETY / PPC SAFETY PRESSURE SWITCH 1 WAY CONN. AMP SUPERSEAL 1 S14 PULSANTE SECONDA VELOCITA' /SECOND SPEED PUSH BUTTON 1 X85 CONNETTORE SWF INTERRUTTORE FARI LAVORO POSTERIORI /REAR WORK LIGHTS SWF SWITCH SWF * 1
X28 TERMINALE MINIMA PRESSIONE OLIO MOTORE /ENGINE MIN.PRESSURE SWITCH TERMINAL * * 1 X33 CONNETTORE 2 VIE EV. SERVOCOMANDI (PPC) /PPC VALVE 2 WAY CONN. * * 1 S15 PULSANTE FLOAT / FLOAT PUSH BUTTON 1 X86 CONNETTORE SWF LUCI STRUM. E FARI ANABB. ANTERIORI /PANEL AND FRONT LIGHTS SWF SWITCH CONN.SWF * 1
X29 CONNETTORE 2 VIE SIRENA BACK-UP /BACK UP ALARM 2 WAY CONN. * * 1 X34 CONNETTORE 2 VIE EV. FLOAT / FLOAT VALVE 2 WAY CONN. * * 1 X44 CONNETTORE RELE' BRAKE / BRAKE RELAY CONN. 1 X87 CONNETTORE PULSANTE FRENO / BRAKE SWITCH CONN. PNEUTRON * 1
XB OCCHIELLO C8 SU MOTORINO AVV. / C8 START MOTOR TERMINAL * * 1 X35 CONNETTORE 2 VIE EV. FRENO /BRAKE VALVE 2 WAY CONN. * * 1 X88 CONNETTORE SWF INTERRUTTORE LAMPEGGIANTE /BEACON LIGHT SWITCH CONN. SWF * 1
XF CONNETTORE 2 VIE FUSIBILE GENERALE / GENERAL FUSE 2 WAY CONN. * * 1 X36 CONNETTORE 2 VIE EV. SECONDA VELOCITA' /SECOND SPEED VALVE 2 WAY CONN. * * 1 X45.1 CONNETTORE MARK 13 VIE DA LINEA TELAIO / FROM FRAME LINE 13 WAY CONN. AMP * 1 X89 CONNETTORE RELE' FLOAT / FLOAT RELAY CONN. 1
GND OCCHIELLO C8 MASSA / C8 GROUND TERMINAL * * 1 X37 CONNETTORE 1 VIA PRESSOSTATO FRENO /BRAKE PRESSURE SWITCH 1 WAY CONN. * * 1 X46.1 CONNETTORE 4 VIE DA LINEA TELAIO / FROM FRAME LINE 4 WAY CONN. DEUTSCH DTP04-4P 1 GND3 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL AMP * 1
GND5 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL * * 1 X45 CONNETTORE 13 VIE LINEA CABINA / CABIN LINE 13 WAY CONN. * * 1 X47.1 CONNETTORE 2 VIA MASSA DA LINEA TELAIO / FROM FRAME LINE 2 WAY GROUND CONN. DEUTSCH DTP04-2P 1
XM OCCHIELLO C4 SU MOTORINO AVV. / C4 START MOTOR TERMINAL * * 1 X46 CONNETTORE 4 VIE LINEA CABINA / CABIN LINE 4 WAY CONN. DEUTSCH DTP-06-4S 1 X48.1 CONNETTORE MARK 5 VIE DA LINEA TELAIO / FROM FRAME LINE 5 WAY CONN. AMP * 1
XS CONNETTORE 2 VIE SAFETY RELAY / SAFETY RELAY 2 WAY CONN. SUMITOMO 6195-0060 1 X47 CONNETTORE 2 VIe MASSA / GROUND 2 WAY CONN. DEUTSCH DTP06-2S 1
XS1 ISOLATORE / INSULATOR * * 1 X48 CONNETTORE 5 VIE LINEA CABINA / CABIN LINE 5 WAY CONN. * * 1 X50 CONNETTORE 23 VIE CENTRALINA ELETTRONICA / ELECTRONIC UNIT 23 WAY CONN. AMP * 1
HA3 SIRENA BACK-UP /BACK UP ALARM CIAM (KUE) 0A001357 (312612100) 1 GND2 OCCHIELLO C8 MASSA / C8 GROUND TERMINAL * * 1 X52 CONNETTORE 1 VIA BUZZER /BUZZER 1 WAY CONN. AMP * 1
RKS03410
GND5 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL 1 X53 CONNETTORE 1 VIA BUZZER /BUZZER 1 WAY CONN. AMP * 1
CK35-1 90-3
OTHER ELECTRICAL DIAGRAM (OPTIONAL)
X14, X18 X13 H8 FANALINO POSTERIORE SX / LEFT REAR LAMP COBO (KUE 885111135) 1
H9 FANALINO POSTERIORE DX /RIGHT REAR LAMP COBO (KUE 885111134) 1
0A005426
HA2 AVVISATORE ACUSTICO /HORN CIAM 112001 (KUE 885100005) 1
G-N1
H-G1
H-N1
H-N1
A-G1
R/N1
N1.5
1 2
G1
C1
A1
L1
X82.1 CONNETTORE MARK 11 VIE / 11 WAY CONN. AMP 1
+ -
3 X108-X109 CONNETTORI 2 VIE FANALI ANTERIORI / FRONT LOW BEAM 2 WAY CONN. PACKARD 2 A B 1 1 1 A B 1 1 1 1 1 1 1 1 1 1 1 1 1 A B A B 1 1
X110-X111 CONNETTORI 2 VIE FARI LAVORO POST/ REAR WORK LIGHTS 2 WAY CONN. PACKARD 2 X108 X108 X115 X116 X117 X109 X109 X118 X119 X120 X121 X122 X123 X124 X125 X126 X127 X128 X129 X130 X110 X110 X111 X111 XP1 XP1A
1 2 3 4 5 6 7 8 9 10 11
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X50 23 L/B1 H-R1
X08 X115-X116-X117 CONNETTORI 1 VIA FANALI POSIZIONE ANT./ FRONT TRAFFIC LIGHTS 1 WAY CONN. AMP 3 BRAKE P.B. IN
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
X07 HI-SPEED P. B. IN
X50 22 A/B1 HA1 R-N2.5 G1.5
R2.5
X118-X119-X120 CONNETTORI 1 VIA FANALI POSIZIONE ANT. / FRONT TRAFFIC LIGHTS 1 WAY CONN. AMP 3
H-N1
N1
L1
G1
N1
N1
H-N1
G-N1
A1
N1
N1
L1
G1
R/N1
R/N1
G-N1
A1
N1
G1
N1
A-G1
N1
A-G1
N1
N1
H-G1
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
FLOAT P. B. IN
X50 21 L/G1
1 2 3 1 2 X121-X122-X123-X124 CONNETTORI 1 VIA FANALI POSIZIONE POST. / REAR TRAFFIC LIGHTS 1 WAY CONN. AMP 4
H-R2.5
R-N2.5
M2.5
SAF. BAR. SW IN
X50 20 C/N1 1 2 3 4 5 6 7 8 9 10 11
X125-X126-X127-X128 CONNETTORI 1 VIA FANALI POSIZIONE POST. / REAR TRAFFIC LIGHTS 1 WAY CONN. AMP 4 1 1 1 1 1 1 1 1 1 1 1
K04
C1
85 87
4 5 6
B1
SEAT SWITCH IN
X50 19 C-B1 1 1 X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76
3 4
X50 H-R1 X52 X53
A-G1.5
1 18
G-N1
H-G1
H-N1
H-N1
R/N1
N1.5
POW. SUPP. +12V FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01 86 30
Z-B1
G1
C1
A1
L1
X113 R1 ACC BR R2 C
EV BRAKE OUT
X50 17 H-L1 OFF ACC 30A 7.5A 10A 10A 10A 10A 15A 10A 15A 3A 3A
R/N1 R1
ST
X78
X79
STOP ENGINE OUT
X50 16 R-N1.5 X89 X89 X89 X89
HA2 H5 H7 H8 H9 H1
WIRE POSITIONING 85 86 30 87
ELECTRONIC UNIT
1 1
58L
58R
58L
54
54
58R
R
H4 H6 H12 H10 H11 M BRAKE LIGHT OUT
X50 15 S/N1 S10 B X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77
H/R1
N1
B-N1
B-R1
B-R1
M-N1
X50
ON CONNECTOR GND6 SAF. BAR.LED OUT 14 B/N1 S12
S11
1 1 1 1 1 1 1 1 1 1 1
31
31
31
31
X50 G/N1
R4
SEAT LED OUT 13
R-N2.5
H-R1.5
A-R1.5
L-R1.5
R-G1
G-N1
H-R1
G/R1
H/R1
B-R1
( WIRE SIDE WIEW WIRING )
G1
WARNING LED OUT
X50 12 M/B1
= Parts not included in the wiring FLOAT OUT
X50 11 B-N1 C A B G/R1 X85 9
2 1
X50 Z-B1 X54 X54 X54 A-R1.5
10
X55 X55 X85 1
H-R1
C/N1
BUZZER OUT (-)
KUE 37C-06-11312
N1
H-R1
C-B1
HI-SPEED OUT
X50 9 M-B1 1 9
1 0
GND4-GND6 OCCH. C6 MASSA /C6 GROUND TERMINAL GND
X50 8 N1.5
0A005893
= Parts not included in the wiring X129-X130
XP1-XP1A
CONN. LUCE TARGA / PLATE LIGHT CONN.
CONN.. PRESA 12V , GIROFARO /
HORN OUT
X50 7 C1
S01 5 10
START SIGN. IN
X50 6 B1
CURRENT INTAKE 12V, BEACON LIGHT +12V HORN
X50 5 H-R1.5 A-G1.5 X85 5
HORN PUSH B. IN
X50 4 B/R1
V1 K02 N1 X85 10
K06 X50 L-G1
POWER
EV PPC OUT 2
86 87 R-N2.5 X01.1 R-N2.5
RELAY M2.5
4
X01 4
X01.1 M2.5
BUZZER OUT (+)
X50 1 R/N1 G/R1 X86 9
R-B1
85 30 3
X01 3 G1.5 X86 8
X07 G1
X07 R1
X07 N1
L/B1
R-N2.5
B2
R-N1.5
R-N1.5
N1
M-V1
L/B1
R-N1.5
N1
R10
4 X86 3
B2.5
R-G1
B1
N1
S-N1
l l
L-R1 X02.1 L-R1.5
-
X02 M2.5 X46 4 3 X46.1 M2.5 H-R1 X86 2
-
H-L1 X44 86
K14 86 87a 87
R4 X46 3 2 X46.1 R4 N1 X86 10
R-N1.5 X10.1 R-N1.5 M1 X44 87a
13
X10 13 R4 X46 2 1 X46.1 R4 85 30
X10.1 H-L1 X44 30 S/N1 X87 6
12
X10 12
1
R2.5 X10.1 R2.5 R-N1.5 X45 13 X45.1 R-N1.5 H-R1 X87 3
11
X10 11 13 B-G1 X44 85
R-V1 X10.1 R-V1 V-N1 X45 12 X45.1 V-N1 15/1 30/3 L/6
10
X10 10 12 0 1
B1 X10.1 B1 M-B1 X45 11 X45.1 M-B1
9
X10 9 11
S1 X10.1 S1 L-R1.5 X45 10 X45.1 L-R1.5
8
X10 8 10 S08 49/4 30b/2 R/7
M-N1
G-N1
M-V1
M-B1
C-N1
H-R1
S-G1
B-G1
M/B1
G/N1
C-N1 B1 X45 B1 L/B1
B-N1
B/N1
X45.1
Z-B1
C-L1
L-N1
X10.1 9 X87
H0.5
X10 C-N1 2
M1
N1
B1
S1
7 7
C-L1 X10.1 C-L1 M-N1 X45 9 8 X45.1 M-N1 H-R1 X87 7
6
X10
S-G1
6
R-G1 X45 8 X45.1 R-G1 K95 G/R1
X10 X10.1 S-G1 7 86 87a 87 X88 9
5 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
R10
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
4
X10 4 85 30
B-N1 C-N1 X45 6 C-N1
GND X10.1 B-N1 5 X45.1 1 9
3
X10 3 1 0
R-G1 X10.1 R-G1 C-L1 X45 5 4 X45.1 C-L1 P1 86 85 30 87a
2
X10 2 X95 X95 X95 X95
1 B-G1 X10.1 B-G1 S-G1 X45 4 3 X45.1 S-G1
X10 CONTROL PANEL (UNIDECK) 5 10
M1
N1
L-R1
R-V1
1 1
B-N1 X45 3 S07
XF 2 X45.1 B-N1 H-G1 X88 5
1
FG1 B-G1 X45 2 1 X45.1 B-G1 N1 X88 10
50A X28 1
C-B1 X49 11 X49.1 C-B1
S31
HA3 C1 X4911 10 X49.1 C1 RELAYS UNIT
XF p V-B1 X4910 9 X49.1 V-B1
2
V1 X49 9 8 X49.1 V1
2 1 A-N1 X49 8 7 X49.1 A-N1 K12 86 87a 87 K08 85 30 K09 85 30 K11 86 87
Z-N1
85 30 86 87 86 87 85 30
R10 A-G1 X49 6 5 X49.1 A-G1
R10
Z-N1 X49 5 4 X49.1 Z-N1
R50
B2.5
R-G1
S1
S-N1
R-G1
C-N1
S-G1
B-N1
M2.5
C-L1
N1
N1
N1
N1
G1
B2
R-V1
Z-N1
L-R1
L-R1
L-R1
X11
3 1 2 - + 1 2 1 C A - + 1 N2.5 1
1 1 X13 X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 1 2 1 2 1 2 1 2
K07 K10
G2 85 30
K13 +
M-N1
M-B1
M-V1
XB XM
L-G1
Z-N1
A-V1
V-N1
M1 R1 R2 R3
R2.5
N2.5
R1.5
B2.5
53M
M1
D+ M2
N1
N1
N1
N1
N1
N1
53S
R CL(T)
31
15
30 50 30 W
GND2
G
T
S25 S26 S27 S28 S29 S30
GND1
86 87
M N4 X47 1
X47.1 N4
N50
Y0
S-N1.5
L-R1.5
3 M p p p p p p -(53S)
A-G1
1 1 1 2 1 2 1 2 1 2 1 2 1 2 1
C-B1
A-N1
A-B1
V-B1
1
N1.5
U
N4 X47 2
X47.1 N4
C1
V1
t X32 X32A X33 X33 X34 X34 X39 X39 X40 X40 X35 X35 X36 X36 X37 2
31
S32 S33
X41
X41
X41
X41
X42
X42
X42
X42
X42
X43
p p
4 3 2 1 5 4 3 2 1 1
ENGINE PARTS X8 X8 X8 X8 X8
P1 CONTROL PANEL (EXTERNAL WIEW)
5 4 3 2 1
Y1 Y2 Y5 Y4 Y6 Y3
INTERNAL CONNECTION CONTROL PANEL
X80-15
X80-16
X80-12
X80-14
X80-11
N1.5
R1.5
A-N1.5
A-B1.5
A-G1.5
L1 L2 L3 L4 L5 C2 C3
X80-8 KUE 37A-06-11363
+
NOME/NAME DESCRIZIONE/DESCRIPTION COSTRUT./SUPPL. TIPO/TYPE QTA
L1 L2 L3 L4 L5
K05 0A007932
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
FG1 FUSIBILE GENERALE 80A /GENERAL FUSE 80A CIAM 163028 1 H F FUEL WATER TEMP.
KUE 37C-06-11331 LEVEL INDICATOR
G1 BATTERIA /BATTERY 100Ah FIAMM (KUE) L5 600 103 085 (37C-06-11110) 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
X121 H A WAY C1
00000 00 h
G2 ALTERNATORE /GENERATOR YANMAR (DENSO) 129423-77200 1
A-V1
C/B1
L-R1.5
A/N1
L-N1
A/V1
R/N1
R-V1
L/N1
Z-N1
N1.5
A-N1
V/B1
L/R1
A-G1
Z/N1
A-B1
A-R1.5
X121 G WAY C2
K01 RELE' SOLENOIDE CARBURANTE /FUEL SOLENID VALVE RELAY MATSUSHITA (KUE) CB1aH (885071022) 1 0A005936
A-B1.5 X121 F C (-) C E
K02 TIMER 1 SEC PULL FUEL SOLENOID VALVE YANMAR (KUE) 1 "B" WAY ATTACHEMENT C D E
N1.5 X121 E
K03 SAFETY RELAY YANMAR (KUE) 119802-77200 1 GROUND B A
A-G1.5 X121 D C1
M1 MOTORINO AVVIAMENTO / STARTER MOTOR YANMAR 1 "A" WAY ATTACHEMENT H G C3 A1 X104
A-N1.5
F HOUR COUNTER 2
X121 C
M2 POMPA GASOLIO / FUEL PUMP YANMAR 129612-52100 1 "C" WAY ATTACHEMENT (+12V) L1 X104 1
R1.5 X121 B WAY L6 L7 L8 L9 L10 DL1 DL2 DL3
R1 RESISTENZA PRERISCALDO /PREHEATING STARTER YANMAR 129100-77500 1 +15 KEY 1 2
N1.5 X121 A 1 0 2
R2 SENSORE LIVELLO CARBURANTE /FUEL LEVEL SENDER COBO (KUE) 29-0419-0000 (37A-04-11140) 1 GROUND B X80-6
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
R3 TRASDUTTORE DI TEMP. ACQUA MOTORE /ENGINE WATER TEMPERATURE SENDER YANMAR (KUE) (7861-92-3320) 1 -
54
S25 SENSORE INTASAMENTO FILTRO ARIA /AIR FILTER BLOCKED SWITCH DONALDSON (KUE) X770317 (37A-06-11960) 1 a c b L6 L7 L8 L9 L10 DL2 DL1 DL3 S03
A/N1 X104 54
S26 PRESSOSTATO INTASAMENTO OLIO IDRAULICO /HYDRAULIC OIL FILTER BLOCKED SWITCH FMDI (KUE) 11716/1 (885261034) 1
X80-9 X80-2 X80-3 N1 X105 10
S27 PRESSOSTATO LUCI STOP /STOP LIGHTS PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1
A/N1 X105 5
S28 PRESSOSTATO STOP /STOP LIGHTS PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1 NOME DESCRIZIONE COSTRUTTORE TIPO QTA
G/R1 X105 8
S29 PRESSOSTATO BACK-UP /BACK-UP ALARM PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1
X121 ATTACHEMENT 8 WAY CONN. DEUTSCH HD34 18-8PN 1 POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR H/R1 X105 2
S30 PRESSOSTATO BACK-UP /BACK-UP ALARM PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1
X121 NUT DEUTSCH 114020-90 1 2 8 5 10
S31 PRESSOSTATO MINIMA PRESSIONE OLIO MOTORE /ENGINE OIL MIN. PRESSURE SWITCH YANMAR * 1 X80-1 X80-9 INTERNAL LIGHTS (+ LUCI) POSITIVE G-N1 DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 1 0
X121 WASHER DEUTSCH 114021 1
V1 DIODO / DIODE CIAM 1A 1N4007 1
X121 MALE PIN DEUTSCH 0460-204-12141 6 C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1 L8 X81-2 FLOAT LAMP POSITIVE M-N1
Y0 ELETTROVALVOLA STOP SOLENOIDE CARBURANTE /STOP FUEL SOLENOID VALVE YANMAR 129005-77950 1 S09 4 6 3 1 7
X121 PLUG DEUTSCH HDC36-18 1 L/R1 X105 4
X01 CONNETTORE 3 VIE LINEA TELAIO /FRAME LINE 3 WAY CONNECTOR * * 1 A B C3 X80-3 WATER TEMPERAT. INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1 L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1
X8 5 WAY FEMALE MARK II CONN. CIAM (AMP) 125216 1 A1 X105 3
X02 CONNETTORE 2 VIE / 2 WAY CONN. * * 1
C X8 MALE PIN CIAM (AMP) 120072 5 +50 X80-4 START SIGNAL +50 B1 L2 X80-12 PREHEATING LAMP POSITIVE M1 L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 L1 X105 1
S-N1.5
L-R1.5
X03 CONNETTORE RELE SOLENOIDE CARBURANTE / FUEL SOLENOID RELAY CONN. * * 1
G/R1
G/R1 X105 7
N1
X06 CONNETTORE 2 VIE DIODO ANTIDISTURBO / DIODE 2 WAY CONN. * * 1 GND X80-5 GROUND GND X80-13
X07 CONNETTORE 4 VIE TIMER / TIMER 4 WAY CONN. * * 1 POS. PIN FUNCTION SIGNAL WIRE COLOUR G/R1 X106 9
GND X80-6 GROUND GND N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1 5 1 9 10
X08 CONNETTORE 6 VIE SAFETY RELAY /SAFETY RELAY 6 WAY CONN. SUMITOMO 6195-0021 1
RIGHT LEVER L9 X81-5 DIRECTION LAMP POSITIVE L-N1 V-B1 X106 7
X91
X91
X91
X91
KUE 37A-06-11460
X09 OCCHIELLO C6 ALTERNATORE / C6 GENERATOR TERMINAL * * 1 X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1 V1 X106 1
A-G1
B-R1
B-R1
A-N1
B/R1
C/B1
Z-N1
A-B1
A/B1
V/B1
L/G1
A/V1
Z/N1
L/N1
L10 X81-6 LOW BEAM LAMP POSITIVE H0.5
N1
N1
X10 CONNETTORE MARK 13 VIE LINEA TELAIO /FRAME LINE MARK 13 WAY CONN. * * 1
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 SWITCH EV ENPI 1 0 2
1 7 9
X11 CONNETTORE 3 VIE ALTERNATORE /GENERATOR 3 WAY CONN. SUMITOMO 6189-0442 1 0A003433 DL1 X81-7 WARNING LED NEGATIVE M/B1
1 2 3 4 5 6 11 1 2 3 4 5 6 7 8 9 11
X13 CONNETTORE 3 VIE POOL-STOP SOLENOIDE CARBURANTE /FUEL POOL-STOP SOLENOID 3 WAY CONN. DEUTSCH DT06-3S 1
3 10
DL2 X81-8 SEAT LED NEGATIVE G/N1 S05
X83
X83
X83
X83
X83
X83
X83
X84
X84
X84
X84
X84
X84
X84
X84
X84
X84
X14 CONNETTORE 2 VIE POMPA GASOLIO / FUEL PUMP 2 WAY CONN. * * 1 L-R1.5 X106 3
X15 OCCHIELLO C6 RESISTENZA PRERISCALDO / PREHEATING START C6 TERMINAL * * 1 RIGHT LEVER N1 X106 10
R-N0.8
R-N0.8
A-G0.5
A-N0.5
A-B0.5
A-B0.5
Z-N0.5
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
N0.8
N0.8
X16 CONNETTORE 2 VIE SENSORE INTASAMENTO FITRO ARIA / AIR FILTER BLOCKED SWITCH 2 WAY CONN. AMP MINITIMER 1
LEFT LEVER
G/R1 X107 9
X17 CONNETTORE 3 VIE SENSORE LIVELLO CARBURANTE /FUEL LEVEL SENDER 3 WAY CONN. * * 1 NOME/NAME DESCRIZIONE/DESCRIPTION COSTRUT. /SUPP. TIPO/ TYPE QTA NOME/NAME DESCRIZIONE/DESCRIPTION COSTRUT. /SUPP. TIPO/ TYPE QTA
C-B1 X107 7
X18 CONNETTORE 2 VIE TRASDUTTORE TEMP. ACQUA /ENGINE WATER TEMPERATURE SENDER 2 WAY CONN. * * 1 FU01 FUSE 3A LEFT SIDE LIGHTS, PLATE LIGHT 1 S32 PRESSOSTATO PPC SAFETY /PPC SAFETY PRESSURE SWITCH FMDI (KUE) 11717.75 (37A-06-11670) 1 C1 X107 1
X19 OCCH. C5 SENSORE INTASA. FILTRO OLIO IDRAULICO / IDRAULIC OIL FILTER BLOCKED SWITCH C5 TERMINAL* * 1 FU02 FUSE 3A CONTROL PANEL LIGHTS, RIGHT SIDE LIGHTS 1 S33 PRESSOSTATO FRENO STAZIONAMENTO /BRAKE VALVE PRESSURE SWITCH FMDI (KUE) 11717.15 (885411439) 1
X20 CONNETTORE 2 VIE PRESSOSTATO 1 LUCI STOP / STOP LIGHT PRESSURE 1 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 FU03 FUSE 15A HORN, LOW BEAM OR FRONT WORK LIGHTS 1 S36 PULSANTE INVERSIONE HI-FLOW MOMENTARY / REVERSE HI-FLOW MOMENTARY PUSH BUTTON 1
= Parts not included in the wiring S13 S14 S36 S37 HL1 S15 S38 HL2 S39 HL3 S40 HL4 HL5
1 0 2
1 7 9
X21 CONNETTORE 2 VIE PRESSOSTATO 2 LUCI STOP / STOP LIGHT PRESSURE 2 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 FU04 FUSE 10A SWITCH LIGHTS, DIRECTION LIGHTS 1 S37 PULSANTE SUPER- FLOW DETENT / SUPER-FLOW DETENT PUSH BUTTON 1
3 10
X22 CONNETTORE 2 VIE PRESSOSTATO 1 BACK-UP / BACK-UP PRESSURE 1 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 FU05 FUSE 15A REAR WORK LIGHT, STOP LIGHT 1 S38 PULSANTE "C" WAY / "C" WAY PUSH BUTTON 1 S06
L-R1.5 X107 3
X23 CONNETTORE 2 VIE PRESSOSTATO 2 BACK-UP /BACK-UP PRESSURE 2 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 FU06 FUSE 10A LEVER SWITCH POWER SUPPLY, FLOAT 1 S39 PULSANTE "A" WAY / "A" WAY PUSH BUTTON 1 N1 X107 10
X28 TERMINALE MINIMA PRESSIONE OLIO MOTORE /ENGINE MIN.PRESSURE SWITCH TERMINAL 1 FU07 FUSE 10A CURRENT INTAKE 12V, HAZARD, BEACON LIGHT 1 S40 PULSANTE "B" WAY / "B" WAY PUSH BUTTON 1
X29 CONNETTORE 2 VIE SIRENA BACK-UP /BACK UP ALARM 2 WAY CONN. * * 1 FU08 FUSE 10A CONTROL PANEL, ELECTRONIC UNIT, FUEL SHUT OFF, SAFETY BAR PROXIMITY, SAFETY SEAT SWITCH, BRAKE SWITCH 1
XB OCCHIELLO C8 SU MOTORINO AVV. / C8 START MOTOR TERMINAL * * 1 FU09 FUSE 10A BACK-UP ALARM, ATTACHEMENT 3 WAY, HI-FLOW, STABILIZER, ENPI VALVE 1 X104 CONNETTORE INTERRUTTORE LUCI DI DIREZIONE / DIRECTION LIGHTS SWITCH CONN. 1 LEFT LEVER RIGHT LEVER
XF CONNETTORE 2 VIE FUSIBILE GENERALE / GENERAL FUSE 2 WAY CONN. * * 1 FU10 FUSE 7.5A FUEL PUMP, SAFETY ENGINE RELAY, GENERATOR 1 X105 CONNETTORE SWF HAZARD / SWF HAZARD CONN. SWF 1
GND OCCHIELLO C8 MASSA / C8 GROUND TERMINAL * * 1 FU11 FUSE 30A PULL SOLENOID, PPC SAFETY PRESSURE SWITCH 1 X106 CONNETTORE SWF PULSANTI PIEDI STABILIZZATORI /STABILIZER PUSH BUTTON CONN. SWF 1 HL1 HL3 HL2 HL4
GND5 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL * * 1 HA1 BUZZER SEGNALAZIONE ANOMALIE /WARNING BUZZER 1 X107 CONNETTORE SWF PULSANTI PIEDI STABILIZZATORI /STABILIZER PUSH BUTTON CONN. SWF 1
XM OCCHIELLO C4 SU MOTORINO AVV. / C4 START MOTOR TERMINAL * * 1 HL1 DIODO LED SUPER-FLOW / SUPER-FLOW LED DIODE 1 X44 CONNETTORE RELE' FRENO PARCHEGGIO / PARKING BRAKE RELAY CONN. BOSCH 1
XS CONNETTORE 2 VIE SAFETY RELAY / SAFETY RELAY 2 WAY CONN. SUMITOMO 6195-0060 1 HL2 DIODO LED "C" WAY / "C" WAY LED DIODE 1 X45.1 CONNETTORE MARK 13 VIE DA LINEA TELAIO/ FROM FRAME LINE MARK 13 WAY CONN. AMP 1
XS1 ISOLATORE / INSULATOR * * 1 HL3 DIODO LED "A" WAY / "A" WAY LED DIODE 1 X46.1 CONNETTORE 4 VIE DA LINEA TELAIO / FROM FRAME LINE 4 WAY CONN. DEUTSCH DTP04-4P 1 WIRING COLOURS
HA3 SIRENA BACK-UP /BACK UP ALARM CIAM (KUE) 0A001357 (312612100) 1 HL4 DIODO LED "B" WAY / "B" WAY LED DIODE 1 X47.1 CONNETTORE 2 VIE MASSA / GROUND 2 WAY CONN. DEUTSCH DTP04-2P 1
Y1 ELETTROVALVOLA SERVOCOMANDI /PPC VALVE HYDRAFORCE * 1 HL5 DIODO LED OPZIONALE / OPTIONAL LED DIODE 1 X48.1 CONNETTORE MARK 5 VIE DA LINEA TELAIO / FROM FRAME LINE MARK 5 VIE CONN. AMP 1
C
A LIGHTBLUE S13 S38
ON
ON
Y2 ELETTROVALVOLA FLOAT /FLOAT VALVE HYDRAFORCE * 1 K04 RELE' FLOAT / FLOAT RELAY CIAM 01170922 (KUE 885070040) 1 X49.1 CONNETTORE MARK 11 VIE DA LINEA TELAIO / FROM FRAME LINE MARK 11 VIE CONN. AMP 1 S14 S15
B WHITE
CN
CN
C
C
Y3 ELETTROVALVOLA SECONDA VELOCITA' /SECOND SPEED VALVE HYDRAFORCE * 1 K05 SUPPORTO RELE' / RELAYS BOX (WITHOUT RELAYS) CIAM 122010 (KUE 885411196) 1 X50 CONNETTORE 23 VIE CENTRALINA SICUREZZE /SAFETY CONTROL BOX 23 WAY CONN. AMP 1
ON
ON
C ORANGE
CN
CN
Y4 ELETTROVALVOLA INVERSIONE HI-FLOW MOMENTARY / REVERSE HI-FLOW MOMENTARY VALVE HYDRAFORCE * 1 K06 CENTRALINA ELETTRONICA / ELETTRONIC UNIT CIAM 01171077 (KUE 885070046) 1 X52 CONNETTORE 1 VIA BUZZER /BUZZER 1 WAY CONN. AMP 1 G YELLOW S36 S37 S39 S40
Y5 ELETTROVALVOLA SUPER-FLOW DETENT / SUPER-FLOW DETENT VALVE HYDRAFORCE * 1 K07 RELE' "B" WAY / "B" WAY RELAY KUE 885071044 1 X53 CONNETTORE 1 VIA BUZZER / BUZZER 1 WAY CONN. AMP 1 H GREY
Y6 ELETTROVALVOLA FRENO /BRAKE VALVE HYDRAFORCE * 1 K08 RELE' "A" WAY / "A" WAY RELAY KUE 885071044 1 X54 CONNETTORE 3 VIE SENSORE BARRA / PROXIMITY BAR 3 WAY CONN. DEUTSCH 1 L BLUE
X01.1 CONNETTORE 4 VIE LINEA MOTORE /ENGINE LINE 4 WAY CONN. DEUTSCH DTP04-4P 1 K09 RELE' "C" WAY / "C" WAY RELAY KUE 885071044 1 X55 CONNETTORE 2 VIE SENSORE SICUREZZA SEDILE /SAFETY SEAT SWITCH 3 WAY CONN. DEUTSCH 1 M BROWN
X02.1 CONNETTORE 2 VIE LINEA MOTORE /ENGINE LINE 2 WAY CONN. AMP * 1 K10 RELE' PASSO PASSO SUPER-FLOW DETENT / SUPER-FLOW DETENT STEP BY STEP RELAY CIAM 01170923 (KUE 37A-06-11430) 1 X56-X57-X58-X59-X60 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP 5 N BLACK
X10.1 CONNETTORE MARK 13 VIE LINEA MOTORE /ENGINE LINE 13 WAY CONN. AMP * 1 K11 RELE' INVERSIONE HI-FLOW MOMENTARY / REVERSE HI-FLOW MOMENTARY RELAY CIAM 157061 (KUE 885071043) 1 X61-X62-X63-X64-X65 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP 5 R RED
X32 CONNETTORE 1 VIA PRESSOSTATO PPC SAFETY /PPC SAFETY PRESSURE SWITCH 1 WAY CONN. AMP SUPERSEAL 1 K12 RELE' LUCI STOP /STOP LIGHTS RELAY CIAM 157061 (KUE 885071043) 1 X66-X67-X68-X69-X70 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP 5 S PINK
X32A CONNETTORE 1 VIA PRESSOSTATO PPC SAFETY /PPC SAFETY PRESSURE SWITCH 1 WAY CONN. AMP SUPERSEAL 1 K13 INTERMITTENZA /FLASHER UNIT CIAM 00105013 (KUE 885151012) 1 X71-X72-X73-X74-X75 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP 5 V GREEN
X33 CONNETTORE 2 VIE EV. SERVOCOMANDI (PPC) /PPC VALVE 2 WAY CONN. DEUTSCH DT06-2S 1 K14 RELE' FRENO / BRAKE RELAY CIAM 157061 (KUE 885071043) 1 X76-X77 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP 2 Z VIOLET
X34 CONNETTORE 2 VIE EV. FLOAT /FLOAT VALVE 2 WAY CONN. DEUTSCH DT06-2S 1 K95 RELE' LUCI STOP / STOP LIGHTS RELAY CIAM 157061 (KUE 885071043) 1 X78-X79 CONNETTORE 1 VIA PRESA DI CORRENTE /CURRENT INTAKE 1 WAY CONN. AMP 2
X35 CONNETTORE 2 VIE EV. BRAKE /BRAKE VALVE 2 WAY CONN. DEUTSCH DT06-2S 1 P1 PANNELLO STRUMENTI /CONTROL PANEL UNIDECK 04610027(KUE 37A-54-14291) 1 X80 CONNETTORE 16 VIE PANNELLO DI CONTROLLO /CONTROL PANEL 16 WAY CONN. AMP 1 EXAMPLE:
X36 CONNETTORE 2 VIE EV. SECONDA VELOCITA' /SECOND SPEED VALVE 2 WAY CONN DEUTSCH DT06-2S 1 S01 INTERRUTTORE SWF FARI LAVORO POST / REAR WORK LIGHTS SWITCH CIAM 106AA008 (KUE 885081160) 1 X81 CONNETTORE 8 VIE PANNELLO DI CONTROLLO /CONTROL PANEL 8 WAY CONN. AMP 1 G/V ->YELLOW/GREEN (TRANSVERSE MARKED)
X37 CONNETTORE 1 VIA PRESSOSTATO FRENO /BRAKE PRESSURE SWITCH 1 WAY CONN. AMP * 1 S02 INTERRUTTORE LUCI STRUMENTO E ANAB./ PANEL LIGHTS AND LOW BEAM LIGHTS SWITCH CIAM 106AA018 (KUE 885081159) 1 X82 CONNETTORE MARK 11 VIE LINEA FARI / LIGHTS LINE 11 WAY CONN. AMP 1
X39 CONNETTORE DEUTSCH 2 VIE EV. HIGHT FLOW DETENT /HIGHT FLOW DETENT VALVE 2 WAY CONN. DEUTSCH * 1 S03 INTERRUTTORE FRECCIE /DIRECTION LIGHTS SWITCH CIAM 116003 (KUE 885081161) 1 X83 CONNETTORE 12 VIE MANIPOLATORE SX / LEFT LEVER 12 WAY CONN. DEUTSCH DT04-12P, DT06-12S 1 YELLOW GREEN
X40 CONNETTORE DEUTSCH 2 VIE EV. HIGHT FLOW MOMENTARY /HIGHT FLOW MOMENTARY VALVE 2 WAY CONN.DEUTSCH * 1 S05 PULSANTE SU-GIU STABILIZZATORE SX /UP-DOWN LEFT STABILIZER BUTTON CIAM 106AA002 (KUE 885081163) 1 X84 CONNETTORE 12 VIE MANIPOLATORE DX / RIGHT LEVER 12 WAY CONN. DEUTSCH DT04-12P, DT06-12S 1
X41 CONNETTORE 5 VIE STABILIZZATORI / STABILIZER 5 WAY CONN. AMP * 1 S06 PULSANTE SU-GIU STABILIZZATORE DX /UP-DOWN RIGHT STABILIZER BUTTON CIAM 106AA002 (KUE 885081163) 1 X85 CONNETTORE SWF INTERRUTTORE FARI DI LAVORO POSTERIORI /REAR WORK LIGHTS SWF SWITCH SWF 1
X42 CONNETTORE 5 VIE ATTACHEMENT / ATTACHEMENT 5 WAY CONN. AMP * 1 S07 INTERRUTTORE SWF LAMPADA ROTANTE /BEACON LIGHT SWITCH CIAM 106AA008 (KUE 885081160) 1 X86 CONNETTORE SWF LUCI STRUM. E FARI ANABB. ANTERIORI /PANEL AND FRONT LIGHTS SWF SWITCH CONN.SWF 1 G-V ->YELLOW-GREEN(LONGITUDINAL COLOURS)
X43 CONNETTORE 1 VIA VALVOLE ENPI / ENPI VALVE 1 WAY CONN. AMP * 1 S08 PULSANTE FRENO / BRAKE SWITCH CIAM 0A003455 (KUE 37A-06-11411) 1 X87 CONNETTORE PULSANTE FRENO / BRAKE SWITCH CONN. PNEUTRON 1
X45 CONNETTORE 13 VIE LINEA CABINA / CABIN LINE 13 WAY CONN. AMP * 1 S09 INTERRUTTORE 4 FRECCIE /HAZARD SWITCH CIAM 106AA014 (KUE 885081162) 1 X88 CONNETTORE SWF INTERRUTTORE LAMPAGGIANTE /BEACON LIGHT SWITCH CONN. SWF 1 YELLOW GREEN
X46 CONNETTORE 4 VIE LINEA CABINA / CABIN LINE 4 WAY CONN. DEUTSCH DTP06-4S 1 S10 QUADRO AVVIAMENTO /STARTING SWITCH 1 X89 CONNETTORE RELE' FLOAT / FLOAT RELAY CONN. BOSCH 1
X47 CONNETTORE 2 VIE MASSA LINEA CABINA / GROUND CABIN LINE 2 WAY CONN. DEUTSCH DTP06-2S 1 S11 FINECORSA DI SICUREZZA SEDILE /SAFETY SEAT SWITCH 1 X90 CONNETTORE 21 VIE CENTRALINA RELE' / RELAYS BOX 21 WAY CONN. AMP 1
X48 CONNETTORE 5 VIE LINEA CABINA / CABIN LINE 5 WAY CONN. AMP * 1 S12 PROXIMITY DI SICUREZZA PNP BRACCIOLO /BAR PNP SAFETY SENSOR SAIET E-A1TMU/3AP (KUE 37A-06-1250) 1 X91 CONNETTORE SWF VALVOLE ENPI / ENPI VALVE SWF CONN. CEMBRE 1
X49 CONNETTORE 11 VIE LINEA CABINA / CABIN LINE 11 WAY CONN. AMP * 1 S13 PULSANTE CLAXON / HORN PUSH BUTTON 1 X95 CONNETTORE RELE' LUCI STOP/STOP LIGHT RELAY CONN. AMP 1
GND1-GND2 OCCHIELLO C8 MASSA / C8 GROUND TERMINAL AMP * 1 S14 PULSANTE SECONDA VELOCITA' /SECOND SPEED PUSH BUTTON 1
GND5 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL AMP * 1 S15 PULSANTE FLOAT /FLOAT PUSH BUTTON 1 GND3 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL SWF 1
RKS03420
CK35-1 90-5