Case CX160D Crawler Excavator Service Manual 87673889 - PDF DOWNLOAD

SERVICE MANUAL

CRAWLER EXCAVATOR CX160B

87673889 B Replaces 87674889 A

Issued July 2009

26

22

Pm1

28

25

Ps

29 *

(G3)

(G3)

G1

T

* 30

C P1

J

I

PL

P2

B1

PL

G1 RE

RED

P1

DR

DR

L1

1 D2

A

L2

16

D C

38.2 MPa / 382 bar / 5540 psi

32.3 MPa / 323 bar / 4684 psi

D DIPPER OUT PORT SECONDARY RELIEF

38.2 MPa / 382 bar / 5540 psi 38.2 MPa / 382 bar / 5540 psi 38.2 MPa / 382 bar / 5540 psi 38.2 MPa / 382 bar / 5540 psi

G BUCKET CLOSE PORT SECONDARY RELIEF

38.2 MPa / 382 bar / 5540 psi

B

H PILOT PRESSURE RELIEF

3.92 MPa / 39.2 bar / 568 psi

I RIGHT-HAND SWING PORT SECONDARY RELIEF

27.9 MPa / 279 bar / 4046 psi

A

J LEFT-HAND SWING PORT SECONDARY RELIEF

27.9 MPa / 279 bar / 4046 psi

PL

TRAVEL REVERSE PORT SECONDARY RELIEF

35.3 MPa / 353 bar / 5119 psi

L1/L2

TRAVEL FORWARD PORT SECONDARY RELIEF

35.3 MPa / 353 bar / 5119 psi 2.55 MPa / 25.5 bar / 370 psi

N1/N2 NEGATIVE CONTROL RELIEF

23

21

K1/K2

DR

F

20.6 MPa / 206 bar / 2989 psi

W1/W2 CRUSHER OPTION SECONDARY RELIEF VALVE (factory)

36.3 Mpa / 363 bar / 5265 psi

W4 BREAKER OPTION SECONDARY RELIEF VALVE (factory)

29.4 Mpa / 294 bar / 4264 psi

LEGEND

LH FORWARD LH REVERSE

RH REVERSE RH FORWARD

23.5 Mpa / 235 bar / 3410 psi

R MAIN RELIEF (2eme OPTION)

BB

P1 PUMP

3

P2 PUMP A

PILOT SYSTEM PUMP

Y18*

P

*

T

* 71

RETURN TO RESERVOIR

134

SECOND OPTION

Y26

* 85

P

C1 B

4b5 4a5

T

58 P5

BB

dr2 A2

FL

dr1

2

41

109

Ps2

PIPING CROSS-OVER

15

Pi3

R1

9

E

* 83

al1

CONNECTION ITEM NO.

N1

39

5B5 5A5

N2

a ck1

COMPONENT ITEM NO. COMPONENT NUMBER

FR

43.51 psi 3 bar

72.51 psi 5 bar

133 T

11.60 psi 0.8 bar

W4

Pi2

R2

OFF 0.08 MPa

10 Pi1

57 S

R3

ON 0.5 MPa OFF 0.3 MPa

14.5 psi 1 bar

0.004 MPa 0.58 psi 0.04 bar

PIPING CONNECTION

Pi1

10 Pi2

P

HOSE

31

*

OPTIONAL ITEM NO.

D1

DIPPER (2)

T1

1

D6 D 0.098 MPa 14.21 psi 0,98 bar

5

6µ

57 T

T D5

6

72 P

CLOSE

Y27

A1 B2

5a4

ON

5b4

BOOM (1)

BOOM (2)

LOWER

72 T

T2

15 5A4

B

4A1 4B1

55 3

DR

15 5B4

A

B

55 4

LEFT RIGHT

4b1

REVERSE

4a1

FORWARD

*

AA

58 T5

B

108

* 76

15 5a4

A2

58 P5

*

141

A1

Y23

Y24

Y9

* 140

P

15 Py

Y5

C3

T

T

5A1 FORWARD

5a1

REVERSE

5b1

C5

Y3

C2

51

1.5 MPa 217.5 psi 15 bar

133

60

71 T

82

P3 8µ

P0 Px3

Py

PL(P2)

dr3

Ps1

Px1

B26

133 C3

134 132 T T

PR(P1)

B42 PH1

0.15 MPa 21.7 psi 1.5 bar

B44 A1

a1

a2

A2

PH2

P1

P2

86

10 P4

P5

T4

P

0.02 MPa 2.9 psi 0.2 bar

EE 71 P

B43

T5

(FRONT)

(REAR)

B40 P2

P3

58

P1

T3

T2

T1

59 54 P

CLOSE

53

85 P

T

OPEN

REVERSE OUT B

D

R

LOWER F

RAISE

RIGHT J

H

FORWARD

FORWARD

DIPPER

LEFT

OUT

P1

LEFT S

L

N

U

P1

P

2

4

3

1

2

4

* 85

BUCKET OPEN CLOSE

BOOM LOWER RAISE

SWING RIGHT

3

Pi1

REVERSE

C1

IN

Y11

OPTION

P2 Pi2

ON

T IN

a6

a5

HAMMER

74 Pi2

31µ

57

TRAVEL (RIGHT)

TRAVEL (LEFT)

15 FR

* 72

55 85

B P

M

C2 T

A

ISUZU 4JJ1X 83,2 Kw à 2200 tr/mn

a4

H Dr1

A3

Y7

1 B1 A

85

85

C

15 a

P

PP

132 134 P G

A

P

G

Y6

5b2

R4

*

Y2

15 4b21

5a2

TRAVEL (LH)

A

B27 W4

Y4

C1

15 5b4

T

5B1

dr6

T

T

T

C4

Px2

DR

G

P

5A2

SWING

TRAVEL (RH)

Y9

Y27

P

1 D1

5B2

132 A1

A1

G

5b3

T

T1

A2

Y24

Y23

75 B

5a32 5a31

RAISE

*

132

*139

ck2

4a21 4a22

29 PL

A2

HAMMER

B 4b21 4b22

72 C2

* 75

32

4A2 4B2

15 5a31

5A4

OPTION

C

B1

PP

83 *

5B4

15 a

EE

A1

W2 76 A

IN

Y9

A

5b51 5b52

OPEN

OUT

4a3

* 132

5a5

IN

BUCKET

N2

83 *

F

OUT

39

4b3

15 5a4

A2

4A3 4B3

29 DR

150 MESH

4

G

4a42

D2

DIPPER (1)

IN

4a41

15 5b4

W1

30 PL

D

OUT

4b4

HYDRAULIC RESERVOIR BREATHER BY-PASS VALVE SCREEN FILTER RETURN FILTER MAIN HYDRAULIC PUMP MAIN CONTROL VALVE HYDRAULIC SWIVEL TRAVEL MOTOR SWING MOTOR TRAVEL MOTOR BRAKE RIGHT BOOM CYLINDER LEFT BOOM CYLINDER DIPPER CYLINDER BUCKET CYLINDER BOOM SAFETY VALVE DIPPER SAFETY VALVE DIPPER LOAD HOLDING VALVE BOOM LOAD HOLDING VALVE SECONDARY RELIEF VALVE PLUG OIL COOLER OIL COOLER BY-PASS VALVE ACCUMULATOR BOOM & BUCKET CONTROL LEVER SWING & DIPPER CONTROL LEVER TRAVEL CONTROL PEDAL BOOM & DIPPER CONTROL SHOCK ABSORBER PILOT AND RETURN SYSTEM MANIFOLD FILTER PILOT SYSTEM MANIFOLD CALIBRATED ORIFICE SECOND OPTION CONTROL VALVE CONTROL PEDAL (OPTIONAL) SECOND OPTION CONTROL VALVE SWING PRIORITY BLOCK HAMMER/CRUSHER SELECTOR HAMMER/CRUSHER SELECTOR PILOT CIRCUIT FILTER SHUT-OFF VALVE (OPTIONAL) PILOT FILTER PILOT FILTER BY-PASS VALVE STRAIGHT TRAVEL VALVE SWING PRIORITY VALVE HAMMER/CRUSHER 2 SOLENOID VALVE BANK 5 SOLENOID VALVE BANK 2 SOLENOID VALVE BANK (SECOND OPTION) 2 SOLENOID VALVE BANK (OPTION 1) 2 SOLENOID VALVE BANK (OPTION 1) 1 SOLENOID VALVE BANK SWING PILOT PRESSURE SWITCH BREAKER / CRUSHER PILOT PRESSURE SWITCH UPPER PILOT PRESSURE SENSOR TRAVEL PILOT PRESSURE SENSOR SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH PRESSURE SENSOR (NEGA-CONT. P2) PUMP PRESSURE SENSOR (P1) PUMP PRESSURE SENSOR (NEGA-CONT. P1) PUMP PRESSURE SENSOR (P2) OVERLOAD INDICATOR PRESSURE SWITCH PRESS.SWITCH FILTER INDICATOR (BREAKER OPTION) PILOT PRESSURE SOLENOID VALVE SWING BRAKE SOLENOID VALVE 2 STAGE TRAVEL SOLENOID VALVE POWER-UP SOLENOID VALVE POWER SAVE SOLENOID VALVE MAIN PUMP POWER PROPORTIONAL SOLENOID CRUSHER OPTION TWO FLOW SOLENOID VALVE MAIN PUMP FLOW PROPORTIONAL SOLENOID FREE SWING SOLENOID VALVE OPTION 1 SOLENOID VALVE OPTION 1 SOLENOID VALVE OPTION 2 SOLENOID VALVE OPTION 2 SOLENOID VALVE HAMMER RETURN CIRCUIT SOLENOID VALVE

CX160B - EXCAVATOR HYDRAULIC SCHEMATIC

0.03 MPa 4.35 psi 0.3 bar

*B28

* 83

74

A

58 T5

ON 0.1 MPa

PILOT SYSTEM CIRCUIT COMPONENT BOUNDARY

Pi4

* S71

*

4A5 4B5

C2

P

73

O

A1

*AA

58 T5

58 P5

0.2 MPa 29 psi 2 bar

SUPPLY CIRCUIT

Y25

G

42

LEAK-OFF RETURN P3

T

44

R

DESCRIPTION

1 2 4 5 6 10 15 16 21 22 23 25 26 27 28 29 30 31 32 39 42 44 51 53 54 55 57 58 59 60 65 71 72 73 74 75 76 82 83 85 86 108 109 132 133 134 139 140 141 B22 B23 B26 B27 B28 B40 B42 B43 B44 B45 S71 Y2 Y3 Y4 Y5 Y6 Y7 Y9 Y11 Y18 Y23 Y24 Y25 Y26 Y27

38.2 MPa / 382 bar / 5540 psi

RELIEF ON BOOM HBCV

C BOOM LOWERING PORT SECONDARY RELIEF

O/P PORT SECONDARY RELIEF (2eme OPTION)

B E

*

65

21

B RIGHT

Mu

15 5b52

Pm2

23 LEFT A

B BOOM RAISING PORT SECONDARY RELIEF

C

D1

Pm2

15 4a21

36.3 MPa / 363 bar / 5267 psi

F BUCKET OPEN PORT SECONDARY RELIEF

GB

GA

A MAIN RELIEF (BOOST)

E DIPPER IN PORT SECONDARY RELIEF

(G3)

P2

ITEM

34.3 MPa / 343 bar / 4977 psi

D1 RELIEF ON DIPPER HBCV

B A

B A

C

T

PRESSURE SETTING

DESCRIPTION

A MAIN RELIEF (STANDARD)

B1/B2

B2 G1

Au

27

B45

* 29

Dr

ITEM

K2

K1

*

P

Pm1

Ps

V T E

G

I

Q

K

M

O

1

P

2

4

T

3

1 D2

132 B1 ON 0.5 MPa

85 B22

15 4a1

15 4b1

72.51 psi 5 bar

132 A2

132 T B3

*

a3

OUT

B23/B25

OFF 0.3 MPa 43.51 psi 3 bar

IN

CX160B HYDRAULIC SCHEMATIC Number 87593999A

15 FL

F34

F1

BOX FUSE (ATTACHMENT FOR CAB MAIN HARNESS)

ITEM

F2

FUSIBLE LINK F1 65A

FUSIBLE LINK F2 50A

1 2

1 2

DESCRIPTION

A1. COMPUTER

PG 041

B

WG 558

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Sb 559

P6

A9

L 560 LG 562

AIR CONDITIONER SWITCH PANEL

BG 621

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

(CN.B4)

YW

BG

B 790

LY

TEMP SENSOR (RECYCLE)

YL

2 1

BG Sb

M8

M

1.25B

VY 463 GY 464

M6

GL 861 GW 862 YL 863 YG 864

MOTOR ACT (MODE)

BG 630

5R 002

5WR 003

8R 105

2 1

2 1

0.85Br 423 0.85BW 443

0.85GL 412 YL 472

0.85W 404 0.85G 424 0.85BW 444

0.85W 405 0.85V 425 0.85BW 445

0.85YG 426

LY 807

0.85BW 446

BrY 855 LB 856 VY 463 GY 464 GL 861 GW 862

LR LG

3W

A6

6 4 7 2 3 1 5

M

M5

YG 864

1 2 3

B43

1 2

PRESS. SENSOR (PILOT SWING)

ENGINE CONTROLLER

1.25W 130

1.25WR 521

0.85LgR 520

1

5Y 004

5WR 003

1 0.85L 867

0.85GW 216

0.85VR 866

0.75BY

2 1 0.85VR 918

0.85WR 917

0.85WR 917

0.85YL 820

0.75BY 0.75RL

WATER TEMP.SENSOR t

t

0.75RW 368

FUEL LEVEL SENSOR

t

YG 864

1 2 3

GY 464

B22

LW 265

PRESS. SENSOR (PILOT UPPER) 1 2 3

YG 864

2 1

0.75RW 0.75RB 0.75G

OP-COM1

OS-INJECTION1

OS-INJECTION2

OS-INJECTION4

OS-INJECTION3

OP-COM2

OP-SC VALVE HI

IA-SC VALVE LO

OP-SC VALVE HI

M8

FLOOR

M8

PLATFORM

H1. AUDIBLE WARNING DEVICE H2. TRAVEL ALARM K2. RELAY-GLOW PLUG

B1

K5. RELAY-ROTARY LIGHT K6. RELAY-AIR CONDITIONER CONDENSER FAN

BG 656 GY 483

GY 483

1 2

0.75W 0.75W

PRESS. SENSOR (PILOT TRAVEL) 1 2 3

BG 657 GY 484

1 2

0.75W 0.75W

2 1

OPTION

0.75R 0.75B

2 SPEED

1 2 3 4 5 6 7 8 9 10 11 12

1.25W 350

0.75G 354

Y27

Y9

K33. MAIN RELAY K34. RELAY STARTER CUT K36. RELAY SPEAKER LEFT

Y35

K37. RELAY SPEAKER RIGHT K38. RELAY HORN LEFT M1. STARTER MOTOR M3. WIPER MOTOR

CYLINDER #1

M4. WASHER MOTOR M5. MOTOR (AIR CHANGING) M6. AIR VENT DIRECTION CONTROL MOTOR

CYLINDER #2

2W

2L 2G 2P 2Y

M8. BLOWER MOTOR

1 2

2R

INJECTOR_1 INJECTOR_4 INJECTOR_2 INJECTOR_3

M14. FUEL FEED PUMP MOTOR M15. EXHAUST GAS RECIRCULATION MOTOR M20. ELECTRIC FUEL PUMP

CYLINDER #3 1 2

P1. INSTRUMENT PANEL P2. SWITCH PANEL (LEFT-HAND) P3. SWITCH PANEL (RIGHT-HAND) P4. MONITOR DISPLAY

CYLINDER #4 1 2

P5. HOURMETER P6. AIR CONDITIONER CONTROL PANEL P9. CLOCK P10. SWITCH PANEL R1. GLOW PLUG

2 1

OPT.1

0.75R 0.75B

KNOB(R)-R (RED TAPE)

2 1

0.75B

AIR INTAKE TEMP.SENSOR 2 1

0.75OL 311 0.85G 321

R4. THERMISTOR INNER TEMPERATURE R5. FUEL LEVEL SENSOR M12

t°C

S1. KEY SWITCH S2. TRAVEL MODE SWITCH

B6

S4. AUTO IDLE SWITCH S9. ENGINE EMERGENCY STOP SWITCH

OPT.1

0.75R

Y23

60B 798

R3. THROTTLE VOLUME

KNOB(R)-L (BLUE TAPE)

Y24

S10. WORKING LIGHT SWITCH

LEGEND

S11. WIPER SWITCH S12. WASHER SWITCH

2 1

NOT CONNECTED

0.75B

2 1

KNOB(L)-R (RED TAPE)

0.75B

Y25

S16. IDLE SWITCH

CABLE GROUND

BOOT GROUND

S22. FREE SWING SWITCH S28. TRAVEL ALARM SWITCH S31. OPTION 1 SOLENOID VALVE SWITCH

OPT.2

0.75R

S14. BREAKER / CRUSHER SWITCH S15. HORN SWITCH

OPT.2

0.75R

KNOB(L)-L (BLUE TAPE)

Y26

HARNESS

SINGLE WIRE CONNECTOR

S32. OPTION 1 SOLENOID VALVE SWITCH S33. OPTION 2 SOLENOID VALVE SWITCH S34. OPTION 2 SOLENOID VALVE SWITCH

CONNECTOR (FEMALE)

B30

BLADE PILOT PRESS.

S35. CRUSHER OPTION TWO FLOW SOLENOID VALVE SWITCH S51. HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH S53. DOOR LIMIT SWITCH S54. FRONT WINDOW LIMIT SWITCH

B31

BLADE PILOT PRESS.

B27 OPTION LINE CIRCUIT <PEDAL TYPE>

LW 260 LY 807

LW 261 BrY 855

BG 630

BG 630

VY 463

VY 463

GY 483

GY 483

BG 657

S52

MAGNET CLUTCH (COMPRESSOR)

B3

K35. RELAY ROOM LAMP

M4

1 2

2B 700

0.75R 0.75B

2 1

0.75R

OPTION 2SPEED

CN12 (R)

Y27

Y9

U1. DC-DC (24V-12V) CONVERTER

CONNECTOR NUMBER (IN CAB) CONNECTOR LETTER LOCATED (OUTSIDE CAB)

0.75W 0.75W

0.75W 0.75W

COLOR OF CONNECTOR (IF NOT INDICATED COLOR IS WHITE)

B23

0.75W

BREAKER/CRUSHER PILOT PRESS.

0.75W

B28

0.75W

B30 B31

X5. CONTROLLER TEST POINT CONNECTOR

CIRCUIT NUMBER

COLOR

BLADE PILOT PRESS. BLADE PILOT PRESS.

M8 (CN.G1)

Y8

X6. CAB SEAT COMPRESSOR MOTOR CONNECTOR X8. RADIO CONNECTOR

TABLE OF COLOR SYMBOLS

2ND-OPTION LINE PILOT PRESS.

X2. ROTARY LIGHT CONNECTOR X4. ENGINE TEST POINT CONNECTOR

SYMBOL 2 1

W1. ANTENNA X3. OPTIONAL POWER CONNECTOR

AREA 0.75W

S69. RADIO MUTE SWITCH S71. PRESSURE SWITCH FILTER INDICATOR

60 B 001 2 1

S64. COOLING HYDRAULIC MOTOR SWITCH S70. HORN VOLUME SWITCH

CRUSHER

0.75B

S62. AIR CLEANER SENSOR

INDICATES POWER WHEN KEY SWITCH IS ON

BREAKER

2BG 600

GY 484

1 2

2 1

S55. RESERVE TANK LOW SWITCH S61. REFUEL PUMP SWITCH

INDICATES CONSTANT POWER

1

DUAL SWITCH (RECIVER DRYER)

1.25G

CRUSHER

K17. BLOWER OFF RELAY K31. REFUEL PUMP STOP RELAY

INSULATION AGAINST MAGNETISM

2 1

1

0.75B

K11. RELAY-WORKING LIGHT (CAB)

M7. MOTOR ACT (AIR-MIX)

HYD.OIL TEMP SENSOR

0.75R

B51

K30. REFUEL PUMP RELAY

OVER HEAT SW. (CN.A24)

BREAKER

K8. RELAY SAFETY K10. RELAY-WORKING LIGHT (UPPERSTRUCTURE / ATTACHMENT)

S52. AIR CONDITIONING COMPRESSOR CLUTCH SWITCH

B26

1.25B 770 0.85BG 670

1.25W 350

0.75Y 353

0.75L 352

0.75P 355

0.75G 354

1.25R 351

0.75RW 369

0.75RW 368

0.75RG 367

0.75RG 366 IA-SC VALVE LO

IS-EGR PSTN2 V

IS-EGR PSTN3 W

IS-EGR PSTN1 U

OM-EGR MOTOR3 W

5B 796

G2. ALTERNATOR

K39. RELAY HORN RIGHT 0.75R

CONNECTOR (MALE)

GY 464

1.25W 981 0.75GR 365

0.75GW 364

0.75GB 363

0.75WL 362

0.75WR 360

0.75RG 316

0.75WB 361 OM-EGR MOTOR2 V

OM-EGR MOTOR1 U

IA-WATER TEMP

IA-EUEL LEAK.TEMP

IA-COMMON.R PRESS

SG-5VRT5

SP-5V5

SG-SLD5

IF-CAM ANGLE

SP-5V

IA-BOOST PRESS

SG-5VRT4(BOOST P)

IF-CRANK-

SP-5V4(BOOST P)

IF-CRANK+

LW 264

BG 631

1.25W 981

B47

S13. OVERLOAD SWITCH

YL 863

LB 856

MOTOR ACT (RECYCLE/FRESH)

F26. FUSE 15A ; LAMP (CAB)

G1. BATTERY

SUCTION CONT.VALVE

0.75YG

CONNECTED

YL 863

LY 807

0.85GW 980 0.75YG 315

0.75G 327

0.75W 307

0.75L 317

0.75L 318

0.75G 359

0.75W 358

0.75BL 687

0.75G 375

0.75L 374

0.75W 373

0.75GW 324

0.75L 314

0.75RW 304

0.75G 372

0.75L 371

0.75R 370

0.75BW 689

(CN.A1)

SG-SLD4

IA-OIL PRESS

SG-5VRT3(OIL P)

SP-5V3(OIL P)

IA-BOOST TEMP

IA-INTAKE TEMP

SG-5VRT2(BARO)

IA-BARO

SP-5V2(BARO)

IA-ACCEL PSTN2

IS-DIAG

IS-MODE MAP0

IS-ENG STOP SW

SP-5V1(ACCEL)

IS-IGKEY(START)

SG-5VRT1(ACCEL)

CC-KW2000

IS-IDLE DOWN SW

IS-MEMORY CLEAR

IS-IDLE UP SW

IS-IGKEY(ON)

IS-IDLE MANU SW

OS-MAIN RELAY

OS-MAIN RELAY

SG-SLD1

CC-CAN-L

CC-CAN-H

OS-OIL P. LAMP

OS-GLOW LAMP

OS-STARTER RELAY

OS-GLOW RELAY

OF-TACHO

OS-BOOST LAMP

OS-DIAG LAMP

PS-+B

PS-+B

PG-CASE(GND)

PG-SIGNAL(GND)

0.85BrR 916

GW 862

GY 464

3WG

IA-COMMON.R PRESS

A2

PG-SIGNAL(GND)

(CN.B6)

PG-POWER(GND)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

PG-POWER(GND)

PG-POWER(GND)

(CN.A0)

LW 263

(CN.172)

(CN.173)

BG 630

108 85 107 106 95 91 109 99 98 86 100 87 101 90 82 88 96 83 84 111 103 110 94 93 92 102 104 112 89 97 105 113 114 115 116 117 118 119 120 121

0.75BY 323

0.75Y 313

0.75WB 303

0.75GR 312

0.75OL 311

0.85G 320

0.85YL 310

0.85W 300

PB 082

0.85LG 340

0.85GrR 337

PL 080

0.85BrY 084

0.85LR 336

0.85YR 333

0.85YR 332

PG 043

P 042

0.85BrR 339

1.25WR 331

1.25WR 330

0.85BG 672

0.85BG 671

0.85BG 670

82 83 84 85 86 87 88 89 114 115 116

1.25B 772

81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63

1.25B 771

2

90 91 92 93 94 95 96 97

9 12 13 15 16 19 22 23 25 26 27 28 33 34 35 36 39 44 45 48 53 54 55 56 57 58 59 65 66 68 69 70 73 75 76 77 78 1 3 4 43 62 81 2 5 6 7 8 10 11 14 17 18 37 20 21 40 24 29 30 31 32 38 41 42 46 47 49 50 51 52 63 64 61 71 60 72 74 80 67 79

1

117118

62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44

3 1 2 5 4

VY 463

LW 260

106 107 108 109 110 111 112 113 119 120 121 98 99 100 101 102 103 104 105

0.85L 868

LB 856

2 1 3

0.85G 321

1.25B 770

3

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

0.85L 867

GW 862

2 1

1 2

5

GL 858

GL 861

(CN.124)

YL 863

LW 262

GL 861

(BLUE TAPE)

LW 260

LB 856

B43

GW859

LB 857

1 2 3

0.85GW 980

PL 080

4

1.25LR 915

2 1

1 2

2 1

BrY855

BG 656

(CN.A1)

1

1.25Br 016

0.85B 758

LW 261

GY 465

0.85Gr 428 0.85BrW 411

BG 690

(CN.A0)

1.25LR 104

1.25R 102

B

60B 799

2B 700

1.25GW 215

0.85VR 866

(CN.172)

(CN.173)

BrY 855

BLOWER AMP 3 2 1

0.85W 403

0.85BW 448

YW

LB 856

M

B44

PRESS. SENSOR (N2)

0.85BW 440

0.85W 408

Y

6 4 7 2 3 1 5

F25. FUSE 10A ; LEVER LOCK (GATE)

F40. FUSE 10A ; FUEL FEED PUMP

2 1

0.85YG 426

0.85Gr 428

YR

LW

BrY

LG

BrY 855

LY 807

YL 466

0.85V 425

0.85W 406

LY 807

LW 260

LY 807

GY 464

0.85G 424

1 2 3 4 5 6 7 8 9 10 11 12

LW 260

LW 260

2 1

0.85Br 423

M7

MOTOR ACT (AIR MIX)

K17

1 2

1.25RL

L

B

R4

BLOWER MOTOR

1.25RL

Sb

GL

1 2

B

1.25LR

WG

LY

M

0.85BW 442

(CN.B5)

GW

YR

W

1 2 3 4 5 6

0.75YG 315

0.75Y 353

2 1 3

1.25LR

G

M14

0.75P 355

2B 700 2BG 600

0.85V 809

0.85LR 489

0.85GW 228

1 2 3 4 5 6 7 8 9 10 0.85BG 613

0.85BG 612

0.85WG 488

1 2 3 4 5 6 7 8 9 10 EVA-SENSOR

G

6 4 7 2 3 1 5

B2

BrY855

(CN.B7)

VW

GW

Y

PRESS.SW (FILTER INDICATOR)

OPTION LINE CIRCUIT <KNOB SWITCH TYPE>

YG 467

0.85Lg 422

E52

1 2 3 4 5 6 7 8 9 10 11 12

GR

GL

3 1 2 5 4

(CN.126)

1 2 3 4 5 6 7 8 9 10 V

YL

0.85B 759

0.85BW 706

0.85WR 281

0.85RY 280

1 2 3 4 5 6 7 8

VY 809 0.85BrR 009

0.85WR 290

0.85LgR 530

0.85RW 120

BL 973

BY 971

0.85B 710

R 152

4 2 5 3 6 1

(CN.45) (CN.46) (CN.47)

G

B

Gr

GND R(-) L(-)

BACK UP OW

GR LR 975

0.85B 710

0.85RG 126

S51

0.85B

B21

F34. FUSE BOX

1 2

0.75L 352

0.85GW 980

C

PB 082

(CN.28)

LY

1.25B

W 557

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 4 3

WG

POWER(ILLUMI)

CCU POWER(IGN)

SIG.WATER TEMP.

WINDOW-OPEN SW. IN

DOOR-OPEN SW.IN

SUNLOAD SENSOR1

SUNLOAD SENSOR2

CCU GND

SENSOR GND

G 555

0.85BG 692

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

(CN.B3)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

GL 910

VW 858

GW 227

GW 226

YR 909

LY 830

LR 908

G 851

LR 907

LgW 176

LgW 175

YW 970

LG 831

YR 974

WR 292

LW 972

LG 832

R(+) L(+)

ACC R

GrR YR 974

0.85WR 291

1 2 3 4 5 6 7 8 9 2 1 6 5 4 3

(CN.8)

0.85B

B5 L

W

0.85VR 195

0.85Y 904

OL 822

VG 478

VY 480

WL 564

WY 563

0.85B 721

BG 620

LG 562 R/F M.ACT.LIMITER

EVA SENSOR

TEMP SENSOR(FRESH)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 TEMP SENSOR(REC)

SHUNT RESISTOR(+)

KEY ON SIG

SHUNT RESISTOR(-)

CCU POWER(IGN)

AIR-MIX M.ACT. LIMITER

MODE M.ACT. LIMITER

MODE_POTENTIO (SIG)

L 560

Sb 559

WG 558

W 557

0.85LgR 532

BrW 556

G 555

Y 554

GL 553

YL 552

LB 550

BL 549

VW 548

LW 546

LR 545

YW 544

YR 543

GW 542

GR 541

LY 540

BrY 551 BLOWER GATE

AIR-MIX_POTENTIO (SIG)

GL 553

K6

BLOWER-OFF RL.

B

2BG 600

0.85RW 121

3 1 2 5 4

3 1 2 5 4

3 1 2 5 4

3 1 2 5 4

3 1 2 5 4 LR 975

WR 293

WR 290

R 154

YL 829

0.85B

0.85LG 340

0.85RG 126

BG 620

1.25B 720

0.85LR 205

1.25WR 200

0.85GW 980

1 2 3 4 5 6 7 8 9

L 852

VY 480

WL 564

VG 478 VG 478

YL 472

0.85Lg 422

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

0.85RG 126

(CN.21)

VW 817 YG 864

0.85RG 126

0.85BG 620 0.85BG 620

1.25B 720

0.85LR 205

1.25WR 200

0.85GW 980

1.25Y 904

OL 822

1 2 3 4 5 6 7 8 9 10

4 5 6 7 2 3 1

PA 1.25B 720

1.25WR 200

0.85LR 205

0.85GW 980

0.85VR 195

1.25Y 904

OL 822

LB 856

BrY 855 BrY 855

LB 856 VY 480

2ND.ACT S/V(L)

LIMIT SWITCH (GATE)

GR

BG

RL

LW

1 2 3

WR 824

1.25GR 903

1.25GrR 186

1.25GrR 185

1.25Y 904

0.85Y 905

WR 823

1.25Y 900

1.25LW 181

1.25LW 180

0.85GrR 010

BG 609

LR 854

0.85BrR 009

LR 854

WV 842

3L 021

0.85BrR 339

3WR 020

0.85LgR 336

1.25WR 521

0.85BG 608

1.25WR 330

3 1 2 5 4 R 153

LR 906

YG

(CN.1)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

1.25B

1.25GR

YG

BG

VG VG

BG

WY 563

LgW 177

(CN.63)

LW

LG

BrY

Y

GW

WL 564

0.85GL 412

S34

9

7 8 11 12

6

4 21 22 1 10

0.85Gr 428 0.85BrW 411

F21. FUSE 10A ; TRAVEL ALARM

F24. FUSE 15A ; SPARE

FUEL TEMP.SENSOR

1.25R 351

B42

1 2 3

t

2 1

(CN.178)

DIAGNOSTIC CONNECTOR

YL 552

Y 554

A

BrY

LR

Y11

1 2

(CN.51)

BL 549

0.85BrY 084

120ohm

0.85LG 340

LG 528

2ND.ACT S/V(R)

F20. FUSE 10A ; DC /DC CONVERTER

F23. FUSE 10A ; FUEL SUPPLY PUMP

BOOST PRESS.SENSOR

1 2

(CN.177)

BrY 084

2

LW 546

0.75BR

M

1 2

PB 082

S33

0.85L 421

1

0.85BrY 084

BG 694

LR 545

0.75RB

1 2

1 2

PL 080

10

YW 544

0.75Y

(CN.165)

PB 082

PG 051

YR 543

0.85GL 412

R5

0.75B

(CN.164)

PG 043

0.85VG 427 0.85BW 440

0.85W 402

(CN.D13)

PL 080

5

GW 542

2 1

0.85BG 660

(BLUE TAPE)

0.85Y 420

1 2

P 042

RADIO MUTE

0.85YG 426

B49

BOOST TEMP.SENSOR

0.75RG 366

PRESS. SENSOR (N1)

(CN.D12)

P 042

0.85G 424

(CN.D10)

PG 043

S69

1 2 3 4 5 6 7

0.85LG 340

0.85Br 423

HORN

1 2 3

0.85W 400

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

0.85GW 980

1 2

0.85G 320

0.85L 421 0.85BW 441

0.85V 425

1 2

VW 170

(CN.D6)

P 050

GR 541

0.75RL

1 2 3

1 2

9

BLOWER FEED-BACK

8

POTENTIO (GND)

6

BY 069

BLOWER-OFF RELAY

YR 067

R/F M.ACT.(FRESH)

3

R/F M.ACT.(RECYCLE)

J

MODE M.ACT.OUT1

1

MODE M.ACT.OUT2

Y 065 YL 066

AIR-MIX M.ACT.OUT1

H

AIR-MIX M.ACT.OUT2

11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

4

BW 064

0.85LgR

BrW

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

0.75L

1 2 3

1 2

WR 062

G

R BrW

1 2

0.85G 320

B 723

1 2 4 3

0.85BrR

1.25WR LY 540

10A

1.25B

S71

1.25R

(CN.163)

F

0.85BrR

(CN.D3)

0.85LG 340

B 724 YG 864

1 2 3

0.85YL 310

12

POTENTIO (5V)

WL 061

(CN.53)

PL 081

6 5 4 3 2 1 7 8 9 10 11 12

E

7

EST CONNECTOR B

W 060

Y7

1.25B

(CN.162)

EST CONNECTOR A

PG 047

FLOW

0.85W 401

COMPRESSOR RL.

(CN.D4)

0.85YL 310

YL 863

1 2 3 4

1 3 2

BG 622

1.25WR

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

0.85W 300

10 3 2 1 8

1.25B

IA-ACCEL PSTN1

P 042

D

LB 550

2 1

0.85BG 663

PRESS. SENSOR (P2)

0.85L 421

S15

L L Y Y G G O O

0.85OR 850

(CN.27)

0.85W 300

10 3 2 1 8

0.85Y 420

(CN.D9)

(CN.52)

P 046

BrY 551

(F40)

E1

PUMP 0.85BL 943

1.25R

1 2

C

A B C

0.85BrR 339

6 7 4 5 3 8 1 2

(CN.31)

VW

1 2 3

0.75RW

24V

1 2 3

R 151

(CN.50)

0.85BrR 339

9 6 5 4 7

V

1.25B 757

PUMP

(CN.122)

B

(CN.29)

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14

S9

ENG.STOP

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

0.85LgR

POWER

1 2

0.85LR 942

0.85W 400

1 2 3 4 5 6 7

A

P 040

X4 0.85YR 332

0.85GW 980

BG 693

0.85BG 691

X23

0.85BY 941

2 1

1.25LR 915

(CN.178)

PG 043

PG 049

PUMP

1 2 3

P 048

BY 069

1 3 2

1.25GW 215

24V 70W

1.25RB

1 2

0.85YR 940

(CN.42)

KNOB (LEFT) (4 SWITCH)

P2

(CN.D8)

YR 067

0.75BY

REFUEL PUMP

1 2

0.85LR 205

E2

(CN.177)

YL 066

MEMORY CLEAR 1 2 3

1.25B 741

1.25RG

(CN.120)

1.25WR 200

PB 083

X24

S22

1 2 3 4 5 6 7

Y 065

10 1 2 6 9 3 4 5 7 8

1 2

1.25L 901

P 040

DIAG.SW

B48

(CN.40)

AIR CONDITIONER UNIT 1.25B 720

0.85W

0.85YL 472

0.85Lg 422

B 722

(CN.D2)

BARO SENSOR

9 6 5 4 7

F19. FUSE 15A ; CIGAR. LIGHTER, CAB SEAT

OIL PRESS.SENSOR

LAMP (HOUSE)

0.85BW 440

1 2

C

10 3 2 1 8

9 6 5 4 7

S28

(CN.D5)

B

TO BACK MONITOR

1 2 3 4

J

D

0.85BL 943

24V 70W

0.85R

1.25B 757

0.85Y 420

(CN.D1)

E

0.85LR 942

1.25B 740

YL 820

FREE SWING

B 722

BrW 556

A

0.85BY 941

1 2

1.25Y 900

0.85W 400

BG 622

VW 548

G

0.85YR 940

1 2

0.85BW 451

TRAVEL ALARM

BG 690

(CN.49F)

H

0.85VW 858

L 852

0.85VR 547

F

0.85B 715

0.85BW 706

1 2 3 4 5 6 7 8 9 10

0.85VG 481

BY 069

0.85WR 281

B 790

PG 041

1.25B 740

PRESS. SENSOR (P1)

5 4 3 2 1 10 9 8 7 6 22 21 20 19 18 17 16 15 14 13 12 11

(CN.26)

YR 067

0.85RY 280

(CN.6)

IS-MODE MAP1

PG 041

VCC OUT(PULSE) GND

F22. FUSE 15A ; SPARE

0.75LY

AUTO STOP ALARM

0.85BrW 411

G 851

IS-MODE MAP2

P 040

1.25Y 900

1.25L 901

LAMP (BOOM)

0.85LR 489 0.85V 809

F18. FUSE 10A ; CLOCK, BACK MONITOR

0.75WB

B

0.85B 759

1 2

0.85BG 635

1.25B

0.75B

R

0.85BrR 916

(CN.169)

1.25BG 634

BW 064

1.25Y 900

1 2 3

0.85B 737

WR 062

3 19 5

BW 064

20 14

WR 062

PG 045

18 17 13

P 044

WL 061

VR

16

WL 061

W 060

VG

2 15

YR 067

0.85BrY 084

FREE SWING SOLENOID

1 2

W 060

0.85YG

SWING

B82

1 3 2

0.5WB

F16. FUSE 15A ; LAMP (BOOM, HOUSE)

K7. RELAY BATTERY

(CN.119)

YL 066

0.85LR

PB 082

(CN.5)

BrY 084

0.85LW

PL 080

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

P 040

PG 041

Y 065

R 151

Y18

(CN.168)

PB 082

X5

0.85YR 332

0.85BY

PW

0.75B

0.5GrB

F15. FUSE 10A ; HORN F17. FUSE 20A ; FUEL FILLER PUMP

CRANK ANGLE SENSOR

0.85WG 488

1 2

(CN.9)

PL

X6

0.75R

1 2

VW 0.85Y

24V

AIR SUSPENSION (KAB SEAT)

VY 806

FREE

(CN.167)

YL

M

1.25B

0.85PW 230

1 2

GR 257

1 2 3

PL 080

BY 069

IMMOBILIZER

0.85GrR 337

WY

YR

1.25R

1 2

GR 257 VY 806

(CN.4)

0.85LgR 533

0.75GW 324

2 3

0.75GR 312

0.85BrG 803

(CN.118)

YG 492

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

YL 066

0.85GrR 337

WL

1 2

SAVE (GREEN TAPE)

(CN.131)

0.85GW 228

(CN.30)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

0.85BrY

0.85B 710

0.75B

Y6

1 2

0.85BrR

0.75L 314

1

(CN.166)

BL

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

0.85BL 943

POWER

0.75R

1 2 3

VW

S32

0.85LR 942

1ST.ACT S/V (L)

0.85BrG 803

0.85YG 802

(CN.117)

PG

0.85BY 941

O

0.75RW 304

1 2

P

1.25RB 145

0.75BY 323

(CN.175)

(CN.A7)

GL

0.85LG R 151

WL 564

GW

VW 817 LG 491

WY 563

VR

0.85LY

Y 065

0.85LgR 336

WL

0.85BrW 236

TO CONTROLLER B

1.25WR 330

VG

LB 856

BG 636

0.75Y 313

0.5VW

1 2

WY

BrY 476

0.75WB 303

1 4 2 5 3

(CN.163)

LG

0.85YG

BrY 855

0.85Y 905

0.75BW 688

1 2

1 2 3

1.25W 140

0.85LR

VG 478

1 2 3 4 5 6

R 158 LgR 161

0.85YR 940

0.85LG 801

(CN.116)

L-G

0.85LW

VY 480

1.25R 146

1ST.ACT S/V (R)

O

(CN.33)

VCC WP HOLD VSS

BrY

L 852

1.25R 146

S31

G

0.85B 711

1 2 3 4 5 6 7 8

9 1 2 10 12 6 14 8 16 5 7 15 4 13 3 11

5V

SERIAL EEPROM 32kbit(4k X 8)

BG

VG

A-G SCK CS SI SO

1 2 3 4 5 6 7 8 9 10 VY

1.25RB 145

YL 075

0.85BW 706

0.75G 372

0.75BW

B50

1 2

SW_IN13

L

YR 074

0.85WR 281

0.75L 371

0.5OB

(CN.A23)

SW_IN12

0.85LG

1.25YR 147

U1

0.85RY 280

S61

(CN.A3)

PROGRAM SELECT

YL

GL 071

VY 809

K31

1 2 3 4 5 6 7 8 9 10 11 12

SW_IN11

YR

0.85LY

BW 078

LR 489

K30

0.75R 370

1 2

SW FAN REVERSE

YL 472

GW 070

WG 488

0.85BW 706

RELAY R13 AUTO STOP (CN.159)

(CN.162)

SW_IN10

WG 488

PW 077

WY 563

SW FILTER IND

PL 076

BL 073

DC/DC(24V/12V) CONVERTER

L 089

1.25RB 145

SW HBCV/TRVL ALM

SW_IN9

GL

0.85BY

PW 077

W 088

0.85WR 281

2 15 16 18 17 13 20 14 3 19 5 4 21 22 1 10 6 7 8 11 12 9

SW_IN8

LR 489

GW

0.85Y

YL 075

SHUT OFF

1.25RB 145

SW FREE SWING

BL

YR 074

PL 076

GND

G

0.85YR 211

2 15 16 18 17 13 20 14 3 19 5 4 21 22 1 10 6 7 8 11 12 9

SW_IN7

GY 464

PW

PG 049

12V OUT (MAIN)

L 089

(CN.54)

P-SW 2OPT/BRADE

VY 463

BL 073

1 2 3 4 5 6 7 8 9 10 11 12 13 14

SW_IN6

LW 471

PL

P 048

W 088

(CN.2)

P-SW OPT/ELV

PG

0.85BrY

GR 072

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A/D

SW AIR CLEANER

SW_IN5

0.85BW 440

BW 078

2 3 4 5 8 9 10 11 12 7 1 6 13 14

GW 228

1.25Y 901

BrY 476

RELAY R12 FUEL PUMP (CN.158)

0.5Br

1 2

SW_IN4

0.85BO 450

GL 071

0.85RY 280

1.25Y 900

Y

0.85VW 858

0.75G 375

F14. FUSE 15A ; WINDSHIELD WIPER / WASHER

(CN.A22)

SENSOR_AGND

P

0.85BrR

GW 070

GR 072

BrY 476

Y

0.85YR 211

1 2

0.75L 374

VCC OUT(PULSE) GND

1 3 2

F11. FUSE 15A ; AIR CONDITIONER BLOWER F13. FUSE 10A ; SOLENOID

1 2

POTENTIO_AGND

SW_IN3

BW

0.85LgR 533

B 705

IDLE SW

GW 862

YR 212

FOR BEACON

0.5Y

F10. FUSE 5A ; AIR CONDITIONER HEATER UNIT F12. FUSE 5A ; AIR CONDITIONER COMPRESSOR

CAM ANGLE SENSOR

0.5LW

(CN.A21)

SW_IN2

0.85W 400

GR

12V OUT (BACKUP)

8 3 4 5 6 7 1 2 10 9

VW 858

PW 230

GL 861

B 712

R 157

BrG 803

L

BL 973

BG 610

X2

1 2

AVcc P-SENSOR

0.85LgR

0.85LgR

1.25YR 147

B 713

1 2

1 2 3

SW_IN1

0.85BrR 523

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1.25RB

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

BATTERY CHARGE

LG 528

TO CONTROLLER S

COMPARATOR_IN3

0.85LgR 531

(CN.C6)

ENG_STOP

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12

KEY SW<M>

COMPARATOR_IN2

(CN.C7)

COMPARATOR_IN1

0.85Gr 428

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

OVER LOAD

GND

OR 220

LR 975

(CN.152)

19 5 18 6 4 2 1 3 20 9 10 11 8 16 17 7 15

B52

1 2

POTENTIO_IN10

0.85LY 430

6 2 5 3 1 4 7

24V IN (MAIN) 24V IN (BACKUP)

YG 802

(CN.115)

I/O

THROTTLE VOL.

0.85VG 427

GW 862

1.25B 755

0.75W 373

0.5Br

F9. FUSE 10A ; OPTION LINE

1 2

POTENTIO_IN9

0.85YG 426

BY 971

(CN.151)

MANUAL/AUTO

Y5

RELIEF (YELLOW TAPE)

(CN.130)

1.25GL 910

0.5L

(CN.A20)

ARM P-SENSOR

B 714

0.75B

0.75G 327

12 13 14

1 2

TRAVEL P-SENSOR

POTENTIO_IN8

1.25B

YR 974

2STAGE

0.75R

1 2

POTENTIO_IN7

0.85V 425

BG 610

GL 861

S16

L

1 2

UPPER P-SENSOR

1.25B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

LG 801

KNOB (RIGHT) (4 SWITCH)

(CN.43)

POTENTIO_IN6

0.85G 424

0.85B 710

YL 475

0.75W 307 0.75L 317

1 2

F8. FUSE 30A ; ENGINE PRE-HEATING

1 2

SWING P-SENSOR

1.25RB

0.85YR 211

BG 614

K8

PRESS.SWICH (AIR CLEANER)

F5. FUSE 20A ; COMPUTEUR CONTROL AND INSTRUMENT PANEL F7. FUSE 10A ; MEMORY, CAB LIGHT, RADIO

(CN.A18)

POTENTIO_IN5

0.85Br 423

YG 492

(CN.59)

BrY 476

0.85BO 450

1 2

0.85YG 802

S62

1.25B

F4. FUSE 20A ; MAIN RELAY AND ENGINE STOP F6. FUSE 15A ; CONTROLLER S

1 2

N2 SENSOR

CN.60

LG 491

0.85LY 430

(CN.129) 0.85R 253

1.25Y

Y4

TRAVEL (RED TAPE)

0.75L

B53

(CN.A17)

POTENTIO_IN4

0.85Lg 422

1.25RB

GW 862

BG 610

0.85R 254

0.75B

0.75GY

F2. FUSE 50A ; MAIN FUSE FOR F1 F3. FUSE 15A ; KEY SWITCH AND MAIN FUSE FOR F7

GND U V W VCC

1 2 3

1 2 3 4 5 6

N1 SENSOR

1 2 3 4 12 13 14 15 9 20 7 18 8 6 17 5 16 19 11 22 21 10

0.85L 421

GL 861

0.85Y 410

6 7 4 5 3 8 1 2

0.85LG 801

2STAGE

0.75R

0.75GW

E4. CAB LIGHT

F1. FUSE 65A ; MAIN FUSE FOR F8 TO F26

COMMONRAIL PRESS. SENSOR

(CN.A5)

POTENTIO_IN3

0.85Y 420

BL 973

YL 475

0.85R 253

1 2

0.85R 254

0.85LgR 530 0.85BrR 009

BRAKE (WHITE TAPE)

0.75GB

E2. WORKING LIGHT (ATTACHMENT) E51. CIGARETTE LIGHTER

EGR POSITION SENSOR

5BW

1 2

P2 SENSOR

LR 975

0.85WR 290

0.85R 252

C

0.75RG 316

(CN.34)

P3

0.75B

Y3

0.85R 251 0.85R 252

0.75W 358

0.75BL 686

(CN.134)

P1 SENSOR

POTENTIO_IN2

BY 971

10 3 2 1 8

1 2 3 4 5 6

SWING

0.75R

1 2

POTENTIO_IN1

0.85GL 412

9 6 5 4 7

S1

2 1

B 755

1 2

FUEL LEVEL

0.85BrW 411

CRUSHER

YR 974

R 152

LOCK (BLUE TAPE)

(CN.128)

(CN.144)

SENSOR_IN2

2 15 21 9 22 10 23 12 24 13 25 26 7 20 8 11 1 14 16 3 17 4 18 5 19 6

BREAKER

ST

12V OUTPUT (FOR RADIO)

(CN.44)

HYD.TEMP

10 3 2 1 8

ON

1 2

SENSOR_IN1

9 6 5 4 7

OPT.LINE SELECT

YL 475

1 2

OPT.2 SPEED

0.85LY 430 0.85BO 450

ON (CN.61)

5V(AVcc_O)

S14

S35

DOOR

ACC

0.85GR 250

0.75GW 364

0.75LW

M15

1 2

M8

VY

0.85Y 410

0.85RW 120

0.75B

1 2

0.85VG 800

0.75GB 363

0.75WL

M

E52. AIR CONDITIONER

8 7 6 5 4 3 2 1

0.75WB

E1. WORKING LIGHT (UPPERSTRUCTURE)

(CN.A16)

VY

EEPROM

LED6 (HORN VOL.)

WR 290 0.85LgR 530

OFF

2 1

1 2

LED5 (AUTO-IDLE)

LR

1 2

OFF

1.25B

U V W

0.75WR

B82. REFUEL PUMP STOP ALARM

EGR MOTOR

3

GrW 470

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

0.85BrR 009 LR

ST

VY 806

R 152

24V,10W

8 1 2 3 4 5 6 7

OG 805

0.85RW 120

ROOM LAMP

ST

1

5B

0.75G 359

0.75GR 365

1 2

LED4 (TRA.MODE)

E4

M

1.25WG

S R E

1 2 3

LED3 (WOR.LAMP)

0.85VG 481

0.85YR

ACC

2

GL 910

Y2

(CN.155)

YL 475

DOOR OPEN-GND

LEVER

1 2

LED2 (WIPER CNT)

E51

0.85B

LED1 (WIPER INT) 0.85Y 410

CIGAR LIGHTER 24V,5A

1.25BG

YG 864

20

G2

HEAT

(CN.36)

L 852

12

GND

G1

0.85BrR 523

0.85LW 471

0.75R

1 2

PG 041

GND(RS232C)

BG

3 4 1 2 5 6 7 8 9

B

ON

1.25BW

M8

1 2

0.85R 251

JOINT CONNECTOR

B 3

B81. HORN

(CN.A15)

P 040

11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

BW 064

RxD(RS232C)

BG

1 2 3

Y VY

HEAT

ACC

RELAY SAFETY

0.85GrR 010

0.85BG 661

0.85OR 850

0.75WL 362

1.25B 750

0.85B 760

(CN.134)

S11 (WIPER) S12 (WASHER) S10 (W.LAMP) S2 (TRA.MODE) S4 (AUTO-IDLE) S70 (HORN VOL.)

10

VY

BG

WL 061

TxD(RS232C)

Y

WL

CONNECTION

OFF

M20

B61. SUNLOAD SENSOR

GLOW PLUG

1 2 3

P10

W 060

VW

3 2 4 1

YL 863

Y

5

WY

YG 864

15

IN5(UPDATE_SW)

SWITCH PANEL

2 1

YL 863

IN4(SW:2SPEED)

PW 055 PL 056

B61

G 851

GW

0.85B

S53

G 851

17

LIMIT SW. (DOOR)

YL 863

IN3(SW:CRUSHER)

0.85YR

(CN.35)

G 851

LW

X8

3 2 1

0.85WR 282

16

LR 906

(CN.22)

IN2(SW:BREAKER)

SUNLOAD SENSOR

0.85B 754

8 7 6 5 4 3 2 1

0.75WR 360 0.75WB 361

24V

(CN.127)

RADIO AM/FM STEREO

R3

0.85YR 210

0.85OR 850

YG

LG 831

0.85OR 850

6

THROTTLE VOL.

0.85OR 850

IN1(SW:WINDOW)

YL 829

BG

WL

ANTENNA

W1

LgR 160

0.85BW 707

LR

1.25R 155

12V

0.85B 779

M

2B

1 2

0.85PW 231

KEY SWITCH

L

WY

0.85BG 633

0.85B 760

1.25W 135

0.85LG 340

19

BG

290,975,974,858

WR 823

VW 170

OUT1(WIPER_INT)

GND

LY 830

VW 170

YR

G 851

0.85LG 340

GrR

18

PW 055

VW 170

3

OUT2(WIPER_CNT)

OUT3(WASHER)

LCD DISPLAY

L

0.85B 753

2BY

5BW

R1

G1

GL 910

906,829,972 831,970,830

PL 056

12V

M8

YL 820

153,175,226

0.85BO 450

IN2(MUTE SW.)

LR

0.85BG 615

3 2 1

G

Y

GrW 470

1 2

0.85LW 471

0.85BrR 190

0.85L

14

0.85YR

WV 841

0.85Y

ILLUMI-OUT

CPU

H1

WR 063

Y

LG

G

LW 972

1 2 3

IN1(DOOR SW.)

LG

BL 973

0.85Y 410

WR

G

0.85PW 230

1

3L 021

K7

1

ELEC.FUEL PUMP

YW 970

0.85LY 430

9

LG

BY 971

(CN.7)

OUT4(LAMP)

ILLUMI

YL

0.85BW 707

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

LY

YL

(CN.74)

PW

8

WR 062

L-G

X9

1 2 3

3 6 5 1 4 2 OU2(RADIO MUTE)

13

(CN.C6)

RxD(UART) OUT5(HORN VOL)

YL

(CN.77)

SW_3 COOLANT

OUT1(ROOM LAMP)

GL 910

WV 841

+

B53. EXHAUST GAS RECIRCULATION VALVE POSITION SENSOR

M4 M4

YR 909

1 2

SW_2 ANTI-THEFT

PL

0.85WR 282

LR 907

1 2

SW_1 IDLE

TCLKA

4

LgR

YL 820

W 840

(CN.146)

AVcc THROTTLE

TxD(UART)

LgR

1 2 3 4 5 6 7 8 9 10 11 12

BZ.

BACK-LIGHT(LCD)

LgR

YR 909

GW 225

(CN.133)

+5V_OUT FREQUENCY_IN

IGN

1.25R

LR 907

LW 471

(CN.38)

CAN_L

1.25W

R

K5

GrW 470

1 2 3 4 5 6 7 8

CAN_H

1

2 1 3 4 9 7 8 6 11 10 5 12

R

K39

W 840

1.25GR 903

1 2 3

GND

iGN

2 1 3 4 8 6 7 5

(CN.62)

GND

BACK UP

K38

GW 225

RELAY R10 BEACON (CN.19)

-

M10

B52. COMMON RAIL PRESSURE SENSOR

(CN.A14)

GND

1.25R

K37

RELAY R6 HORN(R) (CN.15)

+

M10

B51. BOOST TEMPERATURE SENSOR

1 2 3

PC/BOOT_RXD

2

K36

RELAY R5 HORN(L) (CN.14)

-

M10

M8

(CN.A2)

PC/BOOT_TXD

T_IN T_OUT R_OUT R_IN V+ VCAN DRIVER VREF VCC TXD CANH RXD CANL RS GND

BATT.

1.25W

K35

RELAY R7 SPEAKER(R) (CN.16)

LIMIT SWITCH (RESERVE TANK)

0.85VG 800

M8

B50. CAMSHAFT POSITION SENSOR

24V 5.0kw

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

MON_RXD

0.85BrW

WR

1 2 3 4

4 12 3 10 2 5 13 6 14 11 1 9 7 15 16 8

MON_TXD

RS232C DRIVER

7

LY

4 5 6 1 2 3 7 8 9 10

0.85BL 943

CLOCK

HOUR

0.85LR 942

1 2 3 4 5 6 7 8

CPU BUILT-IN LCD DRIVE

PW

RELAY R8 SPEAKER(L) (CN.17)

WV 841

(CN.3)

SW_IN13

BACK-LIGHT(LCD)

0.85BY 941

(CN.D11)

SW_IN12

P5

P9

1 2

FWE

0.85YR 940

HOUR METER

G

P1

PL

(CN.C5)

BOOT_CNT

FREQUENCY_GND

0.85LR 336

(CN.76)

1 2 3 4

(CN.65)

1 2

1.25BG 0.85BrW

RELAY R9 ROOM LAMP (CN.18)

VG 800

0.85GR 250

M1

(CN.A13)

CPU_CNT

(CN.57)

1 2 3 4 5 6 7 8 9 10 11 12 13

WV

(CN.78)

SCI

LW

0.85BrR

P4

HCAN

BL

009,120,145,809,841,850,855,856,861,862,863,864,904,980

0.85OR 850

S55

B49. CRANKSHAFT POSITION SENSOR

1 2

S-G

MD2 MD1 MD0 STBY FWE

COUNTER

VW

GR 250

0.85GrR 010

5Y 004

S

B48. AMBIENT AIR (BAROMETRIC) PRESSURE SENSOR

M

(CN.A12)

SHLD GND

5V

1.25WR 330

YW

0.85OR 850

GrW 470

B B

B

1 2 3

PUMP FLOW(RTN)

(CN.49M)

BY

(CN.68)

0.85GrR 010

0.85OR 850

0.85BrR 523

1 2

B47. BOOST PRESSURE SENSOR

(CN.A11)

FAN SPEED(OUT)

PUMP FLOW(OUT)

0.85BG 632

0.85BW

0.85GrR 010

BG 662

B43. PRESSURE SENSOR (NEGA-CONT) B44. PUMP PRESSURE SENSOR (P2) (BLUE BAND)

M10

1 2

PWM_RTN3

3 6 1 4 2 5 8 7 11 12 9 10

FAN SPEED(RTN)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

0.85WR

0.85BrR 523

M10

0.85LgR 520 1.25WR 521

60R 001

60R 101

BATTERY

(CN.150)

PUMP POWER(RTN)

20 10 22 16 17 18 19 6 5 21 11 12 13 14 15 2 1 3 7 8 4 9

0.85BrR 523

0.85BrR 524

0.85BrW 525

1.25WR 521

24V

1 2

PUMP POWER(OUT)

PWM_OUT3

FLOOR

1.25GR

0.85WR

12V

(CN.69)

VR

(CN.75)

MONITOR DISPLAY

PWM_RTN2

RAM (12k Bytes) FLASH ROM (256k Bytes)

X15

M8

CAB

OL 822

PWM_OUT2

HTXD HRXD RS_CNT

0.85BW

1.25B

M8

YL 820

PWM_RTN1

TXD2 RXD2

(CN.64)

1.25W 130

1.25W 135 1.25W 140

GW

PWM_OUT1

TXD0 RXD0

5B

0.85VR 195

AIR-CON

WINDOW OPEN-GND

LW

0.85Y 904

FUEL PUMP

NPN_OUT10

1 5 6 4 2

W 840

BL

0.85VR 195

NPN_OUT9

BrG 803

24V

E3

YW

0.85LgR 532

TRAVEL ALARM

GR

LY 807

BG

1 2 3 4 5 6

ACCESSORY SOCKET

WIPER MOTOR

M

L 24V 70W

0.85LgR 532

NPN_OUT8

1.25B

3

VY 806

1.25B

GR

YG 802

OG 805

1.25GR

VG

OL 822

S/V BREAKER / CRUSHER

M3

LG 801

LW

BY

YG

0.85LgR 532

NPN_OUT7

VG 800

BL

1 2 3

1.25B

S/V FREE SWING

GND

BL LW

1 2

L

GW

YW

523

1.25GR

S/V FAN REVERSE

NPN_OUT6

WIPER MOTOR(CCW)

(CN.58)

NPN_OUT5

WIPER MOTOR(CW)

SPEAKER(L)

VR

1 3 2 4

BY

1.25WR 521

B42. PUMP PRESSURE SENSOR (P1)

0.5™F

B M6

1 2 3

S/V POWER SAVE

WINDOW LIMIT SW.

0.85B 702

VW

LAMP (CAB-2)

0.85LgR 520

0.85RW 120

B30. DOZER BLADE RAISING PILOT PRESSURE SWITCH (CX130B)

(CN.A10)

NPN_OUT4

STOP SIG.

WV

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

0.85RW 120 0.85LgR 520

M8

LIMIT SW. (F-WINDOW)

337

B28. SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH B31. DOZER BLADE LOWERING PRESSURE PILOT SWITCH (CX130B)

8R 030

2 1

S/V RELIEF

0.85B 701

REV. SIG.

0.85BrR

823,903

60R 100

(CN.139)

NPN_OUT3

1.25BG 602

WASHER CONT.(-) WINDOW CONTROL

GrR

E3

L

M4

1 2

S/V TRAVEL

1.25BG 601

1 2 3 4 5 6

S/V SWING BRAKE

NPN_OUT2

1.25W 133

1.25B

1.25B

1 2

RELAY BATTERY

M4

(CN.137)

I/O

NPN_OUT1

1.25W 132

WASHER CONT.(+)

S54

YW

G2

1 2 3 4 5 6 7 8

A-G

1 2

1 2 3

GND_A

1 2

(CN.106)

L-G

1.25W 131

BY

332,330,336,339

R

1

GND

POWER (24V) IN

R

YR

R 24V 70W

B27. TRAVEL PILOT PRESSURE SENSOR 0.75L

STARTER MOTOR

M

1 2

N-G

WASHER SW. IN

1 2

LR

1.25GR

B 742

1 2

1 2 3 4 5 6 7 8

GND_2

1.25W 130

SPEAKER(R)

11 12 13 1 2 3 9 7 8 4 5 6 10

WIPER SW.IN(INT) WIPER SW.IN(CNT)

020,180,185

0.85LG 340

WIPER CONTROLER

1 2

WV 841

B23. BREAKER / CRUSHER PILOT PRESSURE SWITCH B26. UPPER PILOT PRESSURE SENSOR

20A

WASHER

336

B22. SWING PILOT PRESSURE SWITCH IC

1.25RG 125

(CN.136)

P-G

3L 021

1 2

GND_3

B 743

1 2

1 2

SINGLE CHIP CPU H8S/2626F(20MHz)

1.25W 130

(CN.138)

POWER 24V

1 2

2BG 600

(CN.147)

CONTROLLER A

A1

LAMP (CAB-1)

OPERATOR'S CAB

A4 1 12 11 22 2 13 5 16 9 20 10 21 6 4 7 3 8 14 15 18 17 19

1.25RG 125

2B 700

1.25YR 145

15A

608

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12

POWER 24V

0.85YR 332

126

1.25RG 125

330,332,336,337,339

1 2

6 5 4 3 2 1 12 11 10 9 8 7

520

3L 021

TRAVEL ALARM 24V.107dB

WV 842

20A

B21. ENGINE OIL PRESSURE SWITCH

REGULATOR

FUSE F5 (CONT) (BLUE TAPE)

FUSE F3 (KEY) (NO TAPE)

B6. AIR INTAKE TEMPERATURE SENSOR

24V 50A

M6

M8

1.25Br 016

1.25B 703

1.25GW 215

FUSE F4 (ECM) (RED TAPE)

F5

1.25G 015

1 2

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

055,056,135,151,340,410,430,450,475,488,489,491,492,523,632,634,737,817,821,822

1.25RB 145

GW 225

FUSE F6 (GPS) (YELLOW TAPE)

F3

0.85RW 120

3 1 2 5 4

2 1

1.25BG 600

(CN.B2)

2 3 4 6 7 8 1 5

0.85RB 148

1.25B 700

3 1 2 5 4

LR 880

0.85B 725

6 7 8 2 4 5 3 1

1 2

W 840

H2

15A

(CN.148)

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

(CN.C4)

B81

B 749

1.25W 130

(CN.C3)

8R 106

K11

F4

B5. EVAPORATOR SENSOR

ALTERNATOR

E

8B 797

2 1

K10

8R 105

F6

B3. FUEL TEMPERATURE SENSOR

DIESEL ENGINE

8R 030

HORN HIGH (RIGHT) 24V,415Hz 111dB

YR 909

SUMITOMO MT090 (CN.79)

1 2 3 4 0.85RB 148

0.85BrR 526

RELAY R4 LAMP(CAB) (CN.13)

1 2

130,400,411,412,420,421,422,423,424,425,426,427,428,440,463,464,470,471,472,531$601,701,800,801,802,803,805,806,807,820,840,940,941,942,943

B 747

B2. HYDRAULIC OIL TEMPERATURE SENSOR

5WR 003

1.25R 103

K34

GPS UNIT

0.85LgR 336

0.85LgR 532

0.85LgR 531

0.85LgR 530

R 157

0.85LgR 520

R 153

R 151

R 152

BG 636

1.25R 150

0.85BG 608

1.25BG 634

BG 630

0.85BG 632

BG 610

0.85BG 620

0.85BG 615

0.85B 737

K2

RELAY R3 LAMP(UPPER) (CN.12)

B81

B1. COOLANT TEMPERATURE SENSOR

HORN LOW (LEFT) 24V,370Hz 111dB

1.25RG 125

1 2

K33

1.25B 720

RELAY R11 STARTER CUT (CN.20)

3 1 2 5 4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1 2 3 4

RELAY R2 GLOW (CN.11)

3 1 2 5 4

1.25B 708 0.85B 710

RELAY R1 MAIN (CN.10)

YAZAKI SDL (CN.80)

3 1 2 5 4

1.25BG 600

B 705

(CN.24)

1.25BG 600

1 2 3 4 5 6

1.25B 708

0.85B 701

(CN.25)

1 2 3 4 1.25GR 240

0.85BrW 235

R 158

1.25R 155

1.25R 150

BACK UP

ENGINE PRE-HEAT 3WR 020

LW 260

0.85VR 195

1.25WR 200

OPTION LINE

AIRCON HEATER UNIT

AIRCON BLOWER

AIRCON COMPRESSOR 0.85LR 205

SOLENOID

0.85BrR 190

GR 250

WIPER WASHER

LgW 175

1.25LW 180

HORN

LAMP (BOOM,HOUSE)

FUEL FILLER PUMP 1.25GW 215

CLOCK BACK MONITOR LgR 160

LgR 161

0.85YR 210

0.85YR 211

CIGAR LIGHTER /KAB SEAT

DC/DC CONVERTER OR 220

GW 228

GW 226

TRAVEL ALARM / BEACON GW 225

0.85BrW 236

1.25GR 240

PW 230

0.85BrW 235

SPARE CRANE

ELECT. FUEL PUMP

LAMP (SPARE)

LEVER LOCK (GATE)

X3

1.25B 700

10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11

A9. AIR CONDITIONER CONTROLLER

1 2

VW 170

1 2 3 4 5 6

0.85B 725

JOINT CONNECTOR

1.25BG 601

(CN.23)

LR 907

2 1

130,215,225,230,250,260,400,411,412,420,421,422,423,424,425,426,427,428,440$463,464,470,471,472,520,630,800,801,802,803,805,806,807,820,840,940,941,942,943

1.25R 115

1 2 3 1

(CN.B1)

600,700

(CN.149)

LAMP (CAB)

0.85RW 121

1.25YR 145

(F7) 10A

(F8) 30A

(F9) 10A

0.85RW 121

8R 106

1 2

1.25GrR 185

2 1

8R 106

1.25GW 215

(CN.C2)

A4. WIPER CONTROLLER A6. BLOWER CONTROLLER

8R 106

OPTIONAL POWER

(CN.C1)

1 2

2 1

3R 107

3R 108

(F10) 5A

(F11) 15A

(F12) 5A

(F13) 10A

3R 109

(F14) 15A

(F15)10A

(F16) 15A

3R 110

(F17) 20A

(F18) 10A

(F19) 15A

3R 111

(F20) 10A

(F21) 10A

(F22) 15A

(F23) 10A

(F26) 15A

(F25) 10A

(F24) 15A

3R 112

A2. ENGINE CONTROLLER

COLOR

X9. ANTI-THEFT SYSTEM CONNECTOR X15. ACCESSORY SOCKET X23. CLEAR MEMORY 1

B

BLACK

W

WHITE

Y2. PILOT PRESSURE SOLENOID VALVE (BLUE BAND)

Br

BROWN

Y3. SWING BRAKE SOLENOID VALVE (WHITE BAND)

P

PINK

V

VIOLET

Y6. POWER SAVE SOLENOID VALVE (GREEN BAND)(CX160B)

G

GREEN

Y7. MAIN PUMP POWER PROPORTIONAL SOLENOID

O

ORANGE

Y8. AIR CONDITIONER MAGNET CLUTCH

R

RED

Y

YELLOW

Y18. FREE SWING SOLENOID VALVE

Lg

LIGHT GREEN

Y25. OPTION 2 SOLENOID VALVE (RED BAND)

Sb

SKY BLUE

Y26. OPTION 2 SOLENOID VALVE (BLUE BAND)

L

BLUE

Gr

GRAY

X24. CLEAR MEMORY 2

Y4. 2 STAGE TRAVEL SOLENOID VALVE (RED BAND) Y5. POWER-UP SOLENOID VALVE (YELLOW BAND)

Y9. CRUSHER OPTION TWO FLOW SOLENOID VALVE Y11. MAIN PUMP FLOW PROPORTIONAL SOLENOID

Y27. HAMMER RETURN CIRCUIT SOLENOID VALVE Y35. SUCTION CONTROL VALVE (SCV)

NOTE : 1. "BR" INDICATES BLACK CABLE WITH RED STRIPE. 2. WATERPROOF CONNECTORS USED OUTSIDE OF CAB.

CX160B EXCAVATOR ELECTRICAL SCHEMATIC - 87594014B

CNH AMERICA LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

English Part Number 87673889 B Printed in U.S.A. • Rac © 2009 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America