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SUBJECT ZX200-5G_ZX870-5G-201
ZX200-5G - ZX870-5G NEW CONNECTOR
P/NO. SETTINGS FOR ELECTRICALLY MOUNTED PARTS AND HARNESSES

OUTLINE
As connectors had not been set as individual parts, there were difficulties to obtain a connector
part for a damaged connector for an electrically mounted part and harness. This Service Bulletin is
to inform you that parts numbers have newly been set for connectors that are used frequently for
ZX200 - 5G-ZX870-5G models. When necessary, refer to this Service Bulletin to order a new part.
For details on where to install the connectors, refer to the harness diagram in the service manual.
Refer to the attached instructions.

Thoroughly read the safety section in the service manual before starting the work to ensure safe operation.
Welding work, if any, should only be done by qualified welders.

APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Model(s): ZX200-5G ∼ ZX870-5G

Machine Serial Nos.: ZX200-5G ∼ ZX870-5G

DESCRIPTION
Refer to the following page(s).

DWN
CHKD
SA/GI: ZX-5(G)-024 APPD
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CONTENTS

1 Parts list (No. 46 - No. 55) …………………………………………………………………… 3

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1 Parts list (No. 46 - No. 55)

ZX200-5G_ZX870-5G-201

No. Part No. Part Name Location of Use Q’ty

46 YA00014091 Z02F-GY 3
Z03F-GY 3
Z04F-GY 2
Z06F-GY 1
Z08F-GY 1
Z02M-GY 3
Z03M-GY 3
Z04M-GY 2
Z06M-GY 1
・Main harness
Z08M-GY ・Control valve harness 1
Z F-Terminal ・Pump harness 37
Z M-Terminal ・Lock solenoid valve harness 37
Z Wire Seal ・Attachment sensor harness 74
Z02F-Retainer ・Auto lubrication harness 3
・Oil cooler harness
Z03F-Retainer 3
Z04F-Retainer 2
Z06F-Retainer 1
Z08F-Retainer 1
Z02M-Retainer 3
Z03M-Retainer 3
Z04M-Retainer 2
Z06M-Retainer 1
Z08M-Retainer 1
47 4674050 DL (Small)20F 1
DL (Small)20M ・Control valve harness 1
・Engine harness
DL (Small)F-Terminal ・Pump harness 20
DL (Small)M-Terminal 20
48 4621803 ISO RELAY Connector 5
ISO RELAY F-Terminal (Big) ・Cab harness ISO relay connector 10
ISO RELAY F-Terminal (Small) 15
49 4621801 UFO (Blue) 02F 10
UFO (Blue) F-Terminal ・Control valve harness 20
UFO (Blue) Wire Seal 30
50 4621797 EJ2-MAKE II 02F ・Main harness 4
EJ2-MAKE II 03F (Atmospheric pressure sensor) 6
EJ2-MAKE II F-Terminla (Engine oil pressure sensor) 26
EJ2-MAKE II Wire Seal (Engine coolant pressure sensor) 26
51 4621793 SWP-02F-GY 5
SWP-14F-GY 1
SWP-16F-GY 1
SWP-02M-GY 5
SWP-14M-GY 1
SWP-16M-GY 1
・Cab harness
SWP F-Terminal 40
SWP M-Terminal 40
SWP Retainer-02 10
SWP Retainer-14 2
SWP Retainer-16 2
SWP Wire Seal 80
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No. Part No. Part Name Location of Use Q’ty

52 4621786 C02F-W 5
C02F-B 1
C03F-W 3
C04F-W 1
C06F-W 1
C06F-B 1
C08F-W 1
C10F-W 1
C12F-W 1
C16F-W 1
C02M-W ・Cab harness 5
C02M-B ・Monitor harness 1
C03M-W 3
C04M-W 1
C06M-W 1
C06M-B 1
C08M-W 1
C10M-W 1
C12M-W 1
C16M-W 1
C F-Terminal 83
C M-Terminal 83
53 YA00014100 CA104 M-Terminal 100
CA104 M-Cover ・Main harness 100
CB104 M-Terminal ・Pump harness 100
CB104 M-Cover 100
54 4621800 RV03FB 3F 10
RV03FB Female Terminal ・Pump harness 30
RV03FB Wire Seal 30
55 YA00014099 FUSE (Mini Blade) 1A 2
FUSE (Mini Blade) 3A 2
FUSE (Mini Blade) 5A 15
FUSE (Mini Blade) 10A 15
FUSE (Mini Blade) 15A ・Main harness 5
FUSE (Mini Blade) 20A 5
FUSE (Mini Blade) 30A 3
FUSE (L-TYPE) 45A 2
FUSE (L-TYPE) 65A 2
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Connector Service Box TYPE-F

1. TYPE-F (for ZX-5)

2. ZX200-5G ∼ ZX870-5G

Accessories
① Storage box
② Service Box manual for TYPE-F

One point advice:

It is a comprehensive box that contains the set of connector, terminal, wire seal, retainer, diode and fuse that are used frequently
for a range of machines from mid-size ZX models to large size ZX models. The connectors are differentiated by colors to prevent
wrong connection and the box comes with an exclusive manual.
Note: 1. Terminal crimping work is your own responsibility. Part No.
2. When you insert, make sure that you hear the “click sound” and you are able to feel that YA00014090
it is properly inserted.
3. After inserting, pull the element wire gently to confirm that it is locked.
4. Extraction tool ZT001-00030
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No.46 Z-GY Connector Series

02F -GY 3 pcs 02M -GY 3 pcs Z02F-Retainer 3 pcs
03F -GY 3 pcs 03M -GY 3 pcs Z03F-Retainer 3 pcs
04F -GY 2 pcs 04M -GY 2 pcs Z04F-Retainer 2 pcs
06F -GY 1 pcs 06M -GY 1 pcs Z06F-Retainer 1 pcs
08F -GY 1 pcs 08M -GY 1 pcs Z08F-Retainer 1 pcs
Z02M-Retainer 3 pcs
Z F-Terminal 37 pcs Z03M-Retainer 3 pcs
Z M-Terminal 37 pcs Z04M-Retainer 2 pcs
Z Wire Seal 74 pcs Z06M-Retainer 1 pcs
Z08M-Retainer 1 pcs

Connect
(Assemble Z06M-GY
that comes with
free pin.)

(Assemble Z04M-GY
that comes with
shield pin.)

・Main harness
・Control valve harness
・Pump Harness
・Lock solenoid valve harness
・Attachment sensor harness
・Auto lubrication harness
・Oil cooler harness

One point advice:

It is a waterproof connector that is used for the ZX model engine relay.
Note: 1. Terminal crimping work is your own responsibility. Part No.
2. When you insert, make sure that you hear the “click sound” and you are able to YA00014091
feel that it is properly inserted.
3. After inserting, pull the element wire gently to confirm that it is locked.
4. Extraction tool ZT001-00030
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No.47 SUMITOMO 20P Connector

DL (Small) 20F 1 pcs
DL (Small) 20M 1 pcs
DL (Small) F-Terminal 20 pcs
DL (Small) M-Terminal 20 pcs

SUMITOMO SUMITOMO
・Control valve harness
・Engine harness
・Pump harness

One point advice:

It is a small waterproof connector (0.5sq - 0.85sq) that is used for the ZX model main body relay.
Note: 1. Terminal crimping work is your own responsibility. Part No.
2. When you insert, make sure that you hear the “click sound” and you are able to 4674050
feel that it is properly inserted.
3. After inserting, pull the element wire gently to confirm that it is locked.
4. Extraction tool ZT001-00030
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No.48 ISO RELAY Cnnector

ISO RELAY Connector 5 pcs

ISO RELAY F-Terminal (Big) 10 pcs
ISO RELAY F-Terminal (Small) 15 pcs

Cab harness ISO relay connector

One point advice:

It is a connector that is frequently used for ZX shovels.
Note: 1. Terminal crimping work is your own responsibility. Part No.
2. When you insert, make sure that you hear the “click sound” and you are able to 4621803
feel that it is properly inserted.
3. After inserting, pull the element wire gently to confirm that it is locked.
4. Extraction tool ZT001-00030
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No.49 BLUE UFO Connector

UFO (Blue) 02F 10 pcs
UFO (Blue) F-Terminal 20 pcs
UFO (Blue) Wire Seal 30 pcs

Use the same corrugated tube here.

090 waterproof 090 waterproof 090 waterproof 090 waterproof

Control valve harness

One point advice:

It is a connector that is frequently used for ZX shovels.
Note: 1. Terminal crimping work is your own responsibility. Part No.
2. When you insert, make sure that you hear the “click sound” and you are 4621801
able to feel that it is properly inserted.
3. After inserting, pull the element wire gently to confirm that it is locked.
4. Extraction tool ZT001-00030
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No.50 EJ2-MAKEⅡ Connector

EJ2-MAKEⅡ 02F 4 pcs
EJ2-MAKEⅡ 03F 6 pcs
EJ2-MAKEⅡ F-Terminla 26 pcs
EJ2-MAKEⅡ Wire Seal 26 pcs

Lock
Pay attention to the direction.

Main harness
・Atmospheric pressure sensor
・Engine oil pressure sensor
・Engine coolant pressure sensor

One point advice:

It is a connector that is frequently used for hydraulic shovels.
◆ It is used for pump room 4P-SOL 5P-SOL FP-SOL.
Note 1. Terminal crimping work is your own responsibility. Part No.
2. When you insert, make sure that you hear the “click sound” and you are able to 4621797
feel that it is properly inserted.
3. After inserting, pull the element wire gently to confirm that it is locked.
4. Extraction tool ZT001-00030
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No.51 SWP-12,14,16 Female, Male Connector Box

SWP-02F-GY 5 pcs SWP F-Terminal 40 pcs
SWP-14F-GY 1 pcs SWP M-Terminal 40 pcs
SWP-16F-GY 1 pcs SWP Retainer-02 10 pcs
SWP-02M-GY 5 pcs SWP Retainer-14 2 pcs
SWP-14M-GY 1 pcs SWP Retainer-16 2 pcs
SWP-16M-GY 1 pcs SWP Wire Seal 80 pcs

YAZAKI YAZAKI

Cab harness

One point advice:

It is a leading magnetic connector for ZX models that is multi-polar, simple to connect and waterproof.
◆ ZX models, options, increased usage frequency
Note: 1. Terminal crimping work is your own responsibility. Part No.
2. When you insert, make sure that you hear the “click sound” and you are able to 4621793
feel that it is properly inserted.
3. After inserting, pull the element wire gently to confirm that it is locked.
4. Extraction tool ZT001-00030
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No.52 C Connector Series

C02F-W 5 pcs YAZAKI
C02F-B 1 pcs
C03F-W 3 pcs
C04F-W 1 pcs
C06F-W 1 pcs
C06F-B 1 pcs
C08F-W 1 pcs YAZAKI
C10F-W 1 pcs YAZAKI

C12F-W 1 pcs
C16F-W 1 pcs
C02M-W 5 pcs
C02M-B 1 pcs
C03M-W 3 pcs
C04M-W 1 pcs YAZAKI
C06M-W 1 pcs
C06M-B 1 pcs
C08M-W 1 pcs
C10M-W 1 pcs
C12M-W 1 pcs
C16M-W 1 pcs ・Cab harness
C F-Terminal 83 pcs ・Monitor harness
C M-Terminal 83 pcs

One point advice:

It is a connector that is frequently used for ZX shovels.
Note: 1. Terminal crimping work is your own responsibility. Part No.
2. When you insert, make sure that you hear the “click sound” and you are able to 4621786
feel that it is properly inserted.
3. After inserting, pull the element wire gently to confirm that it is locked.
4. Extraction tool ZT001-00030
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No.53 CA104, CB104 Waterproof

CA104 M-Terminal 100 pcs
CA104 M-Cover 100 pcs
CB104 M-Terminal 100 pcs
CB104 M-Cover 100pcs

Assemble waterproof
sleeve type
YAZAKI 7120-90B0.

Main harness
Pump harness

One point advice:

It is a connection terminal that is frequently used for shovel and crane machines.
◆ Waterproof insulation sleeve
Note: 1. Terminal crimping work is your own responsibility. Part No.
2. When you insert, make sure that you hear the “click sound” and you are able to feel that it is YA00014100
properly inserted.
3. After inserting, pull the element wire gently to confirm that it is locked.
4. Extraction tool ZT001-00030
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No.54 RV03F-B Series Connector

RV03FB 3F 10 pcs
RV03FB Female Terminal 30 pcs
RV03FB Wire Seal 30 pcs

YAZAKI

Character label

Pump harness

One point advice:

It is a connector that is frequently used for ZX shovels.
Note: 1. Terminal crimping work is your own responsibility. Part No.
2. When you insert, make sure that you hear the “click sound” and you are able to 4621800
feel that it is properly inserted.
3. After inserting, pull the element wire gently to confirm that it is locked.
4. Extraction tool ZT001-00030
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No.55 SMALL FUSE

FUSE (Mini Blade) 1A
FUSE (Mini Blade) 3A
FUSE (Mini Blade) 5A
FUSE (Mini Blade) 10A
FUSE (Mini Blade) 15A
FUSE (Mini Blade) 20A
FUSE (Mini Blade) 30A
FUSE (L-TYPE) 45A
FUSE (L-TYPE) 65A

Assemble extraction tool

(YAZAKI 7047-9178) and reserve fuses
(one fuse each of 5A, 10A, 15A and 20A)
to the fuse box.

One point advice:

It is used for ZX and EX1200-5 models.
◆ Many of the P/No settings are for high usage frequency 5A and 10A fuse.
Note: 1. Terminal crimping work is your own responsibility. Part No.
2. Make sure that the terminal crimping position suits the wire diameter YA00014099
(thickness of line element).
3. After crimping, check to make sure that the terminal shape is not
deformed.
4. Never use for a purpose other than terminal crimping.