Product Support Service Training Manual KCM900-01/2004-01

This Manual Covers All ZEE-Fold Diagrams for Models 95/115ZV

• Safety

• Hydraulic Line Diagrams

• Brake Line Diagrams

• Electrical Diagrams (refer to the latest Shop Manual for more details)

• Layout of Electrical Units

This is section 900 of the Product Support Service Training Manual. Pages in this section are numbered from
from 901~1000.
Consult the Shop Manual for specific details on each machine.

February 23, 2004

Safety Precautions
The most important point in providing repair service is safety. To ensure safety, observe the general cautions
described below.

●This manual is intended for properly trained and equipped service technicians.

●Any work on the machine must be performed by the trained personnel only.

●Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine.

●Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles.

●Place the machine on level and solid ground, and place chocks against the wheels to prevent movement.

●Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" tag to the
steering wheel.

●Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe.

●Be sure to apply the articulation stopper before starting work.

●While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks.

●When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate
cribbing under the unit to prevent unexpected dropping.

●Do not start to work in an enclosed area if adequate ventilation is not provided.

●To remove a heavy unit (20kgf (40 lbs) or more), be sure to use a crane or other lifting tool.

●Just after stopping operation, be careful not to directly touch a hot component. You may get burned.

●Contact tire manufacturer's local dealer for tire servicing and changing.

●Always store the tools in good condition, and use them properly.

●Keep the work area clean. Clean up spills immediately.

●Avoid the use of flammable solvents and cleaners.

●When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud.

●Use safe work platforms to reach higher areas of the machine.

901
Safety Symbols
An accident may occur if you disregard safety rules.
In this manual, several expressions are used according to levels of danger for inspection and repair work as shown
below. Read the work procedures and cautions described in this manual, and take preventive measures against
possible problems before starting service work.

DANGER
This danger symbol identifies special warnings or procedures
which, if not strictly observed, will result in death or serious
injury.

WARNING
This warning symbol identifies special warnings or procedures
which, if not strictly observed, could result in death or serious
injury.

CAUTION
This caution symbol identifies special instructions or
procedures which, if not strictly observed, may result in minor
or moderate injury.

IMPORTANT
This important symbol identifies special instructions or
procedures which, if not correctly followed, may result in
serious machine damage.

We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident
that is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when
doing service work.

902
Symbols
For safe and effective service work, the following symbols are used for notes
and useful information in this manual.

Symbol Item Description

Shows the condition or procedure that will be

Reference
useful or efficient in doing service work.

Shows the weight of a part or unit. The weight

should be considered in selecting wire rope or
Weight
cable for slinging work or determining the working
posture.
Shows the tightening torque of a section that
Tightening
torque should be carefully tightened during assembly
work.

Shows the type of coating or adhesive and the

Coating
coating section.

Oil or Shows the oil or water supply port and the refill
water
supply amount.

Shows the oil or water drain port and the drain

Drainage
amount.

IMPORTANT
If the specified conditions are not satisfied or the specified procedure is not
observed, there is a strong possibility that the product will be damaged or
the performance of the product will be reduced.
The message shows the preventive measures.

Abbreviation (acronyms)
To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the
following abbreviation list. Additional abbreviations are listed on page 62-6.

E/G ………Engine B …………Battery 1st ………1st speed

T/C ………Torque converter R …………Rear or Reverse 2nd ………2nd speed
T/M ………Transmission RH …………Right hand side 3rd ………3rd speed
SOL ………Solenoid valve LH …………Left hand side 4th ………4th speed
SW ………Switch H …………High DD ………Dynamic Damper
F …………Front or Forward L …………Low M/C ………Machine
QUAD ……Quick Up and Down GND ………Ground min-1 ………RPM
Shift OPT ………Option
A/M ………Auto/Manual Assy ………Assembly

903
95ZV Diagrams
Hydraulic Circuit Line Diagrams

Brake Circuit Line Diagrams

Electrical Diagrams
Loading/Steering Hydraulic Line 95ZV HYDRAULIC 42
3 5

Loading/Steering Hydraulic Line

(S/N 5001~5140)

Down up
B2

A2
1. Hydraulic pump (loading + pilot & brake)
14 6
P T
19 2. Hydraulic pump (steering)
ø1.3 a2
b2
3. Multiple control valve (loading circuits)

Dump Roll back

TS
23.5±0.5 MPa Rc1/4
(240±5 kgf/cm2)
(3,410 psi) TS 4. Steering valve
at 100L/min G1/4
L R B1
5. Boom cylinder
A1
6. Bucket cylinder
120
cm3 / rev
23.5±0.5 MPa
(240±5 kgf/cm2) 8. Steering cylinder
(3,410 psi)
at 100L/min
11. Check valve (oil cooler bypass)
15 15
b1 a1
12. Return filter element
13. Relief valve (return filter bypass)
T 14. Orbitrol

To brake valve (front axle circuit)

20.6±0.5 MPa
15. Stop valve

To brake valve (rear axle circuit)

(210 kgf/cm2)
(2,990 psi)
A B B A at 450 L/min
P 16. Pilot valve (for loading)
TS
(G1/4)
17. Valve assembly
DR DR
(18) Reducing valve (Orbitrol circuit)
(b1) B2 A2 (a1) 19. Adapter (orifice, slow spool return)
8 21. Breather valve (oil filling port)
22. Unloader valve
(b2) B1 A1 (a2)
G1/4
TS
26
26. Valve assembly (main brake manifold block)
(28) Reducing valve

To axle housing (vent between "trapped air" chambers)

TS P T
G1/4 (pilot, parking brake, auto-brake)
16 A B ACCR

A B
24.5±0.5 MPa
(250±5 kgf/cm2)
24.5±0.5 MPa
(250±5 kgf/cm2)
(3,560 psi)
(29) Solenoid valve for parking (R)
(3,560 psi) at 15 L/min Cooling fan
71 45(46) 33
at 15 L/min
(49) (32) Check valve
(74,75) 80.0 (32) ON when pressure Capacity: 3.0 L
cm3 / rev
12.3 MPa
B drops.
3.9±0.5MPa
Gas charging pressure:
2.94±0.1 MPa (49) Pressure switch (for brake oil pressure)
(125.4 kgf/cm2) (30±1 kgf/cm2)
DR (569±71 psi)
(1,778 psi)
T2
at 0 L/min
A B ACCF
(427±14 psi)
33. Accumulator
Pb
A 81
Pa T T
45. Valve assembly

To parking brake
4
(46) Reducing valve (for accumulator circuit)

(from brake valve)

B A

From auto brake

C 95 µm

solenoid valve

solenoid valve
To auto brake
P.B.
20.6±0.5 MPa (210±5 kgf/cm2)
Priority control flow rate
10 L/min
71. Fan motor
(2,990 psi) at 250 L/min P2 22 ACF

To tank
T1
PG Cut out:
11.8±0.5 MPa
72. Valve assembly (for fan motor)
(120 kgf/cm2) (29)
81 G PC P TG P1 (1,710 psi) (28) (73) Relief valve (two-step relief)
Cut in:
TS Rc1/8
High pressure set:
16.1 MPa (2,335 psi)
6.9±1.0 MPa
(70 kgf/cm2) B (74) Solenoid valve
B A 95µm Low pressure set: (995psi)
11.1 MPa (1,610 psi)
3.5 MPa
(75) Solenoid valve
(36 kgf/cm2)

17 3.5 MPa T
(512 psi)
at 0 L/min P T
81. Line filter
(36 kfg/cm2)
(18) (512 psi)
at 0 L/min
1 11 72 (73) A B
PA
82. Suction strainer
113.0 91.0 74.0 0.3±0.06 MPa
M cm3 / rev M cm3 / rev cm3 / rev (3±0.6 kgf/cm2) Z2 (G1/4)
83. Suction strainer
(43±8.5 psi)
21 T T

10µm
ACF Z PPI Z1
TS TS
2 G1/4 G1/4
1.0 kPa 29.4 kPa
(0.01 kgf/cm2) (0.3 kgf/cm2) TA
(0.14 psi) (4.3 psi)
B A

Port size Rc...... PT

G........PF (with O-ring)
17 3.5 MPa T 0.1±0.02 MPa (G).......PF (without O-ring)
(18) (512 psi) (1±0.2 kgf/cm2)
(14±2.8 psi)

(S/N ~5028) Hydraulic oil cooler Hydraulic oil tank

(incorporated in radiator)
82 83 13 12

904
Loading/Steering Hydraulic Line 95ZV HYDRAULIC 42
3 5

Loading/Steering Hydraulic Line

(S/N 5141~)

Down up
B2

A2
1. Hydraulic pump (loading + pilot & brake)
14 6
P T
19 2. Hydraulic pump (steering)
ø1.3 a2
b2
3. Multiple control valve (loading circuits)

Dump Roll back

TS
23.5±0.5 MPa Rc1/4
(240±5 kgf/cm2)
(3,410 psi) TS 4. Steering valve
at 100L/min G1/4
L R B1
5. Boom cylinder
A1
6. Bucket cylinder
120
cm3 / rev
23.5±0.5 MPa
(240±5 kgf/cm2) 8. Steering cylinder
(3,410 psi)
at 100L/min
11. Check valve (oil cooler bypass)
15 15
b1 a1
12. Return filter element
13. Relief valve (return filter bypass)
T 14. Orbitrol

To brake valve (front axle circuit)

20.6±0.5 MPa
15. Stop valve

To brake valve (rear axle circuit)

(210 kgf/cm2)
(2,990 psi)
A B B A at 450 L/min
P 16. Pilot valve (for loading)
TS
(G1/4)
17. Valve assembly
DR DR
(18) Reducing valve (Orbitrol circuit)
(b1) B2 A2 (a1) 19. Adapter (orifice, slow spool return)
8 21. Breather valve (oil filling port)
22. Unloader valve
(b2) B1 A1 (a2)
G1/4
TS
26
26. Valve assembly (main brake manifold block)
(28) Reducing valve

To axle housing (vent between "trapped air" chambers)

TS P T
G1/4 (pilot, parking brake, auto-brake)
16 A B ACCR

A B
24.5±0.5 MPa
(250±5 kgf/cm2)
24.5±0.5 MPa
(250±5 kgf/cm2)
(3,560 psi)
(29) Solenoid valve for parking (R)
(3,560 psi) at 15 L/min
45(46) 33
at 15 L/min
(49) (32) Check valve
(32) ON when pressure Capacity: 3.0 L

Cooling fan
71 12.3 MPa
B drops.
3.9±0.5MPa
Gas charging pressure:
2.94±0.1 MPa (49) Pressure switch (for brake oil pressure)
(125.4 kgf/cm2) (30±1 kgf/cm2)
(569±71 psi)
(1,778 psi)
80.0
at 0 L/min
A B ACCF
(427±14 psi)
33. Accumulator
Pb
cm3 / rev 73 81
Pa T T
45. Valve assembly

To parking brake
4
T1
(46) Reducing valve (for accumulator circuit)

(from brake valve)

P1 A

From auto brake

Ps 95 µm

solenoid valve

solenoid valve
T

To auto brake
P.B. 74 Priority control flow rate 71. Fan motor
20.6±0.5 MPa (210±5 kgf/cm2)
16.2MPa(2,349psi) 10 L/min
(2,990 psi) at 250 L/min
Radiator 22 ACF

To tank
Cut out:
11.8±0.5 MPa
72. Relief valve
(120 kgf/cm2) (29)
81 G PC P T2 Pp (1,710 psi) (28) 73. Check valve
Cut in:
TS Rc1/8
Ts P
6.9±1.0 MPa
(70 kgf/cm2) B 74. Thermo sensing valve
B A 95µm High pressure set : 16.5MPa(2,393psi) (995psi)
Low pressure set : 6.2MPa( 900psi)
3.5 MPa
81. Line filter
(36 kgf/cm2)

17 3.5 MPa T
(512 psi)
at 0 L/min P T
82. Suction strainer
(36 kfg/cm2)
(18) (512 psi)
at 0 L/min 1 11 72 A B
PA
83. Suction strainer
113.0 91.0 74.0 0.3±0.06 MPa
M cm3 / rev M cm3 / rev cm3 / rev (3±0.6 kgf/cm2) Z2 (G1/4)
(43±8.5 psi)
21 T T

10µm
ACF Z PPI Z1
TS TS
2 G1/4 G1/4
1.0 kPa 29.4 kPa
(0.01 kgf/cm2) (0.3 kgf/cm2) TA
(0.14 psi) (4.3 psi)

Port size Rc...... PT

G........PF (with O-ring)
0.1±0.02 MPa (G).......PF (without O-ring)
(1±0.2 kgf/cm2)
(14±2.8 psi)

Hydraulic oil cooler Hydraulic oil tank

(incorporated in radiator)
82 83 13 12

905
906
Diagram reflects production ~ 97C4-5140

907
Diagram reflects production ~ 97C4-5140
Diagram reflects production ~ 97C4-5140

~ 97C4-5140

97C4-5141 ~ uses different

fan speed control unit.
 ~ 97C4-5140
97C4-5141 ~ uses different
fan speed control unit.
95ZV QSX15 Engine Electrical Diagram
Be sure to follow color guide in upper left corner.
RED DC VOLTAGE
BLUE INPUT SIGNALS
BLACK GROUNDS, SHIELDS AND RETURNS
PURPLE OUTPUT SIGNAL
GREEN DATA LINKS 22
MULTIPLE UNIT 1
SYNCHRONIZATION 2 31
IDENTIFICATION 3 32
SWITCH 4 19

MULTIPLE UNIT 1 1 A
SYNCHRONIZATION 2 2 REMOTE
IDENTIFICATION 3 3 B 21
THROTTLE
SHORTING PLUGS 4 4 C

REMOTE B 43
THROTTLE
SWITCH
A 20

48
5 C C
B 47
3 A
A 49
4 B
2 D 03
C
6 E
B 13
1 F A 09

11
TACHOMETER B
IDLE SHUTDOWN RELAY U 35

L
K 10

ALTERNATE TORQUE SWITCH H 02

E 01
ALTERNATE GOVERNOR SWITCH
A
D 25

33
INTERMEDIATE
SPEED CONTROL
SWITCH 23

ALTERNATE IDLE

C 45

INCREMENT / DECREMENT O 14

N 24
ALTERNATE
DROOP N
SWITCH 41
E
MULTIPLE UNIT C 34
ON/OFF
T 42
ENGINE O 12
PROTECTION
R
DIAGNOSTIC / USER-ENGAGED 44
SNAPSHOT ON/OFF

MANUAL 15
FAN ON/OFF

06
ENGINE STOP LAMP (RED)
ENGINE WARNING LAMP (YELLOW) 16
MAINTENANCE LAMP 05
WAIT TO START LAMP
04

38

29

30

39
40
50
18
28
07
08
17

A
B
C 46
D
B 37
C E
36
A F
26
G
27

B
C
A

REV 8/19/02
PAGE 1 of 2
 SWITCHED
OUTPUT A
SHORTING PLUG SWITCHED
OUTPUT A
CONNECTOR OEM PRESSURE +5 VOLT SUPPLY
A 1 1
OEM PRESSURE SIGNAL
C 3 3
OEM PRESSURE RETURN
B 2 2
SWITCHED OUTPUT A
5 5
SPARE
6 6
SWITCHED OUTPUT A
4 4

ALTERNATE TORQUE CURVE SELECT 2 INPUT

OPTIONAL 2-WIRE
COOLANT LEVEL A
SENSOR B

OPTIONAL COOLANT A
LEVEL MODULE FOR
B 31 PIN-OEM
2-WIRE SENSOR
CONNECTOR
C
D
30
E
D
COOLANT
A
LEVEL
D 05
SENSOR C
SHORTING COOLANT LEVEL A 06
JUMPERS B SENSOR C 07
B
19

31
OEM TEMPERATURE INPUT
OEM TEMPERATURE B 04
OEM TEMPERATURE RETURN
SENSOR A 03

SWITCHED
SWITCHED OUTPUT A
OUTPUT B SOLENOID
SOLENOID
27
PWM DEDICATED OUTPUT 08
09
GRID HEATER
SOLENOID 10
11
FAN CLUTCH A 12
ACTUATOR B 13

OEM SWITCH 28
AIR CONDITIONER
17
PRESSURE SWITCH 18

MAGNETIC
PICKUP SHAFT SHAFT SPEED (+)
SPEED SENSOR A
SHAFT SPEED (-)
21
B 22
FREQUENCY (+)
THROTTLE 16
(-)
FUSE 2A

REV 8/19/02
PAGE 2 of 2
115ZV Diagrams
Hydraulic Circuit Line Diagrams

Brake Circuit Line Diagrams

Electrical Diagrams
Loading/Steering Hydraulic Line 115ZV HYDRAULIC 42

3
Loading/Steering Hydraulic Line 5

DOWN UP
(S/N 5001~5030) 65 (66)

(67)
B2 1. Hydraulic pump (steering)
A P T B
A2 2. Hydraulic pump
6
14

DOWN UP
19 (loading + pilot & brake)
b2 a2

TS
3. Multiple control valve (loading circuit)
P T 23.5±0.5 MPa
G1/4
ø1.3
(3,413±71 psi)
at 100 L/min TS 4. Steering valve
G1/4
B1
5. Boom cylinder
L R
A1
6. Bucket cylinder
A A 23.5±0.5 MPa
8. Steering cylinder
(3,413±71 psi)
DR DR at 100 L/min 11. Check valve (oil cooler bypass)
b1 a1 12. Return filter element

To axle housing (vent between "trapped air" chambers)

B B 13. Relief valve
0.37 MPa 0.37 MPa
(54 psi) 15 (54 psi) T 14. Pilot valve (stick)
20.6±0.5 MPa
(2,986±71 psi) 15. Stop valve
78 kPa ø1.2 ø1.2 78 kPa at 600 L/min
(11.4 psi) (11.4 psi)
P 16. Pilot valve (for loading)

To brake valve (front axle circuit)

To brake valve (rear axle circuit)
TS
17. Valve assembly
25
(18) Reducing valve
8 (b1) B2 A2 (a1)
19. Adapter (orifice, slow spool return)
21. Breather valve (oil filling port)
22. Unloader valve
(b2) B1 A1 (a2)
25. Slow return check valve
TS TS
24.5+1.0
0 MPa 24.5+1.0
0 MPa
26 26. Valve assembly (main brake manifold block)
(3,555±71 psi) (3,555±71 psi) P T A B ACCR
A B at 15 L/min at 15 L/min 16 (28) Reducing valve
45 (46) Turns on
33 (pilot, parking brake, auto-brake)
Cooling fan (32) when pressure (49)
Dr
71 B
drops.
3.9±0.5 MPa
Capacity: 3.0 L (29) Solenoid valve for parking
Gas pressure:
(74,75) 91.0 12.3 MPa (569±71 psi)
2.94±0.1 MPa
Pb cm3/rev 81
(1,783 psi)
at 0 L/min ACCF (427±14 psi) (32) Check valve
A B
Pa T
4 T2 DR
T
(49) Pressure switch (for brake oil pressure)
A Cut out:
11.8±0.5 MPa A To parking brake 33. Accumulator
P.B. (1,706±71 psi) Priority 95 µm ACF
20.6±0.5 MPa (2,986 psi)
at 410 L/min
B Cut in:
6.9±1.0 MPa
control
flow rate
45. Valve assembly
C (995±142 psi) 10 L/min (29)
Control flow rate
22
(46) Reducing valve (for accumulator circuit)
210±13 L/min B
P2
81 G Pc P T1
PG
65. Valve assembly (for steering lock)
TS Rc1/8 (28)
TG P1
(66) Solenoid
95 µm To auto brake
B A 3.5 MPa P T solenoid valve
G3/8 High pressure set: 19.0 MPa (2,759 psi) (512 psi) (67) Block
Low pressure set : 9.5 MPa (1,379 psi) B PA
A
at 150 L/min 71. Fan motor
17 3.5 MPa T
(18) (512 psi)
2 72 (73) 72. Valve assembly (for fan motor)
T
at 0 L/min M 91.0 91.0 M 80.0 87.0 T To tank
cm3/rev cm3/rev cm3/rev cm3/rev 0.3±0.06 MPa
(42.7±8.5 psi)
21 ACF Z PPI
(73) Relief valve (two-step relief)
Z1
1 10 µm (74) Solenoid valve
TS TS
G1/4 11
B A
G1/4 1.0 kPa
(0.14 psi)
29.4 kPa
(4.3 psi) To tank (75) Solenoid valve
81. Line filter
17 3.5 MPa T Port size Rc...... PT 83. Suction strainer
(18) (512 psi) G........PF (with O-ring)
(G).......PF (without O-ring)
0.1±0.02 MPa 0.1±0.02 MPa
(14±2.8 psi) (14±2.8 psi)
(S/N ~5009)
115ZV42038
Hydraulic oil cooler
83 13 12 13
Hydraulic oil tank (incorporated in radiator)
Loading/Steering Hydraulic Line 115ZV HYDRAULIC 42

3
Loading/Steering Hydraulic Line 5

DOWN UP
(S/N 5031~) 65 (66)

(67)
B2 1. Hydraulic pump (steering)
A P T B
A2 2. Hydraulic pump
6
14

DOWN UP
19 (loading + pilot & brake)
b2 a2

TS
3. Multiple control valve (loading circuit)
P T 23.5±0.5 MPa
G1/4
ø1.3
(3,413±71 psi)
at 100 L/min TS 4. Steering valve
G1/4
B1
5. Boom cylinder
L R
A1
6. Bucket cylinder
A A 23.5±0.5 MPa
8. Steering cylinder
(3,413±71 psi)
DR DR at 100 L/min 11. Check valve (oil cooler bypass)
b1 a1 12. Return filter element

To axle housing (vent between "trapped air" chambers)

B B 13. Relief valve
0.37 MPa 0.37 MPa
(54 psi) 15 (54 psi) T 14. Pilot valve (stick)
20.6±0.5 MPa
(2,986±71 psi) 15. Stop valve
78 kPa ø1.2 ø1.2 78 kPa at 600 L/min
(11.4 psi) (11.4 psi)
P 16. Pilot valve (for loading)

To brake valve (front axle circuit)

To brake valve (rear axle circuit)
TS
17. Valve assembly
25
(18) Reducing valve
8 (b1) B2 A2 (a1)
19. Adapter (orifice, slow spool return)
21. Breather valve (oil filling port)
22. Unloader valve
(b2) B1 A1 (a2)
25. Slow return check valve
TS TS
24.5+1.0
0 MPa 24.5+1.0
0 MPa
26 26. Valve assembly (main brake manifold block)
(3,555±71 psi) (3,555±71 psi) P T A B ACCR
A B at 15 L/min at 15 L/min 16 (28) Reducing valve
45 (46) Turns on
33 (pilot, parking brake, auto-brake)
(32) when pressure (49)
Dr 71 B
drops.
3.9±0.5 MPa
Capacity: 3.0 L (29) Solenoid valve for parking
Cooling fan 12.3 MPa (569±71 psi) Gas pressure:
2.94±0.1 MPa
Pb 81
(1,783 psi)
at 0 L/min ACCF (427±14 psi) (32) Check valve
90.0 A B
Pa T cm3/rev
4 73 (49) Pressure switch (for brake oil pressure)
T
T1 P1 Cut out:
11.8±0.5 MPa A To parking brake 33. Accumulator
P.B. T Ps (1,706±71 psi) Priority 95 µm
74 ACF
20.6±0.5 MPa (2,986 psi)
at 410 L/min
Cut in:
6.9±1.0 MPa
control
flow rate
45. Valve assembly
18.1 MPa (2,625 psi)
Radiator (995±142 psi) 10 L/min (29)
Control flow rate
22
(46) Reducing valve (for accumulator circuit)
210±13 L/min B
81 G Pc P
Pp 65. Valve assembly (for steering lock)
T2
TS Rc1/8 (28)
(66) Solenoid
95 µm Ts P High pressure set: To auto brake
B A 3.5 MPa P T solenoid valve
G3/8 18.0 MPa (2,610 psi) (512 psi) (67) Block
Low pressure set : B PA
A
8.1 MPa (1,175 psi)
71. Fan motor
17 3.5 MPa T
(18) (512 psi)
2 72. Relief valve
at 0 L/min 91.0 91.0 80.0 87.0 72 T
T
To tank
M cm3/rev cm3/rev M cm3/rev cm3/rev 0.3±0.06 MPa
(42.7±8.5 psi)
21
73. Check valve
ACF Z PPI Z1
1 10 µm 74. Thermo sensing valve
TS TS
G1/4 11
G1/4 1.0 kPa
(0.14 psi)
29.4 kPa
(4.3 psi) To tank 81. Line filter
83. Suction strainer
Port size Rc...... PT
G........PF (with O-ring)
(G).......PF (without O-ring)
0.1±0.02 MPa 0.1±0.02 MPa
(14±2.8 psi) (14±2.8 psi)

115ZV42039
Hydraulic oil cooler
83 13 12 13
Hydraulic oil tank (incorporated in radiator)
Diagram reflects production ~ 11C4-5030
Diagram reflects production ~ 11C4-5030
 ~ 11C4-5030

11C4-5031 ~ uses different

fan speed control unit.
Fan speed control solenoid ~ 11C4-5030
11C4-5031 ~ uses different
fan speed control unit.
115ZV QSK19 Engine Electrical Diagram
Be sure to follow color guide in upper left corner.
 J1939 DATALINK 2+
A
RED DC VOLTAGE TO J1939 DATALINK 2-
BLUE INPUT SIGNALS J1939 B
DATALINK J1939 DATALINK SHIELD
BLACK GROUNDS, SHIELDS AND RETURNS C
PURPLE OUTPUT SIGNAL
GREEN DATA LINKS

UNSWITCHED BATTERY SUPPLY

D

UNSWITCHED BATTERY SUPPLY

G
DUAL OUTPUT A (SOLENOID 2)
A
DUAL OUTPUT B (SOLENOID 3)
C
SOLENOID 4
H
PWM OUTPUT (12 VDC)
W
FREQUENCY INPUT SIGNAL (VSS)
L
FREQUENCY INPUT SIGNAL (VSS) RETURN
M
OEM PRESSURE SIGNAL
F
OEM TEMPERATURE SIGNAL
K
OEM TEMPERATURE SIGNAL RETURN
SHORTING PLUG J
COOLANT LEVEL SWITCH LOW
A A A T
COOLANT LEVEL SWITCH HIGH
D D D S
COOLANT LEVEL SWITCH RETURN
B B B V
COOLANT LEVEL SWITCH SUPPLY
C C C U

+5VDC REMOTE THROTTLE POSITION SUPPLY

A C P
SIGNAL REMOTE THROTTLE POSITION SIGNAL
B B N
RETURN REMOTE THROTTLE POSITION RETURN
C A X

TWO
ISS THROTTLE 6-PIN 6-PIN NON-ISS THROTTLE REMOTE THROTTLE POSITION SIGNAL
DESIGN OPTION OPTION DESIGN 28
5 VDC SUPPLY
29
+5VDC +5VDC THROTTLE POSITION SUPPLY
C C C A C 04
SIGNAL SIGNAL THROTTLE POSITION SIGNAL
A B B B B 05
RETURN RETURN THROTTLE POSITION RETURN
B A A C A 06
ISS OFF-IDLE OFF-IDLE IDLE VALIDATION SWITCH OFF IDLE SIGNAL
D D C C 07
ON-IDLE IDLE VALIDATION SWITCH IDLE SIGNAL
ON-IDLE
E E B B 08
RETURN RETURN IDLE VALIDATION SWITCH RETURN
F F A A 31
UNUSED
23
OEM SWITCH / COLD IDLE INHIBIT
10
UNUSED
11
RED LAMP RED LAMP
B 16
AMBER LAMP AMBER LAMP / SHUTDOWN OVERRIDE
C 17
WHITE LAMP WHITE LAMP / DIAGNOSTIC SWITCH
P 18

DIAGNOSTIC SWITCH

TORQUE CURVE SELECT ALTERNATE TORQUE CURVE SELECT

L 14

DROOP / HSG SELECT ALTERNATE DROOP / HSG SELECT

15
A
ALTERNATE IDLE ALTERNATE IDLE
J 09
ISC / IDLE INCREMENT INTERMEDIATE SPEED CONTROL / IDLE INCREMENT
H 12
ISC / IDLE DECREMENT INTERMEDIATE SPEED CONTROL / IDLE DECREMENT
M 13
ISC1 INTERMEDIATE SPEED CONTROL 1
F 21

ISC VALIDATE / ISC 3 INTERMEDIATE SPEED CONTROL 3 / VALIDATE

E 19
ISC2 INTERMEDIATE SPEED CONTROL 2 / REMOTE THROTTLE SELECT
G 20
GROUND
N
KEY SWITCH KEY SWITCH INPUT
D 01

A
B

TACHOMETER OUPUT SIGNAL

22

9 PIN 6 PIN
DEUTSCH DEUTSCH
PUBLIC DATALINK 1+
1 A 02
PUBLIC DATALINK 1-
2 B 03

UNSWITCHED BATTERY (+)

3 C 24
BLOCK GROUND
5 E 25
BLOCK GROUND
30
ETHER INJECTION
26
FAN CLUTCH
27

REV 1/30/03
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Use for notes.