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CTG AND CTGD AUTOMATIC TRANSFER SWITCH (ATS) ELECTRICAL SYSTEM

KENR1302 August 1988 CB-534 Electrical System 2EG1-170 2YF1-027 © 1998 Caterpillar All Rights Reserved Printed in U.S.A.
KENR1313-01 October 1992 7 8 4 Component 4 14 12 Alarm — Backup 9 17 1 16 1 A 3 13 2 B 6 5 3 15 2 10 11 A 3 B Schematic Location SH2-E8 Component Location Machine Location 1 Solenoid — Fuel Shutoff Schematic Location 13 Machine Location 13 Alternator SH2-B8 2 Solenoid — Vib Control Valve 12 12 Battery SH2-D6 3 Solenoid — Vib Control Valve 12 12 Battery SH2-D7 3 Solenoids — Vib Select Valve 14 14 Breaker — Main SH2-A8 4 Switch — Auto-Vib/Speed A A Flasher SH1 -C4 B Switch — Automatic/Manual B B Fuse Block SH1-E4 A Switch — Backup Alarm Pressure B B Horn — Alert Operator SH1-F6 5 Switch — Brake Pressure 14 14 Horn — Forward SH2-E3 6 Switch - Brake B B Instrument Cluster SH1-E2 A Switch — Drum Offset B B Instrument Cluster SH1-E2 A Switch - Drum Select B B Lamp — Alternator Indicator SH1-D3 A Switch — Engine Coolant Temp 2 2 Meter — Service Hour SH1-E3 A Switch — Engine Oil Press 15 15 Motor — Front Water Pump SH2-D2 7 Switch — Engine Oil Press (Ser Meter) 15 15 Motor — Rear Water Pump SH2-D8 8 Switch — Filter Press (Fuel) 16 16 Motor — Starter SH2-D8 9 Switch — Forward Horn B B Recorder Module SH1-B7 A Switch — Hydraulic Oil Temp 17 17 Relay — Gage SH1-F3 A Switch — Ignition A A Relay — Main Power SH2-A8 4 Switch - Light B B Relay — Start SH2-B8 4 Switch — Neutral Start B B Relay — Vibratory Tach SH1-A2 B Switch - Turn B B Relay — Water Pump SH1-C4 B Switch — Vibration Cutout B B Sensor — Auto-Vib/Speed SH2-D6 10 Switch — Water Spray A A Sensor Front Vibratory SH2-E4 11 Switches — Vibration Pressure B B Sensor — Rear Vibratory SH2-F6 10 Tachometer — Ground Speed (FPM) A A Sensor — Speed (Recorder) SH2-E6 10 Tachometer — Vibration (VPM) A A Timer — Water Spray A A SH2-A6 Solenoid — Brake 12 Machine locations are repeated for components located close together. A = Components located in dash area. B = Components located in right console. 17 Component CB-434 Vibratory Compactor Electrical System 3TF1-217 5 3 2 2 1 4 4 15 10 16 12 9 1 14 13 8 7 11 6 Machine Harness Connector And Component Locations ©1992 Caterpillar All Rights Reserved Harness Connector Location Chart Connectors Machine Location 1 1 10 Contacts 1 A A 7 Contacts * 2 6 Contacts 2 2 2 5 Contacts B 3 * 4 Contacts 4 4 Harness And/Or Components A—6R1099 E — 6R1 383 A—6R1099 E — 6R1 383 A—6R1099 E — 6R1383 A — 6R1099 K—6R1990 A — 6R1099 L—7R5513 A-6R1 099/B-1 G61 46 Recorder C — 6R0078 E—6R1383 E — 6R1383 H — 6R0046 E — 6R1383 R — 7R4624 E — 6R1383 S—871444 A — 6R1099 Neutral Start Sw A — 6R1099 J—6R1989 A — 6R1099 Horn B—1G6146 F — 1G6145 E—6R1383 Vib Valve Solenoid Machine locations are repeated for connectors located close together. * = Connector is located at the component. A = Connectors located in dash area. B = Connectors located in right console. Schematic Location SH1-E8 SH2-E1 SH1-D8 SH2-E1 SH1-C8 SH2-C1 SH1-D5 SH1-E5 SH1 -A5 SH2-F5 SH2-D5 SH2-D5 SH2-C5 SH1-C3 SH1-05 SH1-F6 SH1-C8 SH2-C1 SH2-B4 Printed in U.S.A.
KENR1648 June 1990 Harness Connector Location Chart Machine Location Connectors Harness And/Or Components WW-7R9109 Diagnostic Connector (3208) XX-7R9110 Diagnostic Connector (3412) 1 20 Contacts 1 9 Contacts Schematic Location B-5 C-5 2 AT - 7R9114 YY-7R9111 D-4 2 AT-7R9114 AV — 7R91 08 A-3 2 2 AT-7R9114 AW—7R9113 C-4 2 AB-7R9112 AT—7R9114 E-4 * AT—7R9114 Rt. Console E-Stop F-1 * AT—7R9114 Lt. Console E-Stop F-4 * AW-7R9113 Rt. Front E-Stop A-5 * AW—7R9113 Lt. Front E-Stop F-5 * AW-7R9113 Cutter Door E-Stop D-4 * AW-7R9113 Rt. Rear E-Stop A-9 * AW-7R9113 Lt. Rear E-Stop F-9 * AW—7R9113 Cutter door Inductor Sw A-7 * AW-7R9113 Kickback Inductor Sw 7 Contacts 6 Contacts 4 Contacts A-8 Machine locations are repeated for connectors located close together. * = Connector is located at the component. PR-1000C Cold Planer Electrical System 5XC138-UP Part No. Function 6T7663 Engine Oil Pressure (S. Meter) 9D7032 Reverse Pressure Off Machine Switch Specification Actuate 93 ± 21 kPa (13.5 ± 3.0 psi) 517 ± 35kPa (75.0 ± 5.0 psi) Deactuate 69 ± 21 kPa (10.0 ± 3.0 psi) 414 ± 35kPa (60.0 ± 5.0 psi) Contact Position Normally Open Normally Open © 1990 Caterpillar All Rights Reserved 9 22 13 21 2 B 24 8 35 3 34 23 A 19 15 36 2 33 4 37 12 18 20 28 31 29 5 11 25 30 16 17 Alarm - Backup 1 1 38 Component 10 32 26 27 6 A 5 8 2 38 24 19 15 9 6 17 7 31 26 21 13 23 22 14 33 30 1 29 16 B 3 2 36 25 28 12 4 34 35 37 32 11 27 20 1 18 14 7 10 Machine Harness Connector And Component Locations Schematic Location C-9 Component Location Machine Location 1 Component Relay -(3) Starter Schematic Location C-6 Machine Location B 21 Alarm - Overheat A-3 A Relay - E Stop* B-2 Alternator (3208) C-8 2 Relay - E Stop* B-5 B Batteries A-6 3 Relay - Kickback B-2 22 Box - Cutter Door E-Stop* AS D-4 4 Relay - Main B-6 B Box - Left Console E-Stop* AS F-4 5 Relay - Reverse B-3 23 Box - Left Front E-Stop* AS F-5 6 Resistors (2.7 Ohms) C-2 24 Box - Left Rear E-Stop* AS F-9 7 Sender - Coolant Temp (3208) B-8 25 Box - Right Console E-Stop* AS F-i 8 Sender - Coolant Temp (3412) E-6 26 Box - Right Front E-Stop* AS A-5 9 Sender - Hydraulic Oil Temp F-8 27 Box - Right Rear E-Stop* AS A-9 10 Sender - Oil Pressure (3208) B-7 28 Breaker - Alternator (3208) D-8 11 Sender - Oil Pressure (3412) E-5 29 Breaker - E-Stop* B-6 B Solenoid - Cutter Drum Clutch C-4 A Breaker - Main B-6 B Solenoid - Fuel (3208) E-8 30 Breaker - Start C-6 B Solenoid - Fuel (3412) E-5 31 Clutch - Water Spray Mag E-8 12 Solenoid - Water Valve B-7 32 Flasher A-2 13 Switch - Coolant (High Temp) E-5 33 Gauge - Coolant Temp (3208) E-2 A Switch - Cutter Clutch C-4 A Gauge - Coolant Temp (3412) E-2 A Switch - Cutter Door Inductor A-7 34 Gauge - Hydraulic Oil Temp F-3 A Switch - Engine Rack Ught E-6 A Gauge - Oil Pressure (3208) F-2 A A-4 A Gauge - Oil Pressure (3412) F-3 A A-4 A Gauge - Pyrometer (3412) E-3 A A-4 A Horn - Warning A-2 14 Switch - Flasher and Beacon Switch - Flood Lamp (Conveyer, Cutter Floods) Switch - Flood Lamp (Dash Lamps, Front Floods) Switch - Key Start D-2 A Horn - Warning 0-5 15 Switch - Kickback Ski Inductor A-8 35 36 Lamp - Kickback Reset C-4 A Switch - Main Disconnect A-6 Meter - Service E-7 A Switch - Neutral Limit D-2 A Meter - Volt E-2 A Switch - Oil Pressure D-7 37 Motor -(2) Starter Aft (3412) D-6 16 Switch - Reverse Pressure B-3 A Motor -(3) Starter Forward (3412) D-5 17 Switch - Spray Bar B-4 A Motor - Starter (1) (3208) C-8 18 Switch - Start D-3 A Pickup - Magnetic (3412 Tach) E-4 19 Tachometer - (3208) E-2 A Pickup - Magnetic (3208 Tach) 0-7 20 Tachometer - (3412) E-3 A Relay -(2) Starter C-6 B Thermocouple E-5 38 Machine locations are repeated for components located close together. A = Components on operator console. B = Components on relay panel. * = E-Stop represents machine stop Printed in U.S.A.
KENR1689 April 1993 11 COMPONENT LOCATION CHART 18 12 15 3 Machine Location 2 A 6 8 13 19 10 17 4 16 1 B 3 7 9 1 2 5 14 Schematic Location Component Machine Location Schematic Location Component 1 Alarm — Backup E-8 11 Sensor — Compactor Drum Speed 2 Alternator C-8 12 Solenoid — Brake B-5 3 Battery D-7 13 Solenoid — Engine Shutdown C-8 3 Battery D-8 14 Solenoid — Ether Start Aid B-8 B Breaker — Alternator F-4 15 Solenoid — Trans Speed Select B-5 A-6 B-5 A Fuse Block E-3, F-3 16 Solenoid — Vibration Control A Gauge — Engine Oil Pressure E-2 17 Solenoids — Propel Interlock A-5 A Gauge — Engine Water Temp E-2 18 Switch — Backup Alarm D-2 A Gauge — Fuel Level E-2 7 Switch — Coolant Temp (Start Aid) B-8 A Gauge — Hydraulic Temperature E-2 8 Switch — Engine Oil Pressure C-7 A Gauge — Vibration Tachometer D-2 B Switch — Ether Start Aid E-4 4 Horn — Forward D-1 B Switch — Flood Lamp C-2 A Meter — Service E-2 B Switch — Forward Horn C-1 5 Motor — Starter D-8 A Switch — Key Start E-4 6 Relay — Main F-4 19 Switch — Neutral Start B-8 6 Relay — Start E-5 B Switch — Park Brake D-3 7 Sender — Engine Coolant Temp C-7 B Switch — Transmission Speed Select C-3 8 Sender — Engine Oil Pressure C-7 B Switch — Vibration On/Off D-2 9 Sender — Fuel Level B-7 B Switch — Vibration Select C-3 10 Sender — Hydraulic Oil Temp C-7 Machine locations are repeated for components located close together. A = Located inside in the dash. B = Located on the right console. 3 CS-563 A B 10 2 18 15 12 6 8 7 2 5 9 1 3 11 8XF779-UP 7GG400-UP 1YJ385-UP 5AJ106-UP HARNESS CONNECTOR LOCATION CHART 16 19 17 13 14 1 4 CAT CP-563 & CS-563 Vibratory Compactors Electrical System Schematic Location Machine Location P1 - R1 E-6 1 P2 - R2 D-6 1 10 P3 - R3 C-5 2 10 P4 - R4 D-5 2 10 P5 - R5 D-5 3 10 P6 - R6 E-5 3 4 P7 - R7 A-6 * Contacts Connector 10 10 Machine locations are repeated for connectors located close together. * = Connector is located at the component. Machine Harness Connector And Component Locations © 1993 Caterpillar All Rights Reserved Harness And Wire Electrical Schematic Symbols A AA Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. T Pin or Socket Number Pressure Symbol Wire, Cable, or Harness Assembly Identification A A 325-PK-14 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 Temperature Symbol Level Symbol Flow Symbol Component Part Number Single Wire Connector C Electrical Schematic Symbols And Definitions Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Normally closed switch that will open with an increase of a specific condition. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. The circle indicates that the component has screw terminals and a wire can be disconnected from it. No circle indicates that the wire cannot be disconnected from the component. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Printed in U.S.A.
KENR1885 September 1993 C OMPON ENT LO CA T ION CH A R T M ach in e L oc ati o n Electrical Schematic Symbols And Definitions T Temperature Symbol Pressure Symbol Flow Symbol Level Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. C om pon e nt S ch em ati c L ocat io n M ach i ne L o catio n S ch em ati c L o catio n Co m p on e nt 1 Alar m — Bac ku p E-8 11 S ens or — Dru m Speed Pick up 2 Alte r nat or C- 8 12 S ol enoi d — B rak e B -5 B -5 3 Bat t er i es D7, D 8 13 S ol enoi d — E ng ine S hut down C-8 B Br ea ker — Alt er nat or F -4 14 S ol enoi d — E ther S tart Aid B -8 A F use Bl ock F -3 15 Solenoid — Transmission Speed Select B -5 A Ga uge — E ngine O il P r es sur e E-2 16 S ol enoi d — V ibration Con trol A -6 A Ga uge — E ngine W at er T em per atur e F -2 17 S ol enoi ds — P ropel Int erlock A -5 A Ga uge — F uel Lev el E-2 18 S wi tch — Bac kup Al arm D-2 A Ga uge — H y dr a uli c T em pe r atu re E-2 7 Switch — Coolant Temperature (Start Aid) B -8 A Ga uge — V ibr a ti on T achom eter E-2 8 4 H orn — Fo r war d D- 1 B S wi tch — Engine O il P re ssure (S ervice M ete r) S wi tch — Fl ood Lamp A M et er — Ser v ic e F -2 B S wi tch — F orward Horn D-1 5 M ot or — St ar te r D- 8 A S wi tch — Key S tart E -4 6 R ela y — M ain F -4 19 S wi tch — Neu tral S tart B -8 6 R ela y — St ar t F -4 B S wi tch — Park B rak e D-3 7 Sender — Engine Coolant Temperature C- 7 B S wi tch — St art A id F -4 8 Sen de r — Fuel Lev el C- 7 B S wi tch — Tra nsm is sio n Spe ed Selec t D-3 9 Sen de r — Engi ne O il P r essur e C- 7 B S wi tch — Vibration O n/Of f D-2 10 Sen de r — Hy dr aul ic Oil T em perat ur e C- 7 B S wi tch — Vi brat ion Sel ec t D-3 D-7 D-2 CS-531, CP-533, CS-533, CS-573 & CS-583 Vibratory Compactors Electrical System M ac hin e lo cat i ons ar e r epe at ed f or com ponents loc ated cl ose together. Normally closed switch that will open with an increase of a specific condition. A = Loc at ed ins id e in t he das h. B = Loc ate d on th e r ight c ons ole. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 8YJ1-UP 8PK1-UP 1EL1-UP The circle indicates that the component has screw terminals and a wire can be disconnected from it. 3BL1-UP 3ZL1-UP 4HL1-UP 5AL1-UP 3WM1-UP 4KM1-UP H A RN ESS C ON NEC T OR LOC A TIO N C HA R T No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. S chemati c Lo cat ion M achi ne Lo cat ion P 1 - R1 E -6 1 P 2 - R2 D-6 1 10 P 3 - R3 C-5 2 10 P 4 - R4 D-5 2 10 P 5 - R5 D-5 3 10 P 6 - R6 E -5 3 4 P 7 - R7 A -6 * Con tac ts Con nect or 10 10 M ach ine locations ar e r e peat ed for c onnecto rs loc ated c los e t oget her. * = Connecto r is locat ed at t he com pon ent. © 1993 Caterpillar All Rights Reserved Harness And Wire Electrical Schematic Symbols A AA Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. 11 B 12 18 2 15 16 1 13 Pin or Socket Number 3 A 17 4 Wire, Cable, or Harness Assembly Identification 19 10 Component Part Number A A 325-PK-14 Pin AA 1 1 7 6 9 5 Single Wire Connector C 8 3 2 14 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. A 3 B 14 1 18 RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. 13 10 4 11 15 2 17 12 6 9 8 2 7 16 19 5 1 3 CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. Machine Harness Connector And Component Locations Printed in U.S.A.
KENR2474 May 1988 PR-450 Electrical Panel 7DC315-UP © 1988 Caterpillar All Rights Reserved Printed in U.S.A.
10 COMPONENT LOCATIONS B 2 3 Engine Location 6 9 7 11 A 1 5 8 1 4 KENR2533 October 1993 Component Description Schematic Location Engine Location Component Description Schematic Location 1 Alarm - Backup C-7 7 Selenoids (2) - Brake/Interlock 2 Alternator C-3 8 Selenoids (4) - Vibration/Select E-3 E-3 3 Batteries B-3 9 Switch - Air Filter C-3 3 Breaker - Alternator C-3 B Switch - Backup Alarm C-6 3 Breaker - lamp D-3 10 Switch - Belt B-3 A Flasher D-5 A Switch - Brake E-5 3 Fuse C-2 9 Switch - Engine Oil Pressure C-3 4 Horn - Forward E-2 A Switch - Horn D-5 A Lamp - Alternator Indicator E-5 B Switch - Interlock C-6 5 Motor - Spray Pump C-7 A Switch - Key Start C-4 6 Motor - Starter C-3 A Switch - Light E-5 A Relay - Brake(No.1) E-4 B Switch - Neutral C-6 A Relay - Brake(No.2) D-4 11 Switch - Seat C-7 A Relay - Interlock(No.1) D-4 A Switch - Spray C-5 A Relay - Interlock(No.2) D-4 A Switch - Turn Signal D-5 3 Relay - Main Power D-3 B Switch - Vibration Control C-6 A Relay - Spray C-4 B Switch - Vibration Select C-6 3 Relay - Start D-3 A Timer C-5 A Service Meter E-5 CB-214C & CB-224C Vibratory Compactors Electrical System A = components located in operators front console. B = Components located inside vibratory lever control. 9XK1-UP 3AL1-UP A Harness Connector Location Chart 11 8 10 9 B 2 Connectors Machine Location 24 contacts A 1 CAT Harness and/or Components A - 1G-4633 1 4 A - 1G-4633 A - 1G-4633 C C-6 B - 1G4634 A - 1G-4633 1 4 Contacts C-6 B - 1G4634 6 Contacts 6 D-6 C - 1G-3894 C 3 Schematic Location B-4 D - 104-7726 A = Connectors located in operator's console. 5 C = Connectors located under floor plate in operator's compartment. 7 © 1993 Caterpillar All Rights Reserved Machine Harness Connector and Component Locations Electrical Schematic Symbols And Definitions Harness And Wire Electrical Schematic Symbols A AA T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Wire, Cable, or Harness Assembly Identification Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Component Part Number Single Wire Connector Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. C A A 325-PK-14 Pin AA 1 Wire Color Socket Normally closed switch that will open with an increase of a specific condition. 2 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 9X-1123 325-PK-14 200-BK-14 Circuit Number Identification The circle indicates that the component has screw terminals and a wire can be disconnected from it. Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. Printed in U.S.A.
KENR2579 March 1994 CB-634 Vibratory Compactor Electrical System CB-634: 5CL1-UP 1994 Caterpillar All Rights Reserved Printed in U.S.A.
Harness And Wire Electrical Schematic Symbols Electrical Schematic Symbols And Definitions A AA T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 KENR2628-01 June 1998 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Wire, Cable, or Harness Assembly Identification Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Component Part Number Single Wire Connector Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. C A A 325-PK-14 Pin Normally closed switch that will open with an increase of a specific condition. AA 1 325-PK-14 Wire Color Socket 2 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 9X-1123 200-BK-14 Circuit Number Identification The circle indicates that the component has screw terminals and a wire can be disconnected from it. Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. No circle indicates that the wire cannot be disconnected from the component. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. This indicates that the component has a wire connected to it that is connected to ground. T This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. CS-431C, CP-433C, & CS-433C Vibratory Compactors Electrical System CS-431C: 9XL1-UP 6EN1-UP 3WZ1-UP CP-433C: 2JM1-UP 1ZN1-UP 4JZ1-UP CS-433C: 3TM1-UP 2TN1-UP 5BZ1-UP SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. 1998 Caterpillar All Rights Reserved Printed in U.S.A.
Component Location Schematic Location E-15 Machine Location 11 B-12 12 Solenoid - Brake H-14 3 F-10, G-10 B Solenoid - Cold Start Timing C-14 13 C-12 5 Solenoid - Drum Offset H-13 24 Beacon - Light E-3 18 Solenoid - Flow Divider E-13 15 Breaker - Light C-4 B Solenoid - Fuel Shut-off C-14 13 A-B Normally Open B-C Normally Closed Breaker - Throttle Control D-3 19 Solenoid - Rear Wheel H-13 1 Cluster - Diagnostic Light H-7 A Solenoid - Speed H-14 3 Normally Closed Cluster - Functional Light H-9 A Solenoid - Throttle Control D-14 13 Off Machine Switch Specification Part No. 9D-7032 Function Backup Alarm Pressure 103-4977 Hour Meter Pressure 107-0611 Engine Oil Pressure 108-3190 Engine Coolant Temp. 114-4308 Hydraulic Temperature 165-2521 Hydraulic Oil Pressure Component Actuate Deactuate 517 ± 34.5 kPa MAX (75 ± 5 psi MAX) 60 kPa MAX (8.7 psi MAX) 93 ± 21 kPa (13.5 ± 3.1 psi) 107 ± 1.5 °C (224.6 ± 34.7 °F) 92 ± 2.8 °C (198 ± 37 °F) 1400 kPa MAX (205 psi MAX) 414 ± 34.5 kPa MIN (60 ± 5 psi MIN) 28 ± 15 kPa (4 ± 2 psi) 70 ± 21 kPa (10.2 ± 3.1 psi) 100 °C MIN (212 °F MIN) 83 °C MIN (181 °F MIN) 1100 ± 75 kPa (160 ± 11 psi) Contact Position Normally Open Alarm - Backup Alternator Assembly - Diode Normally Open Normally Open Batteries Flasher A-C Normally Closed A-B Normally Open B Solenoid - Vibration Control G-15 7 A Starter Motor B-12 6 Fuses - Cab Option H-1 C Switch - Rear Wheel C-2 B Gauge - Fuel I-9 A Switch - 3 Speed F-5 B Gauge - Ground Speed I-8 A Switch - Auto Vibration (Fwd) G-3 B Gauge - Vibration Tach I-9 A Switch - Auto Vibration (Rev) G-3 B Horn - Warning E-12, E-10 16 Switch - Auto/Manual H-4 B Lamp - Indicator G-9 A Switch - Backup Alarm Pressure G-5 B Lamp - Flow divider indicator C-2 C Switch - Beacon H-1 C Motor - Front Wiper 6T-3670 140-2238 Resistor: Cold Start Timing ¹ At room temperature. 4 Switch - Brake G-4 B 22 Switch - Disconnect C-12 2 F-2 22 Switch - Drum Offset 14 Switch - Engine Coolant Temperature Motor - Rear Wiper F-2 25 Switch - Engine Oil Pressure C-15 9 Empty: 0 to 3 Full: 86 to 94 Motor - Washer F-1 26 Switch - Fan H-1 C Relay - Brake #1 F-4 20 Switch - Flow Divider E-3 C 25 Relay - Brake #2 F-4 20 Switch - Front Water Spray B-3 B Relay - Coolant Temperature D-5 20 Switch - Front Wiper/Washer G-1 C Relay - Engine Oil Pressure D-5 20 Switch - Hour Meter Pressure C-15 9 Relay - Functional Light E-5 20 Switch - Hydraulic Oil Pressure E-12 9 Relay - Hydraulic Charge Oil Pressure D-5 20 Switch - Hydraulic Temperature E-12 4 Relay - Hydraulic Temperature E-5 20 Switch - Ignition G-9 A B-2 20 Switch - Interior Light I-1 23 B-11, C-3 B Switch - Light C-4 B B Resistance (Ohms)¹ Sender: Fuel Level I-7 D-12 D-14 Motor - Rear Water Pump Resistor, Sender and Solenoid Specifications Relay - Intermittent Relay - Main C-1 B D-15, C-14 10 Relay - Neutral Start # 1 I-4 20 Switch - Neutral Start G-4 Relay - Neutral Start # 2 F-4 20 Switch - Rear Water Spray C-3 B B-12 20 Switch - Rear Wiper/Washer F-2 C Relay - Warning Light E-5 20 Switch - Start Aid Resistor - Cold Start Timing C-14 B Switch - Throttle Control Resistor - Fuel Shut-off C-14 B Resistor - Start Aid E-5 B Sender - Fuel E-12 8 Sensor - Front Speed E-14 21 Relay - Start KENR2756 January 2000 Machine Location 21 B-4 Motor - Front Water Pump Component Description Sensor - Front Vibration Sensor Schematic Location E-12 G-8, G-7 Fuses Meter - Hour Part No. Component G-9 A H-7, D-3 A Switch - Turn Light B-5 B Switch - Vibration On/Off G-4 B Switch - Warning Horn G-5 B Electrical Schematic Symbols And Definitions T Temperature Symbol Pressure Symbol Flow Symbol Level Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. CB-535B Vibratory Compactor Electrical System Normally closed switch that will open with an increase of a specific condition. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 3AR152-UP The circle indicates that the component has screw terminals and a wire can be disconnected from it. No circle indicates that the wire cannot be disconnected from the component. Machine locations are repeated for components located close together. A Located in or near the center dash panel. B Located in or near the lefthand dash panel. C Located in or near the righthand dash panel. Related Electrical Service Manuals Title This indicates that the component has a wire connected to it that is connected to ground. Form Number Alternator: 9W-3043 SENR3685 Electric Starting Motor: 143-0541 SENR3828 This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Printed in U.S.A. © 2000 Caterpillar All Rights Reserved Harness And Wire Electrical Schematic Symbols Wire Description Wire Number Wire Color Description Wire Number Wire Color Power Circuits 29 28 15 25 Connector Location 27 Description 101 RD Bat (+) B439 RD Front Drum Vpm Sensor 103 YL Aux Ckt B440 GN Rear Drum Vpm Sensor 105 BR Key Sw B440 RD Vibration Sensor 109 OR Alt Output (+) Term. B440 WH Vibration Sensor 110 GN Water Spray Fuse 112 PU Main Power Rly Output 537 GN Turn Signal SW To Flasher 114 GN Light Switch 568 GN Warning Buzzer To Diodes 121 YL Back Alarm To Lamp 123 WH Gauges 604 OR Stop Lamp 148 WH Start Aid 605 YL Turn Lamp - Left 155 PK Brake Fuse 606 GY Turn Lamp - Right 173 YL Flasher (option) 608 GN Flood Lamp - Rear 175 PK Drum Offset 611 PU Head Lamp Hi 176 WH Recording Module (option) 614 PU Park/Tail/Dash/Lamp E-15 26 176 YL Recording Module (option) 619 GN Head Lamp Lo CONN 2 E-14 27 181 GY Eng Speed Ctrl (+) Bat 635 BR Flasher to Indicator CONN 3 Ground Circuits 27 CONN 4 F-13 27 200 BK Main Chassis 751 GN XMSN Shift Sol No1 Or 3 CONN 5 C-11 32 200 GY Main Chassis 777 PU Brake Release Motor CONN 6 E-11 32 206 BK Bat Side Of Disconnect B765 BR Park Brake SW To Relay CONN 7 E-11 27 220 BK Eng Oil Press Sensor C720 BU Relay Interlock CONN 8 B-10, I-2 12 221 BK Eng Coolant Temp Sensor C729 BU Rear Wheel - SW To Sol BK Hyd Oil Temp Sensor C730 BR Flow Divider - SW to Sol BK XMSN Ctrl Ident Code 0 C850 GN Amp Signal To Recording Module Basic Machine Circuits C851 PU Speed Amplifier CONN 9 B-10, I-2 12 226 CONN 10 B-10, I-2 12 276 CONN 11 F-9 A CONN 12 F-8 A 304 WH Starter Relay No1 Output A919 BU Left Eng Throttle SW To Relay/Diode CONN 13 F-8 A 306 GN Starter Relay Coil To Neut Start SW A920 BR Left Eng Throttle SW To Relay/Diode 307 OR Key SW To Neutral Start SW A953 PK Right Console Eng Throttle SW To Relay/Diode 308 YL Main Power Relay Coil A982 BR Eng Throttle Cont 309 GY Alternator Regulator Term. A983 BU Eng Throttle Cont - Signal CONN 14 F-8 A CONN 15 F-7 A CONN 16 H-4 B CONN 17 D-3, G-2 C 321 BR Backup Alarm Lamp B920 GN FWD/REV (Fwd) SW To EDC GY Warning Horn (Forward) B921 WH FWD/REV (Rev) SW To EDC CONN 19 H-2 C 322 CONN 20 H-2, E-1 C 326 PU Key SW "C" Term. C922 BR Front Drum Water Pump CONN 21 H-2 C 330 YL Neutral Start Relay Coil C923 OR Rear Drum Water Pump GN Start Aid SW To Start Aid Resistor C924 YL Forward Vibratory Valve OR Start Aid Resistor To Start Aid C925 GN Reverse Vibratory Valve C926 BU Front Drum Select Solenoid CONN 22 G-2 C 376 CONN 23 G-2 C 377 Monitoring Circuits CONN 24 G-2 C The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. 26 28 14 15 29 27 Machine Harness Connector And Component Locations Pin or Socket Number Wire, Cable, or Harness Assembly Identification 400 GN Service Meter SW C928 GY Left Hand Offset 405 GY Opr Mon Oil Press(Low Setting) C929 WH Right Hand Offset 406 PU Opr Mon Coolant Temp C930 BR Functional Lights GP to Relay 419 YL Opr Mon Parking Brake C931 OR Warning Lights GP to Relay 428 OR Opr Mon Xmsn Oil Temp C932 YL Vib Cut-Out SW to Auto Vib SW 439 YL Lamp Indicator C933 GN Auto/Manual SW to Forward/Reverse Press SW 447 PK Fuel Level Gauge C934 BU Auto Vib SW to Forward/Reverse SW 449 BU Speed Amplifier C935 PU Front SW to Timer 449 RD Spdom Sender (Signal No. 1) C936 GY Spray SW to Front Water Pump 449 WH Spdom Sender (Signal No. 1) C937 WH Intermittent Relay To Timer 450 BU Vibration Amplifier C938 BR Diagnostic Warning Horn 450 YL Tach Sender (+) N909 PU Timing Advance Request 465 OR Low Charge PressWarning N910 GN Timing Advance Command B438 OR Water Spray Indicator Component Part Number Single Wire Connector C Control Circuits D-13 25 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Lighting Circuits CONN 1 14 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 Accessory Circuits Machine Location Connector Number AA 1 Monitoring Circuits (Continued) Schematic Location 26 A A A 325-PK-14 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
KENR2763 January 1996 Harness And Wire Electrical Schematic Symbols Electrical Schematic Symbols And Definitions A AA T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. C A A 325-PK-14 Pin Normally closed switch that will open with an increase of a specific condition. AA 1 325-PK-14 Wire Color Socket 2 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 9X-1123 200-BK-14 Circuit Number Identification The circle indicates that the component has screw terminals and a wire can be disconnected from it. Wire Gauge CP-323C And CS-323C Vibratory Compactor Electrical System Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. No circle indicates that the wire cannot be disconnected from the component. CP-323C 1EN1-UP CS-323C: 6DM1-UP REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. This indicates that the component has a wire connected to it that is connected to ground. T This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. © 1996 Caterpillar All Rights Reserved Printed in U.S.A.
Electrical Schematic Symbols And Definitions A AA Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 T KENR2766 July 1995 Harness And Wire Electrical Schematic Symbols 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. C A A 325-PK-14 Pin Normally closed switch that will open with an increase of a specific condition. AA 1 Wire Color Socket 2 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 9X-1123 325-PK-14 200-BK-14 Circuit Number Identification The circle indicates that the component has screw terminals and a wire can be disconnected from it. Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. No circle indicates that the wire cannot be disconnected from the component. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. CB-535B Vibratory Compactor Electrical System 3AR1-UP This indicates that the component has a wire connected to it that is connected to ground. T This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. © 1995 Caterpillar All Rights Reserved Printed in U.S.A.
Electrical Schematic Symbols And Definitions Harness And Wire Electrical Schematic Symbols A AA T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 KENR2856 December 1995 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Wire, Cable, or Harness Assembly Identification Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Component Part Number Single Wire Connector Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. C A A 325-PK-14 Pin AA 1 Wire Color Socket Normally closed switch that will open with an increase of a specific condition. 2 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 9X-1123 325-PK-14 200-BK-14 Circuit Number Identification The circle indicates that the component has screw terminals and a wire can be disconnected from it. Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T CB-634C Vibratory Compactor Electrical System 3BR1-UP SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. © 1995 Caterpillar All Rights Reserved Printed in U.S.A.
Electrical Schematic Symbols And Definitions Harness And Wire Electrical Schematic Symbols A AA T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 KENR2857 December 1995 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Wire, Cable, or Harness Assembly Identification Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Component Part Number Single Wire Connector Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. C A A 325-PK-14 Pin AA 1 Wire Color Socket Normally closed switch that will open with an increase of a specific condition. 2 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 9X-1123 325-PK-14 200-BK-14 Circuit Number Identification The circle indicates that the component has screw terminals and a wire can be disconnected from it. Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T CB-434C Vibratory Compactor Electrical System 4DN1-UP SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. © 1995 Caterpillar All Rights Reserved Printed in U.S.A.
Part No. Function Actuate Deactuate Contact Position Wire Number Wire Color Wire Number Description Wire Description Color Monitoring Circuits Continued 52±3°C 43°C MIN Normally (125.6±6°F) (109.4°F MIN) Closed 101 RD Bat (+) 82.22±2.78°C 73.89°C MIN Normally 104 RD Alt Breaker (180±5°F) (165°F MIN) Open 107 RD Eng Shut - Down Fire Suppr ¹A hysteresis band exist: with increasing pressure the closed condition can be maintained up to 2800kPA (405 psi), 109 RD Alt Output (+) Term. 500 BR Wiper - Front (Park) with decreasing pressure the closed condition can be maintained down to 170 kPa (25 psi). 112 RD Main Power Rly Output 501 GN Wiper - Front (Low) ²Contact position at the contacts of the harness connector. 115 RD Lamp/Wiper 506 PU Washer - Front 120 YL Radio 508 PU Radio Speaker - Left 121 YL Back Alarm To Lamp 509 WH Radio Speaker - Left (Commom) 124 GN A/C 511 BR Radio Speaker - Right 142 BU Aux Ckt 512 GN Radio Speaker - Right (Common) 151 GN Hyd Lock Sol 513 OR A/C Compressor/Refrigerant Pressure SW 190 BK Eng Gov/Monitor 515 GY Blower Motor (HI) 517 BU Blower Motor (Low) 3E9350 Oil Cooler Temp Switch 7N7848 Hyd Oil Temp Switch KENR2918 January 2000 Wire Description Off Machine Switch Specification Power Circuits PK GN Fuel Level guage Hyd Shutoff Valve Accesory Circuits Ground Circuits 200 BK Main Chassis 519 PK Thermostat To Refrigerant Press. SW 201 BK Operator Monitor Return 535 BU SW To Wiper SW A588 GN Safety Sol Relay To Sol+ Basic Machine Circuits Related Electrical Service Manuals 447 C400 Lighting Circuits 306 GN Starter Relay Coil To Neut Start SW 307 OR Key SW To Neutral Start SW 612 GY Backup Lamp 309 GY Alternator Regulator Term. 616 BU Bucket Flood Lamp/Boom Flood Lamp 310 PU Start Aid SW To Start Aid Sol 315 GN Start Aid Breaker To Start Aid Relay 762 YL Bucket Positioner Sol SW 320 OR Horn Relay Coil To SW 763 BU Torque Converter SW 321 BR Backup Alarm Lamp Travel Alarm 799 WH Sensor Power 322 GY Warning Horn (Forward) B786 BU Low Idle SW 323 WH Fuel Pump Power D746 PK Alt Signal To Anti-Start Relay 327 PK Shutdown Solenoid E771 OR Low Torque Mode Sol 330 YL Neutral Start Relay Coil 817 WH Back-Up Alarm Relay 877 YL Glow Plug Magnetic SW To Glow Plug D813 OR Low Idle SW HEDC Control Circuits Title Form Number 332 BU Shutdown SW To Shutdown Ctrl Alternator 163-3362 SENR5841 364 BU Engine Shutdown SW - Ctrl Monitoring Circuits D814 GY Implement Press SW 403 GN Alternator (R) Term. D815 PU Low Idle Indicator 405 GY Opr Mon Oil Press. (Low Setting) D816 WH Eng/Pump Cont Sol 406 PU Opr Mon Coolant Temp B965 GY Level Finish Sol 441 OR Eng Coolant Temp Guage K906 GN Swing Brake Sol - Signal 442 GY Hyd System Temp Guage K915 GN Fine Swing SW - E/P Controller CB-214D, CB-224D, and CB-225D Vibratory Compactor Electrical System CB-214D: 1TZ1-UP CB-224D: 8RZ1-UP CB-225D: 9FZ1-UP ©2000 Caterpillar All Rights Reserved Printed in U.S.A. Harness And Wire Electrical Schematic Symbols Component Location Schematic Location Component Machine Location Comonent Schematic Location Machine Location Alternator D-12 8 Solenoid - Drum Select A-10 19 Battery F-11 10 Solenoid - Flow Divider B-9 25 Breaker - Alternator Cicuit E-7 2 Solenoid - Fuel Shutoff A-11 20 Breaker - Light Circuit E-7 2 Solenoid - Interlock A-11 18 Control - Handle VIB A-5 15 Solenoid - Neutral/Brake A-10 21 Flasher F-3 3 Solenoid - VIB On/Off A-10 19 Fuse Block F-4/5 3 Starter F-10 9 Glow Plugs B-12 20 Switch - Brake B-1 1 Gound B-11 19 Switch - Cool Temp A-11 20 Ground - Chassis E-12/F-12 23/11 Switch - Drum Select E-1 1 Ground - Engine F-12 11 Switch - Emulsion F-1 1 Ground - Frame C-9 24 Switch - Flow Divider A-8 26 Ground - Front/Rear E-12 23 Switch - Hazard D-1 1 Hour Meter E-7 2 Switch - Horn C-1 1 Lights - Warning C-1 1 Switch - Hyd Oil Temp B-8 22 Pump - Emulsion Spray A-7 5 Switch - Key B-1 1 Pump - Water Spay (225 Only) A-7 4 Switch - Light F-2 1 Pump - Water Spay (214, 224 Only) A-7 6 Switch - Neutral A-5 14 Relay - Brake 1 A-3 14 Switch - Neutral Backup A-12 18 Relay - Brake 2 A-3 14 Switch - Oil Pressure A-11 20 Relay - Fan Motor A-4 14 Switch - Seat A-6 16 Relay - Interlock 1 A-3 14 Switch - Start Aid D-1 1 Relay - Interlock 2 A-2/E-7 14 Switch - Turn Signal E-1 1 Relay - Main Power E-8 2 Switch - Water Spray E-1 1 Relay - Spray A-4 14 Timer F-3 3 Relay - Starter E-8 2 Turn Signal Indicator D-1 1 Relay - Starter A-2/E-7 14/2 VIB Lamp Indicator D-1 1 Electrical Schematic Symbols And Definitions A AA 4 25 26 19 21 18 23 Pressure Symbol 9 20 8 6 2 Level Symbol Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Flow Symbol Pin or Socket Number 10 2 11 24 15 Temperature Symbol 17 3 14 5 Receptacle T 1 16 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 22 Plug 1 2 1 2 1 Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector Normally open switch that will close with an increase of a specific condition (temp-press-etc.). C A A 325-PK-14 Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Pin Normally closed switch that will open with an increase of a specific condition. AA 1 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. Wire Gauge Electrical Schematic Symbols And Definitions The circle indicates that the component has screw terminals and a wire can be disconnected from it. Machine locations are repeated for components located close together. A Located in the cab. B Located in the lefthand console. FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. 15 C Located in the righthand console. 1 D Located on or near relay panel. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. No circle indicates that the wire cannot be disconnected from the component. 3 16 19 2 14 22 20 18 5 Connector Location CONN 1 Schematic Location D-9 Machine Location 25 CONN 2 C-9 25 CONN 3 E-5 24 CONN 4 E-5 24 CONN 5 D-5 24 CONN 6 C-5 24 Connector Number 21 6 4 T 10 8 26 This indicates that the component has a wire connected to it that is connected to ground. 17 SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. 9 This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. 24 11 25 23 CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. The connectors shown in this chart are for harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Machine Harness Connector And Component Locations MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
KENR3058 October 1996 Harness And Wire Electrical Schematic Symbols 5 2 1 9 15 11 A AA 10 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. 1314 Pin or Socket Number 3 Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector C A A 1 325-PK-14 Pin 8 7 6 9 4 AA 9X-1123 325-PK-14 Wire Color Socket 12 2 Circuit Number Identification 5 1 2 PS-150B Pneumatic Compactor PS-200B Pneumatic Compactor Electrical System 200-BK-14 Wire Gauge Electrical Schematic Symbols And Definitions 7 6 9 4 11 FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. 1314 PS-150B: 3XR001-UP PS-200B: 5JR001-UP REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 15 12 SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T 10 RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. 3 CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. 8 MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. Electrical Schematic Symbols And Definitions STANDARD COMPONENTS Item Component No. 1 Item Component No. Instrument Cluster 9 Batteries Starter Relay Ignition Switch 10 3 Water Spray Motor 11 Starter Motor 4 Water Spray Switch 12 Alternator Main Relay 13 Brake Solenoid Two Speed Solenoid Interlock Solenoid 2 5 Two Speed Switch 14 7 Horn Switch 15 8 Electrical Disconnect Switch 6 T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Normally closed switch that will open with an increase of a specific condition. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. The circle indicates that the component has screw terminals and a wire can be disconnected from it. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. © 1996 Caterpillar All Rights Reserved Printed in U.S.A.
Electrical Schematic Symbols And Definitions Harness And Wire Electrical Schematic Symbols A AA Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Receptacle Plug 1 2 1 2 1 2 KENR3069-01 March 1998 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. C A A 325-PK-14 Normally closed switch that will open with an increase of a specific condition. Pin AA 1 325-PK-14 Wire Color Socket 2 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 9X-1123 200-BK-14 Circuit Number Identification The circle indicates that the component has screw terminals and a wire can be disconnected from it. Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. No circle indicates that the wire cannot be disconnected from the component. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. This indicates that the component has a wire connected to it that is connected to ground. T This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. CB-224C Combi Vibratory Compactor Electrical System CB-224C Combi: 3AL1-UP SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. © 1998 Caterpillar All Rights Reserved Printed in U.S.A.
Off Machine Switch Specification Part No. Function 3E-6449 Temperature 3E-6451 Coolant Temperature 3E-7382 103-4977 VIB Charge Pressure Propel Charge Pressure Engine Oil Pressure Deactuate Contact Position 38 ± 3°C (100 ± 5°F) 27°C MIN (80.6°F) Normally Closed 107.0 ± 3.0°C (224.6± 6.0°F) 1400 kPa MAX (205 psi MAX) 60.0 kPa (8.7 psi) 93.0°C MIN (199.0°F MIN) 1100 ± 150 kPa (160 ± 22 psi) – Schematic Location E-2 Machine Location 3 Alarm - Backup F-10 5 Relay - Start Alternator G-10 8 Relay - Throttle E-5 4 Amplifier H-15 B Relay - Warning Light G-2 B Assembly - Regulator I-13 B Resistor B-14 B Batteries H-10 1 Rheostat B-14 B Breaker - Alternator Ckt G-6 B Sender - Fuel G-10 19 Breaker - Throttle F-5 B Sensor - VIB Speed H-12 20 Control - Throttle G-4 A Solenoid - A/C Compressor Group D-7 8 Controller - VIB C-15 B Solenoid - Axle Interlock H-9 11 Converter F-13 A Solenoid - Drum Interlock H-8 11 Dial - CMV F-15 A Solenoid - Engine Shutdown H-10 7 Dial - Frequency G-15 A Solenoid - Speed Shift E-8 12 Dial - RMV F-15 A Solenoid - Throttle Control H-7 7 Diode #1 D-6 A Solenoid - VIB Control H-9 21 Diode #2 D-6 A Switch - A/C D-8 B Diode #3 D-6 A Switch - A/C Refrigerant C-6 8 Fuses H-5 B Switch - Backup Alarm H-4 B G-12 B Switch - Beacon I-5 B Gauge - Fuel B-3 A Switch - Brake H-4 B Gauge - VPM Tach B-4 A Switch - Coolant Temperature G-10 8 Resistance (Ohms)¹ Gauge - Warning B-5 A Switch - Disconnect H-9 2 24.6 ± 2.0 21.7 ± 2.0 Ground - Platform H-12 10 Switch - Engine Oil Pressure H-8 22 Group - Conditioner/Heater B-9 18 Switch - Engine Oil Pressure H-8 22 Horn - Forward D-2 10 Switch - Fan D-10 B Lamp - Alternator Indicator B-6 A Switch - Flood Light H-6 B Meter - Hour B-2 A Switch - Front Wiper C-10 B Motor - Front Washer Fluid C-8 15 Switch - Horn D-2 A Motor - Front Wiper B-12 17 Switch - Hydraulic Oil Temperature E-9 23 Motor - Rear Washer Fluid C-8 15 Switch - Key C-6 A Motor - Rear Wiper C-12 16 Switch - Neutral Start (Propel Pump) G-7 14 Motor - Starter H-10 6 Switch - Propel Charge Pressure H-7 24 Recorder I-15 B Switch - Rear Wiper C-10 B Receptacle - Housing H-14 B Switch - Ref VIB C-14 B Relay - Brake G-3 B Switch - Speed Select D-2 A Relay - Brake G-3 B Switch - Start Aid C-5 A Relay - Coolant Temperature H-2 B Switch - Temperature F-9 14 Relay - Engine Oil Pressure H-2 B Switch - Throttle C-2 A Relay - Function Light G-2 B Switch - VIB Charge Pressure F-7 25 Relay - Hydraulic Oil Pressure H-3 B Switch - VIB On/Off H-4 B Relay - Hydraulic Temperature G-2 B Switch - VIB Select H-5 B Valve - Start Aid F-6 23 Component Alarm Normally Closed A-C Normally Closed A-B Normally Open Normally Open 93.00 ± 21.00 kPa 70.00 ± 21.00 kPa Normally Open (13.49 ± 3.05 psi) (10.15 ± 3.05 psi) 92 ± 1.5 °C 85°C A-B Normally Open 110-514 Hydraulic Oil Temperature (197.6 ± 34.7 °F) (185°F MIN) B-C Normally Closed 275 to 1750 kPa¹ – 114-5333 A/C High/Low Pressure Normally Open² (40 to 255 psi) – ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 3740 kpa (542.4 psi), with decreasing pressure the closed condition can be maintained down to 166 kpa (24.1 psi). ² Contact position at the contacts of the harness connector. 107-611 Engine Oil Pressure Fuse - Recording Module Resistor, Sender and Solenoid Specifications Part No. Component Description 3E-1906 VIB Control: Solenoid: Fixed Variable Solenoid: A/C Clutch 8C-3663 Solenoid: Engine Shutdown -- 137-1761 17.6 ± 0.6 Latch: 1.55 ± 0.15 Unlatch: 10.3 ± 1.03 130 ± 6.5 Resistor: VIB Controller Fuel: Sender: Full Empty 144-9420 27.5 to 39.5 240 to 260 ¹ At room temperature unless otherwise noted. Related Electrical Service Manuals Title Alternator: Relay - Main E-5 4 Relay - Neutral Start G-3 B Component Relay - Neutral Start Schematic Location H-3 Machine Location B E-5 4 Electrical Schematic Symbols And Definitions T Flow Symbol Level Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. CS-531D, CP-533D, and CS-533D Vibratory Compactor Electrical System Normally closed switch that will open with an increase of a specific condition. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. The circle indicates that the component has screw terminals and a wire can be disconnected from it. AGH1-UP 4MZ1-UP AET1-UP 5CZ1-UP AFC1-UP 6AZ1-UP No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. A = Located in or on the Steering Console. SENR3685 Temperature Symbol Pressure Symbol Machine locations are repeated for components located close together. Form Number 9W-3043 KENR3530 April 2000 Component Location Actuate B = Located in or on the Right Console. Printed in U.S.A. © 2000 Caterpillar All Rights Reserved Harness And Wire Electrical Schematic Symbols Wire Description Wire Number Wire Color Description Wire Number Wire Color 1 5 14 23 12 19 13 Schematic Location Machine Location CONN 1 H-15 10 CONN 2 F-14 A CONN 3 G-13 RD Bat (+) 447 PK Fuel Level Gauge 103 YL Speed Switch 449 BU Recorder 105 RD Key Sw 450 BU Recorder 109 RD Alt Output (+) Term. 450 YL Tach Sender (+) 110 GN Recorder 465 OR Low Charge Press Warning 111 OR Compactometer 112 PU Main Power Rly Output 500 BR Wiper - Front (Park) 115 PK Front Flood 501 GN Wiper - Front (Low) 116 BR Rear Flood 502 OR Wiper - Front (HI) 118 GY Wipers 503 BR Wiper - Rear (Park) 121 YL Back Alarm To Lamp 504 YL Wiper - Rear (Low) 122 RD Dome Lamp 505 BU Wiper - Rear (HI) 123 WH Gauge Relay 506 PU Washer - Front 124 GN A/C 507 WH Washer - Rear 128 RD Forward Horn 513 OR A/C Compressor/Refrigerant Pressure SW 143 PK Speed Switch 515 GY Blower Motor (HI) 143 RD Brake 516 GN Blower Motor (Medium) 144 RD Hood Actr 517 BU Blower Motor (Low) Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Accessory Circuits 21 11 16 A 18 17 7 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. 6 A 2 15 26 10 B 9 H-13 10 CONN 5 H-13 10 CONN 6 H-12 10 CONN 7 H-12 10 CONN 8 H-12 10 CONN 9 C-12 16 CONN 10 B-12 17 CONN 11 C-10 26 CONN 12 B-9 18 148 WH Start Aid 521 YL A/C SW To Refrigerant SW CONN 13 C-9 B 165 RD Recording Module 522 WH A/C Clutch To Thermostat SW CONN 14 C-9 B 176 YL Recording Module 567 WH A/C SW Jumper CONN 15 D-9 B 181 GY Eng Speed Ctrl (+) Bat 568 GN Warning Buzzer To Diodes CONN 16 D-8 26 CONN 17 C-7 8 200 BK Main Chassis 603 PK Rotary Beacon 1 25 4 20 Ground Circuits 8 CONN 19 D-7 8 206 BK Recorder 603 PU Rotary Beacon CONN 20 G-6 9 210 BK Freq Dial 607 PK Flood Lamp - Front CONN 22 G-6 9 220 BK Eng Oil Press Sensor 608 GN Flood Lamp - Rear CONN 23 G-6 9 221 BK Eng Coolant Temp Sensor CONN 24 E-5 4 CONN 25 E-5 4 226 BK Hyd Oil Temp Sensor 751 GN XMSN Shift Sol No1 Or 3 230 BK RMV Dial 776 YL Brake Release Relay Cont 276 BK XMSN Ctrl Ident Code 0 777 PU Brake Release Motor 277 BK XMSN Ctrl Ident Code 1 801 PU Ref Vib Switch Basic Machine Circuits 852 GN Recorder E-5 CONN 27 H-4 B CONN 28 E-4 10 CONN 29 E-3 10 CONN 30 E-3 10 16 13 8 B 7 3 14 26 23 2 5 19 22 6 9 4 C 15 18 11 12 1 20 24 25 Machine Harness Connector And Component Locations Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions Control Circuits 301 BU Starter No1 Sol 906 YL Converter 304 WH Starter Relay No1 Output 916 OR Scraper XMSN Gear Code 6 306 GN Starter Relay Coil To Neut Start SW 919 GN Eng Overspeed Test SW 307 OR Key SW To Neutral Start SW 920 GN Oil Press SW To Lift Detent 308 YL Main Power Relay Coil 921 WH XMSN Sol No 1 Or 3 Return 309 GY Alternator Regulator Term. 923 YL XMSN Sol No 3 Or 1 Return 311 PU Start Aid Sol To Temp SW 924 OR XMSN Sol No 4 Or 5 Return 321 BR Backup Alarm Lamp A919 BU Left Eng Throttle SW To Relay/Diode 322 GY Warning Horn (Forward) A920 BR Left Eng Throttle SW To Relay/Diode 326 RD Key SW "C" Term. A953 PK Right Console Eng Throttle SW To Relay/Diode 330 YL Neutral Start Relay Coil A982 BR Eng Throttle Cont 373 GN Start Aid Switch To Timer A983 BU Eng Throttle Cont - Signal 377 OR Start Aid Resistor To Start Aid B919 GN VIB On/Off SW To FWD/REV SW 397 OR Hood Raise Motor B920 GN FWD/REV (Fwd) SW To EDC 398 BU Hood Raise Motor B921 WH FWD/REV (Rev) SW To EDC C720 BU Relay Interlock Monitoring Circuits A A 325-PK-14 FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 10 21 Component Part Number Single Wire Connector A 4 CONN 31 E-2 10 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. 17 Wire, Cable, or Harness Assembly Identification Lighting Circuits D-7 CONN 26 Pin or Socket Number 3 22 CONN 4 CONN 18 AA 8 Connector Location Connector Number 24 A Monitoring Circuits (Continued) Power Distribution Circuits 101 Description 400 GN Service Meter SW C905 OR Cont to Relay 400 YL Recorder C906 PU Cont to SW 405 GY Opr Mon Oil Press(Low Setting) C930 BR Functional Lights GP to Relay 406 PU Opr Mon Coolant Temp C931 OR Warning Lights GP to Relay 428 OR Opr Mon Xmsn Oil Temp C938 BR Diagnostic Warning Horn 439 YL Lamp Indicator F765 BR Park Brake SW To Relay T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
KENR3589 December 2001 Part No. Off Machine Switch Specification Function Actuate Deactuate Contact Position 1400 kPa MAX 1100 ± 150 kPa A-B Normally Open (205 psi MAX) (160 ± 22 psi) A-C Normally Closed 60 kPa 28 ± 15 kPa 103-4977 Engine Oil Pressure Normally Open (8.7 psi) (4.0 ± 2.2 psi) 93.0 ± 21.0 kPa 70.0 ± 21.0 kPa 107-0611 Engine Oil Pressure Normally Open (13.5 ± 3.0 psi) (10.2 ± 3.0 psi) Coolant Temperature 107.0 ± 1.5 °C 100 °C MIN A-B Normally Open 108-3190 Hydraulic Oil Temperature (224.6 ± 34.7 °F) (212 °F MIN) B-C Normally Closed 275 to 1750 kPa¹ 114-5333 A/C High/Low Pressure Normally Open² (40 TO 255 psi) ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25psi). 3E-7382 VIB Charge Pressure Schematic Location ² Contact position at the contacts of the harness connector. Air Conditioner/Heater F-10 Resistor - Neutral Start Switch C-10 Machine Location 18 Alarm - Backup D-12 2 Resistor - Start Aid C-9 18 Alarm - Horn C-3 3 Resistor - VIB Controller (2) E-7 B Alternator D-11 4 Rheostat - VIB Controller E-7 B Arc Suppressor - A/C H-7 25 Sender - Fuel Level D-12 20 D-11,D-12 5 Sensor - Start Aid D-10 28 Breaker - Alternator (2) D-11 13 Sensor - VIB Tach C-8 14 Breaker - Throttle B-7 13 Solenoid - A/C Compressor Group H-6 25 Control - CAT Product Link B-8 7 Solenoid - Brake D-9 23 Control - Throttle D-4 B Solenoid - Cold Start Timing Advance C-12 25 Controller - VIB D-3 B Solenoid - Fuel Pump C-11 25 Diode F-4,G-4 A Solenoid - Speed Shift D-9 17 Fuses D-5,D-6 B Solenoid - Throttle Control C-10 18 Gauge - Fuel H-3 A Solenoid - VIB Pump C-9 15 Gauge - VPM Tach G-3 A Switch - A/C H-8 B Ground - Engine D-10 26 Switch - A/C Refrigerant H-6 25 Ground - Frame C-9 7 Switch - Beacon E-7 B Ground - Platform C-4 27 Switch - Brake D-4 B Ground - Platform F-9 27 Switch - Brake D-7 B Horn - Forward F-5 6 Switch - Coolant Temperature D-11 4 Lamp - Alternator Indicator F-3 A Switch - Disconnect D-11 13 Lamp - Warning F-3 A Switch - Engine Oil Pressure C-11 10 Meter - Hour H-3 A Switch - Engine Oil Pressure C-11 10 Motor - Front Washer Fluid G-8 11 Switch - Fan H-10 B Batteries Part No. Resistor, Sender and Solenoid Specifications Component Description 7W-1251 Resistance (Ohms)¹ Resistor: Start Aid 0.85 ± 0.1 137-1761 Resistor: VIB Controller 147-6937 Solenoid: Speed Shift 41.74 ± 4.2 148-1517 Resistor: Neutral Start 10 ± .3 153-4981 Sender: 130 ± 6.5 Empty: 240 to 250 Full: 28 to 33 Fuel Level ¹ At room temperature unless otherwise noted. Component Location Machine Location 1 Component Component Schematic Location Motor - Front Wiper E-9 8 Switch - Flood Light E-7 B Motor - Rear Washer Fluid G-8 11 Switch - Front Wiper H-10 B Motor - Rear Wiper E-10 9 Switch - Horn G-4 A Motor - Starter D-10 12 Switch - Hydraulic Temperature C-9 16 Relay - Brake (2) C-6 B Switch - Key E-3 A Relay - Coolant Temperature C-6 B Switch - Neutral Start (2) Relay - Engine Oil Pressure C-6 B Switch - Rear Wiper Relay - Function Light B-6 B Relay - Hydraulic Oil Pressure C-6 Relay - Hydraulic Temperature D-9 23 G-10 B Switch - Speed Select H-4 A B Switch - Start Aid E-4 A B-5 B Switch - Throttle H-4 A Relay - Main B-3 11 Switch - VIB Charge Pressure D-10 19 Relay - Neutral Start (2) C-5 B Switch - VIB On/Off D-4 B Relay - Warning Light C-5 B Switch - VIB Select E-7 B CS-423E, CS-433E, and CP-433E Vibratory Compactor Electrical System CS-423E: CFX1-UP CS-433E: CFP1-UP CP-433E: CFK1-UP Machine locations are repeated for components located close together. A = Located in or on the Steering Console. B = Located in or on the Right Console. Related Electrical Service Manuals Title Form Number Alternator: SENR3685 Electric Starting Motor: SENR3828 Printed in U.S.A. © 2001 Caterpillar All Rights Reserved 13 5 4 17 28 26 6 9 23 1 15 A 24 8 18 2 25 20 10 16 21 3 B 16 7 27 11 14 Connector Location Wire Color 101 RD 103 Electrical Schematic Symbols And Definitions Wire Number Wire Color Bat (+) 503 BR Wiper - Rear (Park) YL Throttle SW 504 YL Wiper - Rear (Low) 105 BR Key SW 505 BU Wiper - Rear (HI) 112 PU Main Power Relay Output 506 PU Washer - Front 115 PK Front Flood 507 WH Washer - Rear 116 BR Rear Flood 513 OR A/C Compressor/Refrigerant Pressure SW 118 GY Wipers 515 GY Blower Motor (HI) 121 YL Backup Alarm 516 GN Blower Motor (Medium) 122 RD Dome Lamp 517 BU Blower Motor (Low) 123 WH Gauge Relay 521 YL A/C SW To Refrigerant SW 124 GN A/C 522 WH A/C Clutch To Thermostat SW 128 RD Forward Horn 567 WH A/C Switch Jumper 143 PK Speed Select SW 568 GN Horn Alarm to Diodes 143 BR Brake Switch 148 WH Start Aid 603 PU Rotary Beacon Description Power Circuits 12 19 Wire Number Wire Description Description Accessory Circuits (Continued) Machine Location CONN 1 D-12 19 170 RD CAT Product Link 607 PK Flood Lamp - Front CONN 2 G-11 21 177 RD Main Breaker 608 GN Flood Lamp - Rear CONN 3 F-11 21 181 GY Engine Speed Control (+) Bat 615 YL Cab Flood Lamps (Rops) CONN 4 A-10 7 CONN 5 C-9 15 CONN 6 A-9 7 Ground Circuits BK Main Chassis 751 GN Speed Shift Solenoid 220 BK Engine Oil Pressure SW 776 YL Brake Relay 777 PU Brake Solenoid CONN 7 B-8 7 CONN 8 C-8 11 221 BK Engine Coolant Temperature SW CONN 9 C-8 11 226 BK Hydraulic Oil Temperature SW C720 BU Brake Relay to Neutral Start Relay CONN 10 E-8 21 CONN 11 H-8 B 229 BK CAT Product Link F765 BR Park Brake SW to Brake Relay CONN 12 E-5 24 276 BK VIB Charge Pressure SW 892 BR CAT Data Link (-) CONN 13 E-5 24 Basic Machine Circuits 893 GN CAT Data Link (+) CONN 14 E-5 24 CONN 15 D-4 B 4 CONN 16 D-4 B 25 CONN 17 C-3 3 9 A 8 28 18 CONN 18 C-3 B The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. 26 16 2 5 13 10 12 B 19 21 1 3 27 11 17 7 24 6 23 15 20 16 306 GN Starter Relay Coil C801 PU VIB Select SW 307 OR Key SW to Neutral Start Relay E825 GN VIB Controller 308 YL Main Power Relay Coil 906 PU VIB Controller 309 GY Alternator Regulator Terminal 916 BU VIB Controller to Rheostat 321 BR Backup Alarm 919 GN VIB Select SW 322 GY Warning Horn (Forward) 920 GN VIB Select SW to VIB Pump Solenoid 326 PU Fuel Pump Solenoid 921 WH VIB Select SW to VIB Pump Solenoid 330 YL Neutral Start Relay Coil 924 GN VIB Select SW to VIB Controller 373 GN Start Aid SW A919 BU Throttle Control to Throttle Control Solenoid 377 OR Start Aid Resistor to Start Aid A982 BR Throttle Control to Throttle SW A983 BU Throttle Control to Throttle Control Solenoid 400 GN Service Meter C901 PU Rheostat to Resistor ( Loc. E-7) 403 GN Alternator (R) Term. C905 OR Speed Select SW to Throttle SW 405 GY Opr Mon Oil Press. (Low Setting) C906 PU Throttle SW to VIB On/Off SW 406 PU Opr Mon Coolant Temperature C930 BR Function Light Relay to Warning Light Relay 428 OR Opr Mon Hydraulic Oil Temperature C931 OR Warning Light Relay to Warning Light 439 YL Lamp (Alternator Indicator) C938 BR Function Light Relay to Horn Alarm 447 PK Fuel Level Gauge T930 WH CAT Product Link 450 YL Tach Sender (+) T931 YL CAT Product Link 465 OR Low Charge Pressure Warning T932 PK CAT Product Link T934 OR CAT Product Link Monitoring Circuits 14 Accessory Circuits Machine Harness Connector And Component Locations Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Control Circuits 200 500 BR Wiper - Front (Park) T935 BU CAT Product Link 501 GN Wiper - Front (Low) T936 GN CAT Product Link 502 OR Wiper - Front (HI) Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Lighting Circuits Schematic Location Connector Number T Pressure Symbol Sender - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols Harness identification code This example indicates wire 135 in harness "AG". * * AG-C3 C-C4 130-6795 130-6795 325-A135 PK-14 Socket Pin Single Wire Connector 1 2 Wire Color Ground Circuit Connection Number Identification Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. * Harness identification letter(s) and a serializing code. The "C" stands for connector and the number indicates which connector in the harness. Wire, Cable, or Harness Assembly Identification Part Number For L-C12* AG-C4* Connector Assembly 3E-5179 111-7898 325-A135 PK-14 1 Wire Gauge Receptacle Plug 2 200-L32 BK-14 Pin or Socket Number 1 2 Fuse Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. 105-9344 Component Part Number
Off Machine Switch Specification Part No. Function Actuate 3E-6449 Temperature 27°C MIN 38 ± 3°C(100 ± 5°F) (80.6°F) Normally Closed 93.0°C MIN (224.6± 6.0°F) (199.0°F MIN) VIB Charge Pressure 1400 kPa MAX 1100 ± 150 kPa A-C Normally Closed Propel Charge Pressure (205 psi MAX) (160 ± 22 psi) A-B Normally Open 103-4977 Engine Oil Pressure 60.0 kPa (8.7 psi) 107-611 Engine Oil Pressure – 93.00 ± 21.00 kPa 70.00 ± 21.00 kPa (13.49± 3.05 psi) (10.15 ± 3.05 psi) 110-514 Hydraulic Oil Temperature Normally Closed Normally Open Normally Open 92 ± 1.5 °C 85°C A-B Normally Open (197.6 ± 34.7 °F) (185°F MIN) B-C Normally Closed 275 to 1750 kPa¹ 114-5333 A/C High/Low Pressure Component Location Schematic Location Machine Location Schematic Location Machine Location Alarm E-2 3 Alarm - Backup F-10 5 Relay - Neutral Start G-3 B Relay - Neutral Start H-3 Alternator G-10 B 8 Relay - Start E-5 4 Amplifier H-15 B Relay - Start Aid E-7 14 Assembly - Regulator Assembly - Timer I-13 B Relay - Throttle E-5 4 E-9 14 Relay - Warning Light G-2 B H-10 1 Resistor B-14 B Breaker - Alternator Ckt G-6 B Rheostat B-14 B Breaker - Throttle F-5 B Sender - Fuel G-10 19 Control - Throttle G-4 A Sensor - VIB Speed H-12 20 Controller - VIB C-15 B Solenoid - A/C Compressor Group D-7 8 Converter F-13 A Solenoid - Axle Interlock H-9 11 Dial - CMV F-15 A Solenoid - Drum Interlock H-8 11 Dial - Frequency G-15 A Solenoid - Engine Shutdown Dial - RMV F-15 A Diode #1 D-6 Diode #2 Diode #3 Fuses Contact Position 107.0 ± 3.0°C 3E-6451 Coolant Temperature 3E-7382 Deactuate – Normally Open² (40 to 255 psi) ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). ² Contact position at the contacts of the harness connector. Component Batteries H-10 7 Solenoid - Speed Shift E-8 12 A Solenoid - Throttle Control H-7 7 D-6 A Solenoid - VIB Control H-9 21 D-6 A Switch - A/C D-8 B H-5 B Switch - A/C Refrigerant C-6 8 G-12 B Switch - Backup Alarm H-4 B Gauge - Fuel B-3 A Switch - Beacon I-5 B Gauge - VPM Tach B-4 A Switch - Brake H-4 B Gauge - Warning B-5 A Switch - Coolant Temperature G-10 8 Ground - Platform H-12 10 Switch - Disconnect H-9 2 Group - Conditioner/Heater B-9 18 Switch - Engine Oil Pressure H-8 22 Heater - Air Inlet E-7 13 Switch - Engine Oil Pressure Horn - Forward D-2 10 Switch - Fan Lamp - Alternator Indicator B-6 A Meter - Hour B-2 A Motor - Front Washer Fluid C-8 15 Motor - Front Wiper B-12 Fuse - Recording Module Resistor, Sender, and Solenoid Specifications Part No. Component Resistance (Ohms)¹ Solenoid - VIB Control – Fixed: 24.6 ± 2.0 Variable: 3E-1906 21.7 ± 2.0 Solenoid - A/C Clutch 17.6 ± 0.6 Latch:1.55 ± 0.15 8C-3663 Solenoid - Engine Shutdown 137-1761 Resistor - VIB Controller Unlatch:10.3 ± 1.03 130 ± 6.5 Sender - Fuel 144-9420 Full:27.5 - 39.5 -12 Empty:240 - 260 -20 ¹ At room temperature Component Motor - Rear Washer Fluid H-8 22 D-10 B Switch - Flood Light H-6 B Switch - Front Wiper C-10 B Switch - Horn D-2 A 17 Switch - Hydraulic Oil Temperature E-9 23 C-8 15 Switch - Key C-6 A Motor - Rear Wiper C-12 16 Switch - Neutral Start (Propel Pump) G-7 14 Motor - Starter H-10 6 Switch - Propel Charge Pressure H-7 24 Recorder I-15 B Switch - Rear Wiper C-10 B Receptacle - Housing H-14 B Switch - Ref VIB C-14 B Relay - Brake G-3 B Switch - Speed Select D-2 A Relay - Brake G-3 B Switch - Start Aid C-5 A Relay - Coolant Temperature H-2 B Switch - Temperature F-9 14 Relay - Engine Oil Pressure H-2 B Switch - Throttle C-2 A Relay - Function Light G-2 B Switch - VIB Charge Pressure F-7 25 Relay - Hydraulic Oil Pressure H-3 B Switch - VIB On/Off H-4 B Relay - Hydraulic Temperature G-2 B Switch - VIB Select H-5 B Relay - Main E-5 4 KENR7039-02 February 2001 Electrical Schematic Symbols And Definitions T Title Form Number Alternator: 9W-3043 Flow Symbol Level Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. CS-563D, CP-563D, CS-573D and CS-583D Vibratory Compactor Electrical System CS-563D: 9MW1-UP 1SZ1-UP 2RZ1-UP CP-563D: 9ZW1-UP 5LZ1-UP CS-573D: CMK1-UP 2YZ1-UP Normally closed switch that will open with an increase of a specific condition. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. CS-583D: 2CZ1-UP 3GZ1-UP The circle indicates that the component has screw terminals and a wire can be disconnected from it. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Machine locations are repeated for components located close togather. Related Electrical Service Manuals Temperature Symbol Pressure Symbol A = Located in or on Steering Console. B = Located in or on Right Console. SENR3685 Printed in U.S.A. © 2001 Caterpillar All Rights Reserved Harness And Wire Electrical Schematic Symbols Wire Description Wire Number Wire Color Description Wire Number Wire Color Power Distribution Circuits 1 5 14 23 24 12 19 8 13 Connector Location¹ 21 CONN 1 Schematic Location H-15 Machine Location 10 CONN 2 F-14 A CONN 3 G-13 A CONN 4 H-13 10 CONN 5 H-13 10 CONN 6 H-12 10 CONN 7 H-12 10 CONN 8 H-12 10 CONN 9 C-12 16 CONN 10 B-12 17 CONN 11 C-10 26 CONN 12 B-9 18 CONN 13 C-9 B CONN 14 C-9 B CONN 15 D-9 B CONN 16 D-8 26 CONN 17 C-7 8 CONN 18 D-7 8 CONN 19 D-7 8 CONN 20 G-6 9 CONN 22 G-6 9 CONN 23 G-6 9 CONN 24 E-5 4 CONN 25 E-5 4 Connector Number CONN 26 E-5 4 CONN 27 H-4 B CONN 28 E-4 10 CONN 29 E-3 10 CONN 30 E-3 10 11 16 A 18 17 7 3 22 6 2 15 26 1 10 B 9 25 4 20 16 A 13 7 8 B 3 14 26 23 2 5 19 6 22 21 RD Bat (+) 500 BR Wiper - Front (Park) 103 YL Aux Ckt 501 GN Wiper - Front (Low) 105 RD Key Sw 502 OR Wiper - Front (HI) 109 RD Alt Output (+) Term. 503 BR Wiper - Rear (Park) 112 PU Main Power Rly Output 504 YL Wiper - Rear (Low) 115 PK Aux Ckt 505 BU Wiper - Rear (HI) 116 BR Aux Ckt 506 PU Washer - Front 118 GY Aux Ckt 507 WH Washer - Rear 121 YL Back Alarm To Lamp 513 OR A/C Compressor/Refrigerant Pressure SW 122 RD Aux Ckt 515 GY Blower Motor (HI) 123 WH Aux Ckt 516 GN Blower Motor (Medium) 124 GN A/C 517 BU Blower Motor (Low) 128 RD Aux Ckt 521 YL A/C SW To Refrigerant SW 143 BR Aux Ckt 522 WH A/C Clutch To Thermostat SW 143 RD Aux Ckt 567 WH A/C SW Jumper 148 WH Aux Ckt 568 GN Warning Buzzer To Diodes 160 PU Aux Ckt 181 GY Eng Speed Ctrl (+) Bat 603 PK Rotary Beacon Ground Circuits 603 PU Rotary Beacon BK Main Chassis 607 PK Flood Lamp - Front 220 BK Eng Oil Press Sensor 608 GN Flood Lamp - Rear 221 BK Eng Coolant Temp Sensor 226 BK Hyd Oil Temp Sensor 751 GN XMSN Shift Sol No1 Or 3 276 BK XMSN Ctrl Ident Code 0 776 YL Brake Release Relay Cont 277 BK XMSN Ctrl Ident Code 1 777 PU Brake Release Motor Basic Machine Circuits 916 OR Scraper XMSN Gear Code 6 9 15 18 4 10 11 12 1 20 24 25 CONN 31 E-2 10 ¹ The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located BU Starter No1 Sol 919 GN Eng Overspeed Test SW 304 WH Starter Relay No1 Output 920 GN Oil PressSW To Lift Detent 306 GN Starter Relay Coil To Neut Start SW 921 WH XMSN Sol No 1 Or 3 Return 307 OR Key SW To Neutral Start SW 923 YL XMSN Sol No 3 Or 1 Return 308 YL Main Power Relay Coil 924 OR XMSN Sol No 4 Or 5 Return 309 GY Alternator Regulator Term. A919 BU Left Eng Throttle SW To Relay/Diode 311 PU Start Aid Sol To Temp SW A920 BR Left Eng Throttle SW To Relay/Diode 321 BR Backup Alarm Lamp A953 PK Right Console Eng Throttle SW To Relay/Diode 322 GY Warning Horn (Forward) A982 BR Eng Throttle Cont 326 RD Key SW "C" Term. A983 BU Eng Throttle Cont - Signal 330 YL Neutral Start Relay Coil B919 GN VIB On/Off SW To FWD/REV SW 373 GN Start Aid Switch To Timer B920 GN FWD/REV (Fwd) SW To EDC 377 OR Start Aid Resistor To Start Aid B921 WH FWD/REV (Rev) SW To EDC C720 BU Relay Interlock 400 GN Service Meter SW C905 OR Cont to Relay 405 GY Opr Mon Oil Press(Low Setting) C906 PU Cont to SW 406 PU Opr Mon Coolant Temp C930 BR Functional Lights GP to Relay 428 OR Opr Mon Xmsn Oil Temp C931 OR Warning Lights GP to Relay 439 YL Lamp Indicator C938 BR Diagnostic Warning Horn 447 PK Fuel Level Gauge F765 BR Park Brake SW To Relay 450 YL Tach Sender (+) 465 OR Low Charge PressWarning Monitoring Circuits at or near the component. See the Component Location Chart. Machine Harness Connector And Component Locations Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector C A A 325-PK-14 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Control Circuits 301 1 2 1 2 Receptacle Plug Lighting Circuits 200 AA 1 Accessory Circuits 101 17 A Description Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
KENR7052-01 January 2000 Harness And Wire Electrical Schematic Symbols A AA Electrical Schematic Symbols And Definitions Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Pin or Socket Number T Pressure Symbol Temperature Symbol Level Symbol Wire, Cable, or Harness Assembly Identification Flow Symbol Single Wire Connector C A A 325-PK-14 Pin AA 1 2 Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. The circle indicates that the component has screw terminals and a wire can be disconnected from it. T This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. 200-BK-14 Circuit Number Identification Normally closed switch that will open with an increase of a specific condition. This indicates that the component has a wire connected to it that is connected to ground. 9X-1123 325-PK-14 Wire Color Socket Normally open switch that will close with an increase of a specific condition (temp-press-etc.). No circle indicates that the wire cannot be disconnected from the component. Component Part Number CB-334D & CB-335D Vibratory Compactor Electrical System CB-334D: 3JZ1-UP 4CZ1-UP CB-335D: 5PZ1-UP BBW1-UP SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. © 2000 Caterpillar All Rights Reserved Printed in U.S.A.
B 19 20 5 D 3 21 6 A 10 9 Connector Location C E 22 7 18 2 13 11 8 14 12 16 6 A 22 B 17 19 1 2 4 11 14 Schematic Location Connector Number 17 1 15 D 12 8 E 9 F 18 10 13 5 16 C 21 20 7 3 Wire Number F 4 15 Wire Description RENR1023 February 1997 Machine Location CONN 1 A-9 1 CONN 2 F-9 D CONN 3 F-9 D CONN 4 G-9 D CONN 5 G-9 D CONN 6 G-8 D CONN 7 G-8 D CONN 8 G-8 D CONN 9 F-8 D CONN 10 C-6 A CONN 11 C-5 A CONN 12 C-5 A CONN 13 C-4 A CONN 14 F-5 C CONN 15 F-5 C CONN 16 F-5 C CONN 17 F-5 C CONN 18 F-4 C CONN 19 F-4 C CONN 20 F-4 C CONN 21 F-4 C CONN 22 H-5 B CONN 23 H-5 B CONN 24 H-4 B CONN 25 H-4 B CONN 26 H-4 B CONN 27 H-4 B CONN 28 H-3 B CONN 29 H-3 B CONN 30 C-3 A CONN 31 B-3 7 CONN 32 A-3 13 CONN 33 B-2 7 CONN 34 Service Connector D-2 C CONN 35 B-2 22 CONN 36 G-5 F CONN 37 G-5 F CONN 38 G-8 F CONN 39 G-8 F CONN 40 G-8 F CONN 41 F-9 F CONN 42 F-9 F CONN 43 G-9 F CONN 44 G-9 F CONN 45 G-9 D CONN 46 H-9 F 322B L Forest Swing Machine Electrical System 1YS1-UP CONN 47 H-9 F The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Machine Harness Connector And Component Locations Wire Color 101 103 105 107 108 109 111 112 113 114 115 118 120 123 124 129 140 147 149 150 151 152 154 168 172 177 180 185 189 191 RD RD RD RD BU RD RD PU OR RD PK GY YL WH GN BU BU PU PU RD GN BU RD RD RD RD GN YL RD WH 200 201 235 BK BK BK 301 304 306 307 308 309 310 311 320 321 322 326 386 BU WH GN OR YL GY PU WH OR BR GY PU PK 403 405 412 430 487 491 492 495 496 A495 C468 GN GY BU BU OR PK GY GN WH GY BU 501 506 508 509 511 512 513 519 546 547 548 GN PU PU WH BR GN OR PK BU OR GY Wire Number Description Power Circuits Battery (+) Dome Lamp Key Sw Eng Shutdown Aux Ckt Alt Output (+) Term Timer Relay Output 1 Main Power Rly Opr Mon Panel B+ Switched Warning Horn (Forward) Aux Ckt Aux Ckt Aux Ckt Aux Ckt A/C Aux Ckt Aux Ckt Aux Ckt Aux Ckt Hyd Lock Aux Ckt Aux Ckt Neut Start Relay Aux Ckt Eng Gov Main Breaker Aux Ckt Aux Ckt Timer Relay Output 2 Aux Ckt Ground Circuits Main Chassis Opr Mon Panel Electronic Pump Ctrl Gnd Basic Machine Circuits Starter No. 1 Sol Starter Rly No. 1 Output Starter Rly Coil Key Sw to Neut Start Sw Main Power Rly Coil Alt Regulator Term Start Aid Sw To Start Aid Sol Start Aid Sol To Temp Sw Horn Rly Coil to Sw Travel Alarm Warning Horn (Forward) Key Sw "C" Term Air Shutoff Sol Enable Monitoring Circuits Alternator (R) Term Opr Mon Oil Press (Lo Setting) Opr Mon Cool Flow Opr Mon Air Filter Hyd Oil Flow Sw Hyd Oil Temp Sensor Coolant Temp Sensor Signal Fuel Level Signal Opr Mon Panel Hyd Oil Level Alternator (R) Terminal #2 Engine Oil Level Accessory Circuits Wiper - Front (Lo) Washer - Front Radio Speaker - Left Radio Speaker - Left (Common) Radio Speaker - Right Radio Speaker - Right (Common) A/C Compressor/Refrigerant Press Sw Thermostat to Refrigerant Press Sw Aux Hyd - Rotate CW Aux Hyd - Rotate CCW Aux Hyd - Open Wire Color 549 576 578 590 592 A513 A571 A572 A579 A586 A588 C537 C538 PK PK BU GY BU RD PU PK OR OR GN GN OR 607 615 616 PK YL BU 763 786 788 791 A718 A755 A756 A757 A758 A761 A762 A768 A769 A770 A771 F771 F772 F773 F774 J704 J705 J706 J707 J708 J709 J710 J711 J712 J713 J714 J715 877 961 K904 K905 K906 K907 K909 K911 K912 K915 K997 L908 L909 L968 L969 L970 L971 L972 L973 L974 L975 L977 L978 BU GN YL PK PU PK BU GY BR PU PU BU GY PK PU OR WH OR WH WH WH PU YL BR GN WH GN YL BU BR OR YL GN GN RD GN BU BU PK GN GN BU OR BU OR WH GY GN BU GN GN PK YL GY Description Accessory Circuits (Continued) Aux Hyd - Close Wiper - Aux (Lo) Washer - Aux Wiper Sw to Intermittent Module DC/DC Converter Power Output DC/DC Converter Memory Output Aux Ckt 1 Aux Ckt 2 Wiper Motor + Wiper Sw to Wiper Ctrl Safety Sol Relay to Sol A/C Photo Sensor + Sig A/C Photo Sensor - Sig Lighting Circuits Flood Lamps - Front Cab Flood Lamp Boom Flood Lamp Control Circuits Torque Converter Sw Eng Speed Cont - Hi Press Sw Eng Speed (+) Eng Speed Cont - Lo Sol Start Aid Coolant Sensor Signal Throttle Sw #1 Throttle Sw #2 Throttle Sw #3 Throttle Sw #4 Electronic Pump Cont Ground Electronic Pump Cont Engine Speed Ground Pump Control Valve #1 (+) Pump Control Valve #2 (-) Electronic Pump Control Bypass Sw Float Sw Backup Sw Backup Sw Governor Accel Governor Decel Hyd Lock Sol Relay to Grapple and Rotate Sw Rotate CCW Relay to Sol Grapple Close Relay to Sol Grapple Open Relay to Sol Rotate CW Relay to Sol Cab/Chassis Lamp Relay Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Glow Plug Magnetic Sw to Glow Plug Hyd Cont Sw Pump Discharge - Signal Pump Discharge - + B Swing Brake Sol - Signal Swing Brake Sol - + B Backup Sw - + B E/P Controller - RS485 (+) E/P Controller - RS485 (-) Fine Swing Sw - E/P Controller (+)V Sensor Controller RS-232C TX Controller RS-232C RX Electronic Pump Cont PS Valve (-) Electronic Pump Cont PS Valve (+) Electronic Pump Cont to Switch Common Electronic Pump Cont to Travel Press Sw Low Idle Sw Fine Swing Cont Relay to Sol Valve Electronic Pump Cont Boom Raise Press Sw Start Aid Cont Lamp 1 Output Trenching Sol Level Finish Sol ©1997 Caterpillar All Rights Reserved Component Location Component Actuator - Engine Gov Schematic Location A-9 Machine Location 1 Off Machine Switch Specification Component Resistor - Timer Relay Schematic Location E-7 Machine Location D Air Inlet Heater C-8 2 Sender - Hydraulic Oil Temp A-5 12 Alarm - Travel G-9 3 Sensor - Air Inlet Heater Coolant Temp C-9 2 Alternator B-8 4 Sensor - Coolant Temperature C-8 2 Assembly - Terminal Block F-8 D Sensor - Fuel Level A-5 13 Batteries - 12VDC Breaker - Alternator H-8,I-8 I-8 5 D Sensor - Pump Discharge Press Sensor - Sun Load B-8 F-1 14 E Part No. Function Actuate Deactuate 38.0 ± 3.0 °C 27 °C MIN Normally Closed (100.4 ± 5.4 °F) (80.6 °F MIN) 90 ± 21 kPa 70 ± 21 kPa A-B, Normally Open 3E-6455 Engine Oil Pressure (13 ± 3.0 psi) (10 ± 3.0 psi) A-C, Normally Closed Implement Pressure 1225.00 ± 98.00 kPa 882.00 kPa MIN 106-0179 Normally Open Travel Pressure (177.67 ± 14.21 psi) (127.92 psi MIN) 2646.00 ± 196.00 kPa 2156.00 ± 196.00 kPa 106-0180 Boom Raise Pressure Normally Open (383.77 ± 28.43 psi) (312.70 ± 28.43 psi) 490.00 ± 49.00 kPa 290.00 kPa MIN 106-0181 Hydraulic Pressure Normally Open (71.07 ± 7.11 psi) (42.06 psi MIN) 275 to 1750 kPa ¹ 114-5333 A/C High/Low Pressure Normally Open ² (40 to 255 psi) ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25psi). 3E-6449 Start Aid Coolant Temperature - Code Description of Problems 1301 Engine oil pressure is too low. 1302 Engine coolant temperature is too high. 1303 Hydraulic oil temperature is too high. 1304 Air filter is clogged. 1305 Battery voltage is not normal. 2201 Governor actuator feedback sensor circuit is open or shorted to battery voltage. 2202 Governor actuator feedback sensor circuit is shorted to body ground. 2301 Governor actuator feedback signal is not stable. 2302 Governor actuator feedback signal deviates. 2303 Governor actuator does not move. 2304 Calibration data error. Breaker - Main I-8 D Solenoid - A/C Clutch C-9 15 Control - Engine/Pump F-2 C Solenoid - Eng/Pump Control A-7 16 Controller - Wiper/Washer E-1 A Solenoid - Engine Shutdown B-9 17 Converter - Voltage C-5 A Solenoid - Fine Swing E-7 18 3201 Monitor RAM is not normal. Diode G-7 D Solenoid - Grapple E-7 18 4101 Electric power supply to the controller is too much (43 volts). Diode - Main Relay H-7 D Solenoid - Hydraulic Lock I-1 A 4102 Over-current in proportional reducing valve. I-4,5,6 B Solenoid - Level Finish A-7 16 4103 Proportional reducing valve circuit is open. Ground - Cab B-5 6 Solenoid - Rotate D-7 18 4105 Over-current in digital output (trenching solenoid). 4106 Over-current in digital output (fine control solenoid). Ground - Cab E-1 E Solenoid - Start Aid H-9 19 4107 Over-current in digital output (travel speed change solenoid). Ground - Chassis A-3 7 Solenoid - Swing Brake E-7 18 Ground - Chassis A-9 8 Solenoid - Travel Speed A-7 16 Fuses Ground - Chassis I-8 D Solenoid - Trenching A-7 16 Ground - Platform G-2 B Switch - Air Cleaner Flow H-9 20 Ground - Platform H-1 9 Switch - Aux Hydraulic Pressure H-3 B Ground - Relay Panel H-7 D Switch - Backup EPR Valve E-5 C Ground Strap - Chassis to Riser H-1 F Switch - Backup Governor D-5 C Ground Strap - Riser to Platform I-6 10 Switch - Boom Raise Pressure D-8 18 Horn A-2 7 Switch - Coolant Level H-9 19 Lighter E-1 E Switch - Disconnect I-8 D ² Contact postion at the contacts of the harness connector. 4108 Over-current in digital output (travel alarm). 410A Over-current in digital output (swing brake solenoid). Form Number 4201 Engine speed is not normal. SENR4252 4202 Engine coolant temperature sensor is shorted to body ground. SENR9291 4203 Hydraulic oil temperature sensor is shorted to body ground. 4204 PWM sensor of pump delivery pressure is shorted to body ground. 4207 PWM sensor of pump delivery pressure is open in circuit. 420A Fuel sensor is shorted to body ground 420B Fuel sensor is open or shorted to battery voltage. 420C Electric power supply is to low (below 23 volts). 420D Electric power supply is to high (above 32 volts). 420E Engine speed dial is not in one of the 10 specified positions. 4301 Data mismatch 1 between alternator and speed sensor (alternator is abnormal). 4302 Data mismatch 2 between alternator and speed sensor (speed sensor is abnormal). Related Electrical Service Manuals Title Alternator: (9W-3043) Engine/Pump Control Starting and Charging Starting Motor: SENR9292 (104-7040) Consist: 6V-5720 SENR3581 Consist: 106-8557 SENR3859 Meter - Service F-1 E Switch - Engine Oil Level A-8 1 Monitor F-1 E Switch - Engine Oil Pressure B-9 15 Motor - Starter A-9 8 Switch - Fine Swing Control D-4 C 4303 Engine stalls. Motor - Tilt I-9 F Switch - Grapple Close F-2 C A201 Monitor communication is not normal. Motor - Upper Washer I-9 D Switch - Grapple Open I-1 B A202 Monitor takes too much time to respond to controller's signal. A203 Communication is abnormal in controller. Motor - Upper Wiper C-5 6 Switch - Horn I-1 B Pickup - Engine Speed B-9 11 Switch - Hydraulic Oil Filter A-5 12 Radio - 12VDC C-6,I-3 A Switch - Hydraulic Oil Level A-5 12 Relay - Boom Lamp I-7 D Switch - Implement Pressure D-8 18 Relay - Cab/Chassis Lamp E-7 D Switch - Key F-3 C Relay - Cab/Chassis Lamp Switch I-7 D Switch - Neutral Start Limit I-1 B Relay - Grapple Close H-6 F Switch - One Touch Low Idle F-2 C Resistor: Relay - Grapple Open H-5 F Switch - Refrigerant Low Pressure C-9 15 Resistor: Relay - Heater F-7 D Switch - Rotate CCW F-2 C Relay - Horn I-7 D Switch - Rotate CW I-1 B Relay - Hydraulic Lock Solenoid I-7 D Switch - Start Aid D-5 C Relay - Main G-7 D Switch - Start Aid Coolant Temp B-9 4 Relay - Neutral Start F-7 D Switch - Suction Line Shutoff Limit A-6 12 Relay - Rotate CCW H-6 F Switch - Throttle Position E-3 C Relay - Rotate CW H-5 F Switch - Travel Pressure D-8 18 Relay - Start F-8 D Switch Panel F-2 C Relay - Timer E-7 D Unit - A/C, Heater H-5 21 Resistor - Backup I-8 D Unit - Air Inlet Heater Control I-7 D Electrical Schematic Symbols And Definitions Real Time Error Codes Contact Position Printed in U.S.A. T Pressure Symbol Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols Resistor and Solenoid Specifications Component Part No. Resistance (Ohms)¹ Backup 102-8015 41.0 ± 2.05 Timer Relay 7Y-8242 47.0 ± 4.7 Solenoid: A/C Clutch 134-3998 17.6 ± 0.6 Solenoid: Engine/Pump Control 111-9916 Solenoid: Engine Shutdown 8C-3663 Solenoid: Grapple Hydraulic Lock Swing Brake Travel Speed Level Finish Trenching Start Aid 3E-9205 11.7 ± 1.2 Start (Latch) Coil: 1.55 ± 0.15 Stop (Unlatch) Coil: 10.3 ± 1.03 24.9 121-1491 32.0 ± 3.2 Solenoid: Solenoid: Solenoid: 121-1490 32.0 ± 3.2 3E-6332 6 Pin Socket Wire Color A Circuit Number Identification AA 105-9344 Receptacle Wire Gauge Ground Connection Fuse 1 325-PK-14 Single Wire Connector Component Part Number Wire, Cable, or Harness Assembly Identification Plug 2 200-BK-14 Pin or Socket Number ¹ At room temperature. Machine locations are repeated for components located close together. A = Located in the operator's compartment. B = Located in operator's left console area. C = Located in operator's right console area. D = Located on or near the relay panel. E = Located in dash area. F = Located in Cab Riser. 1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.
Component Location Component Actuator - Engine Gov Air Inlet Heater Schematic Location A-9 Machine Location 1 C-8 2 Component Sender - Hydraulic Oil Temp Sensor - Air Inlet Heater Coolant Temp Schematic Location A-5 Machine Location 12 C-9 2 Alarm - Travel G-9 3 Sensor - Coolant Temp C-8 2 Alternator B-8 4 Sensor - Fuel Level A-5 13 Assembly - Terminal Block F-8 D Sensor - Pump Discharge Press B-8 14 H-8,I-8 5 Sensor - Sun Load F-1 E Breaker - Alternator I-8 D Solenoid - A/C Clutch C-9 15 Breaker - Generator I-8 D Solenoid - Eng/Pump Control A-7 16 Breaker - Main I-8 D Solenoid - Engine Shutdown B-8 17 Control - Engine/Pump F-2 C Solenoid - Fine Swing E-7 18 Controller - Wiper/Washer E-1 A Solenoid - Grapple E-7 18 Batteries - 12VDC Converter - Voltage C-5 A Solenoid - Hydraulic Lock I-1 F Diode G-7 D Solenoid - Level Finish A-7 16 Diode - Main Relay H-7 D Solenoid - Rotate D-7 18 I-4,5,6 B Solenoid - Start Aid H-9 19 Generator B-2 F Solenoid - Swing Brake E-7 18 Ground - Cab B-5 6 Solenoid - Travel Speed A-7 16 Ground - Cab E-1 E Solenoid - Trenching A-7 16 Ground - Chassis A-3 7 Switch - Air Cleaner Flow H-9 20 Ground - Chassis A-9 8 Switch - Aux Hydraulic Pressure H-3 B Ground - Chassis I-8 D Switch - Backup EPR Valve E-5 C Ground - Platform G-2 B Switch - Backup Governor D-5 C Fuses Ground - Platform H-1 9 Switch - Boom Raise Pressure D-7 18 Ground - Relay Panel H-8 D Switch - Coolant Level H-9 19 Ground Strap - Chassis to Platform I-6 10 Switch - Disconnect I-8 D Ground Strap - Chassis to Riser H-1 F Switch - Engine Oil Level A-8 1 Horn A-2 7 Switch - Engine Oil Pressure B-9 15 Lighter E-1 E Switch - Fine Swing Control D-4 C Meter - Service F-1 E Switch - Grapple Close or Magnet Lift F-2 C Monitor F-1 E Switch - Grapple/Magnet E-3 C Motor - Lower Washer I-9 D Switch - Grapple Open or Magnet Drop I-1 B Motor - Lower Wiper H-1 9 Switch - Horn I-1 B Motor - Starter A-9 8 Switch - Hydraulic Oil Filter A-5 12 Motor - Upper Washer I-9 D Switch - Hydraulic Oil Level A-5 12 Motor - Upper Wiper C-5 6 Switch - Implement Pressure D-7 18 Pickup - Engine Speed B-9 11 Switch - Key F-2 C Radio - 12VDC C-6,I-3 A Switch - Lower Washer D-4 C Relay - Boom Lamp I-7 D Switch - Lower Wiper D-3 C Relay - Cab/Chassis Lamp I-7 D Switch - Neutral Start Limit I-1 B Relay - Grapple Close H-6 F Switch - One Touch Low Idle F-2 C Relay - Grapple Open H-5 F Switch - Refrigerant Low Pressure C-9 15 Relay - Heater F-7 D Switch - Rotate CCW I-1 C Relay - Horn I-7 D Switch - Rotate CW F-2 B Relay - Hydraulic Lock Solenoid I-7 D Switch - Start Aid D-5 C Relay - Main G-7 D Switch - Start Aid Coolant Temp B-9 4 Relay - Neutral Start F-7 D Switch - Suction Line Shutoff Limit A-6 12 Relay - Rotate CCW H-6 F Switch - Throttle Position E-3 C Relay - Rotate CW H-5 F Switch - Travel Pressure D-7 18 Relay - Start F-8 D Switch Panel F-2 C Relay - Timer E-7 D Unit - A/C, Heater H-5 21 Resistor - Backup I-8 D Unit - Air Inlet Heater Control I-7 D Resistor - Timer Relay E-7 D 19 B 20 A = Located in the operator's compartment. D = Located on or near the relay panel. B = Located in operator's left console area. E = Located in dash area. C = Located in operator's right console area. F = Located in Cab Riser. Solenoid: Start Aid 3E-9205 Solenoid: Grapple 4I-5394 Sender: 7Y-8242 Resistor: Timer Relay 8C-3663 Solenoid: Engine Shutdown 102-8016 Resistor: Backup 111-9916 Solenoid: 121-1490 Solenoid: Engine/Pump Control Level Finish Trenching Hydraulic Lock Swing Brake Travel Speed A/C Clutch 134-3998 Solenoid: 10 E 7 24 18 2 13 1 11 23 8 14 12 16 6 22 A C B E 9 F 17 19 14 1 2 4 11 15 21 20 D 12 8 18 10 13 5 16 325B L Material Handler Electrical System 2JR1-UP 24 23 7 3 Connector Number 6 (9W-3043) Engine/Pump Control Starting and Charging Schematic Location Machine Location Code 1301 Engine oil pressure is too low. 24.9 CONN 1 A-9 1 1302 Engine coolant temperature is too high. CONN 2 F-9 D 1303 Hydraulic oil temperature is too high. 47.0 ± 4.7 Start (Latch) Coil: 1.55 ± 0.15 Stop (Unlatch) Coil: 10.3 ± 1.03 47.0 ± 2.35 CONN 3 F-9 D 1304 Air filter is clogged. CONN 4 G-9 D 1305 Battery voltage is not normal. CONN 5 G-9 D 2201 Governor actuator feedback sensor circuit is open or shorted to battery voltage. CONN 6 G-8 D 2202 Governor actuator feedback sensor circuit is shorted to body ground. 11.7 ± 1.2 CONN 7 G-8 D 2301 Governor actuator feedback signal is not stable. CONN 8 G-8 D 2302 Governor actuator feedback signal deviates. CONN 9 F-8 D 2303 Governor actuator does not move. CONN 10 C-6 22 2304 Calibration data error. CONN 11 C-5 22 3201 Monitor RAM is not normal. CONN 12 C-5 F 4101 Electric power supply to the controller is too much (43 volts). CONN 13 C-5 F 4102 Over-current in proportional reducing valve. CONN 14 F-6 C 4103 Proportional reducing valve circuit is open. CONN 15 F-5 C 4105 Over-current in digital output (trenching solenoid). CONN 16 F-5 C 4106 Over-current in digital output (fine control solenoid). CONN 17 F-5 C 4107 Over-current in digital output (travel speed change solenoid). CONN 18 F-5 C 4108 Over-current in digital output (travel alarm). CONN 19 F-4 C 410A Over-current in digital output (swing brake solenoid). CONN 20 F-4 C 4201 Engine speed is not normal. CONN 21 F-4 C 4202 Engine coolant temperature sensor is shorted to body ground. CONN 22 F-4 C 4203 Hydraulic oil temperature sensor is shorted to body ground. CONN 23 H-5 B 4204 PWM sensor of pump delivery pressure is shorted to body ground. Form Number CONN 24 H-5 B 4207 PWM sensor of pump delivery pressure is open in circuit. SENR4252 CONN 25 H-5 B 420A Fuel sensor is shorted to body ground SENR9291 CONN 26 H-4 B 420B Fuel sensor is open or shorted to battery voltage. SENR9292 CONN 27 H-4 B 420C Electric power supply is to low (below 23 volts). CONN 28 H-4 B 420D Electric power supply is to high (above 32 volts). CONN 29 H-3 B 420E Engine speed dial is not in one of the 10 specified positions. CONN 30 H-3 B 4301 Data mismatch 1 between alternator and speed sensor (alternator is abnormal). 32.0 ± 3.2 32.0 ± 3.2 17.6 ± 0.6 (104-7040) 6V-5720 SENR3581 Consist: 106-8557 SENR3859 CONN 31 C-3 F 4302 Data mismatch 2 between alternator and speed sensor (speed sensor is abnormal). Starting Motor: (6V-5821) SENR3581 CONN 32 B-3 7 4303 Engine stalls. CONN 33 A-3 23 A201 Monitor communication is not normal. CONN 34 B-2 24 A202 Monitor takes too much time to respond to controller's signal. CONN 35 Service Connector D-2 C A203 Communication is abnormal in controller. CONN 36 G-5 F CONN 37 G-5 F CONN 38 G-8 F CONN 39 G-8 F CONN 40 G-8 F CONN 41 F-9 F CONN 42 F-9 F CONN 43 G-9 F CONN 44 G-9 F Off Machine Switch Specification Actuate Wire Color RD RD RD RD BU RD RD PU OR RD PK GY YL WH GN BU BU PU PU RD GN BU RD RD RD RD GN YL RD WH 200 201 235 BK BK BK 301 304 306 307 308 309 310 311 320 321 322 326 386 BU WH GN OR YL GY PU WH OR BR GY PU PK 403 405 412 430 487 491 492 495 496 A495 C468 GN GY BU BU OR PK GY GN WH GY BU 501 506 508 509 511 512 513 519 546 547 548 549 576 GN PU PU WH BR GN OR PK BU OR GY PK PK Description Accessory Circuits (Continued) Bat (+) Aux Ckt Key Sw Eng Shutdown Aux Ckt Alt Output (+) Term Aux Ckt Main Power Rly Output Opr Mon Panel B (+) Switched Warning Horn (Forward) Aux Ckt Aux Ckt Aux Ckt Aux Ckt A/C Aux Ckt Aux Ckt Aux Ckt Aux Ckt Bat (+) Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Main Brkr Aux Ckt Aux Ckt Aux Ckt Aux Ckt Ground Circuits Main Chassis Opr Mon Panel Elec Pump Ctrl Gnd Basic Machine Circuits Starter No. 1 Sol Starter Rly No. 1 Output Starter Rly Coil Key Sw to Neut Start Sw Main Power Rly Coil Alternator Regulator Terminal Start Aid Sw To Start Aid Sol Start Aid Sol To Temp Sw Horn Rly Coil to Sw Travel Alarm Lamp Warning Horn (Forward) Key Sw "C" Term Air Shutoff Sol Enable Monitoring Circuits Alternator (R) Term Opr Mon Oil Press Opr Mon Cool Flow Opr Mon Air Filter Hyd Oil Flow Sw Hyd Oil Temp Sensor Coolant Temp Sensor Fuel Level Opr Mon Panel Hyd Oil Level Alternator (R) Terminal #2 Engine Oil Level Accessory Circuits Wiper - Front Washer - Front Radio Speaker - Left Radio Speaker - Left (Common) Radio Speaker - Right Radio Speaker - Right (Common) A/C Compressor/Refrigerant Pressure Sw Thermostat to Refrigerant Press Sw Aux Hyd - Rotate CW Aux Hyd - Rotate CCW Aux Hyd - Open Aux Hyd - Close Wiper - Aux 578 590 592 A513 A571 A572 A579 A586 A588 C537 C538 BU GY BU RD PU PK OR OR GN GN OR 607 615 616 PK YL BU 763 786 788 791 A718 A755 A756 A757 A758 A761 A762 A768 A769 A770 A771 F771 F772 F773 F774 J704 J705 J706 J707 J708 J710 J711 J712 J713 J714 J715 J718 J719 J720 J721 J722 877 961 K904 K905 K906 K907 K909 K911 K912 K915 K997 L908 L909 L968 L969 L970 L971 L972 L973 L974 L975 L977 L978 BU GN YL PK PU PK BU GY BR PU PU BU GY PK PU OR WH OR WH WH WH PU YL BR WH GN YL BU BR OR WH BU YL PU BR YL GN GN RD GN BU BU PK GN GN BU OR BU OR WH GY GN BU GN GN PK YL GY Washer - Aux Wiper Sw to Intermittent Module DC/DC Converter Power Output DC/DC Converter Memory Output Aux Ckt 1 Aux Ckt 2 Wiper Motor (+) Wiper Sw to Wiper Cont Safety Sol Relay to Sol A/C Photo Sensor (+) Sig A/C Photo Sensor (-) Sig Lighting Circuits Flood Lamps - Front Cab Flood Lamp Boom Flood Lamp Control Circuits Torque Converter Sw Eng Speed Cont Eng Speed (+) Eng Speed Cont Start Aid Coolant Sensor Signal Throttle Sw #1 Throttle Sw #2 Throttle Sw #3 Throttle Sw #4 Elec Pump Cont Gov Feedback Elec Pump Cont Eng Speed Ground Pump Control Valve #1 (+) Pump Control Valve #2 (-) Elec Pump Control Bypass Sw Float Sw Backup Sw Backup Sw Governor Accel Governor Decel Hyd Lock Sol Relay to Grapple and Rotate Sw Rotate CCW Relay to Sol Grapple Close Relay to Sol Grapple Open Relay to Sol Rotate CW Relay to Sol Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Hyd Cont Sw Pump Discharge - Signal Pump Discharge - (+) B Swing Brake Sol - Signal Swing Brake Sol - (+) B Backup Sw - (+) B E/P Controller - RS485 (+) E/P Controller - RS485 (-) Fine Swing Sw - E/P Controller (+) V Sensor Controller RS-232C TX Controller RS-232C RX Elec Pump Control PS Valve (-) Elec Pump Control PS Valve (+) Elec Pump Control to Switch Return Elec Pump Control to Travel Pressure Sw Low Idle Sw Fine Swing Cont Relay to Sol Valve Elec Pump Cont Boom Raise Press Sw Start Aid Cont Lamp 1 Output Trenching Sol Level Finish Sol Deactuate Contact Position 38.0 ± 3.0 °C 27 °C MIN 3E-6449 Start Aid Coolant Temperature Normally Closed (100.4 ± 5.4 °F) (80.6 °F MIN) 90 ± 21 kPa 70 ± 21 kPa A-B, Normally Open 3E-6455 Engine Oil Pressure (13 ± 3.0 psi) (10 ± 3.0 psi) A-C, Normally Closed Implement Pressure 1225.00 ± 98.00 kPa 882.00 kPa MIN 106-0179 Normally Open Travel Pressure (177.67 ± 14.21 psi) (127.92 psi MIN) 2646.00 ± 196.00 kPa 2156.00 ± 196.00 kPa 106-0180 Boom Raise Pressure Normally Open (383.77 ± 28.43 psi) (312.70 ± 28.43 psi) 490.00 ± 49.00 kPa 290.00 kPa MIN 106-0181 Hydraulic Pressure Normally Open (71.07 ± 7.11 psi) (42.06 psi MIN) 275 to 1750 kPa ¹ 114-5333 A/C High/Low Pressure Normally Open ² (40 to 255 psi) ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25psi). Printed in U.S.A. Electrical Schematic Symbols And Definitions Description of Problems Consist: Function 101 103 105 107 108 109 111 112 113 114 115 118 120 123 124 129 140 147 149 150 151 152 154 168 172 177 180 185 189 191 Real Time Error Codes 6130 to 7500 Hydraulic Oil Temp Title Part No. 9 17 Resistance (Ohms)¹ Related Electrical Service Manuals Starting Motor: C 4 15 6 A Wire Number Description Power Circuits F Connector Location ¹ At room temperature unless otherwise noted. Alternator: D 22 Wire Color ©1997 Caterpillar All Rights Reserved Component 3E-6332 Solenoid: 5 3 Resistor, Sender and Solenoid Specifications 121-1491 21 Wire Number Machine Harness Connector And Component Locations Machine locations are repeated for components located close together. Part No. Wire Description RENR1063 July 1997 T Pressure Symbol Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols Pin Socket Wire Color A CONN 45 G-9 D The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Circuit Number Identification - 105-9344 Receptacle Wire Gauge Ground Connection Fuse AA 1 325-PK-14 Single Wire Connector Component Part Number Wire, Cable, or Harness Assembly Identification Plug 2 200-BK-14 Pin or Socket Number ² Contact postion at the contacts of the harness connector. 1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.
Wire Description Wire Number Component Location Schematic Location A-9 Machine Location 1 Schematic Location B-8 Machine Location 6 Alarm - Travel G-9 2 Sensor - Fuel Level A-5 12 Alternator C-8 3 Sensor - Pump Discharge Press B-8 13 Assembly - Terminal Block F-8 D Sensor - Sun Load F-1 E H-8,I-8 4 Solenoid - A/C Clutch C-9 14 Breaker - Alternator I-8 D Solenoid - Eng/Pump Control A-7 15 Breaker - Generator I-8 D Solenoid - Engine Shutdown B-8 6 Breaker - Main I-8 D Solenoid - Fine Swing E-7 16 Control - Engine/Pump F-2 C Solenoid - Grapple E-7 16 Component Actuator - Engine Gov Component Sensor - Engine Speed 17 B 18 Batteries - 12VDC Controller - Wiper/Washer E-1 E Solenoid - Hydraulic Lock I-1 F Converter - Voltage C-5 A Solenoid - Level Finish A-7 15 Diode - Main Relay H-7 D Solenoid - Rotate D-7 16 Fuses I-4,5,6 B Solenoid - Start Aid H-9 17 Generator B-2 F Solenoid - Swing Brake E-7 16 Ground - Cab B-5 5 Solenoid - Travel Speed A-7 15 Ground - Cab E-1 E Solenoid - Trenching A-7 15 Ground - Chassis A-3 6 Switch - Air Cleaner Flow H-9 18 Ground - Chassis A-8 7 Switch - Aux Hydraulic Pressure H-3 B Ground - Chassis I-8 D Switch - Backup EPR Valve E-5 C Ground - Platform G-2 F Switch - Backup Governor D-5 C Ground - Platform H-1 F Switch - Boom Raise Pressure D-7 C Ground - Relay Panel H-8 D Switch - Coolant Level H-9 17 Ground Strap - Riser to Platform I-6 8 Switch - Disconnect I-8 D Ground Strap - Chassis to Riser H-1 F Switch - Engine Oil Level B-8 21 Horn A-2 7 Switch - Engine Oil Pressure B-9 19 Lighter E-1 E Switch - Fine Swing Control D-4 C Meter - Service F-1 E Switch - Grapple Close F-2 C Monitor F-1 E Switch - Grapple/Magnet E-3 C Motor - Lower Wiper H-1 24 Switch - Grapple Open I-1 B Motor - Starter B-8 6 Switch - Horn I-1 B Motor - Upper Washer I-9 D Switch - Hydraulic Oil Filter A-5 11 Motor - Upper Wiper C-5 9 Switch - Hydraulic Oil Level A-5 11 C-6,I-3 A Switch - Implement Pressure D-7 16 I-7 D Switch - Key F-2 C Radio - 12VDC Relay - Boom Lamp Relay - Cab/Chassis Lamp I-7 D Switch - Lower Washer D-4 H-6 F Switch - Lower Wiper D-3 C Relay - Grapple Open H-5 F Switch - Neutral Start Limit I-1 B Relay - Horn I-7 D Switch - One Touch Low Idle F-2 C Relay - Hydraulic Lock Solenoid I-7 D Switch - Refrigerant Low Pressure C-9 17 Relay - Main G-7 D Switch - Rotate CCW I-1 B Relay - Neutral Start F-7 D Switch - Rotate CW F-2 C Relay - Rotate CCW H-6 F Switch - Start Aid D-5 C Relay - Rotate CW H-5 F Switch - Start Aid Coolant Temp B-9 10 Relay - Start F-8 D Switch - Suction Line Shutoff Limit A-6 11 Relay - Timer E-7 D Switch - Throttle Position E-3 C Resistor - Backup I-8 D Switch - Travel Pressure D-7 16 Sender - Coolant Temperature B-9 10 Switch Panel F-2 C Sender - Hydraulic Oil Temp A-5 11 Unit - A/C, Heater H-5 20 20 4 2 D 10 24 8 C 3 14 9 A F 5 E 23 7 16 1 12 19 21 6 22 13 11 15 9 5 A 330B Material Handler Electrical System 24 20 6DR1-UP 23 F E C B 10 1 3 C Relay - Grapple Close RENR1064 December 1997 19 17 20 16 18 101 103 105 107 108 109 111 112 113 114 115 118 120 123 124 129 140 147 149 150 151 152 154 168 172 177 180 185 189 191 RD RD RD RD BU RD RD PU OR RD PK GY YL WH GN BU BU PU PU RD GN BU RD RD RD RD GN YL RD WH 200 201 235 BK BK BK 301 304 306 307 308 310 311 320 321 322 326 386 BU WH GN OR YL PU WH OR BR GY PU PK 403 405 412 430 487 491 492 495 496 C468 GN GY BU BU OR PK GY GN WH BU 501 506 508 509 511 512 513 519 546 547 548 549 576 GN PU PU WH BR GN OR PK BU OR GY PK PK D 14 21 2 13 22 11 6 8 4 12 7 15 Machine locations are repeated for components located close together. A = Located in the operator's compartment. Machine Harness Connector And Component Locations B = Located in operator's left console area. Wire Color C = Located in operator's right console area. D = Located on or near the relay panel. E = Located in dash area. F = Located in Cab Riser. Wire Number Description Power Circuits Bat (+) Aux Ckt Key Sw Eng Shutdown Aux Ckt Alt Output (+) Term Aux Ckt Main Power Rly Output Opr Mon Panel B (+) Switched Warning Horn (Forward) Aux Ckt Aux Ckt Aux Ckt Aux Ckt A/C Aux Ckt Aux Ckt Aux Ckt Aux Ckt Bat (+) Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Main Brkr Aux Ckt Aux Ckt Aux Ckt Aux Ckt Ground Circuits Main Chassis Opr Mon Panel Elec Pump Ctrl Gnd Basic Machine Circuits Starter No. 1 Sol Starter Rly No. 1 Output Starter Rly Coil Key Sw to Neut Start Sw Main Power Rly Coil Start Aid Sw To Start Aid Sol Start Aid Sol To Temp Sw Horn Rly Coil to Sw Travel Alarm Lamp Warning Horn (Forward) Key Sw "C" Term Air Shutoff Sol Enable Monitoring Circuits Alternator (R) Term Opr Mon Oil Press Opr Mon Cool Flow Opr Mon Air Filter Hyd Oil Flow Sw Hyd Oil Temp Sensor Coolant Temp Sensor Fuel Level Opr Mon Panel Hyd Oil Level Engine Oil Level Accessory Circuits Wiper - Front Washer - Front Radio Speaker - Left Radio Speaker - Left (Common) Radio Speaker - Right Radio Speaker - Right (Common) A/C Compressor/Refrigerant Pressure Sw Thermostat to Refrigerant Press Sw Aux Hyd - Rotate CW Aux Hyd - Rotate CCW Aux Hyd - Open Aux Hyd - Close Wiper - Aux Wire Color 578 590 592 A513 A571 A572 A579 A586 A588 C537 C538 BU GY BU RD PU PK OR OR GN GN OR 607 615 616 PK YL BU 763 786 788 791 A755 A756 A757 A758 A761 A762 A768 A769 A770 A771 F771 F772 F773 F774 J704 J705 J706 J707 J708 J710 J711 J712 J713 J714 J715 J718 J719 J720 J721 J722 961 K904 K905 K906 K907 K909 K911 K912 K915 K997 L908 L909 L968 L969 L970 L971 L972 L973 L974 L975 L977 L978 BU GN YL PK PK BU GY BR PU PU BU GY PK PU OR WH OR WH WH WH PU YL BR WH GN YL BU BR OR WH BU YL PU BR GN GN RD GN BU BU PK GN GN BU OR BU OR WH GY GN BU GN GN PK YL GY Description Accessory Circuits (Continued) Washer - Aux Wiper Sw to Intermittent Module DC/DC Converter Power Output DC/DC Converter Memory Output Aux Ckt 1 Aux Ckt 2 Wiper Motor (+) Wiper Sw to Wiper Cont Safety Sol Relay to Sol A/C Photo Sensor (+) Sig A/C Photo Sensor (-) Sig Lighting Circuits Flood Lamps - Front Cab Flood Lamp Boom Flood Lamp Control Circuits Torque Converter Sw Eng Speed Cont Eng Speed (+) Eng Speed Cont Throttle Sw #1 Throttle Sw #2 Throttle Sw #3 Throttle Sw #4 Elec Pump Cont Gov Feedback Elec Pump Cont Eng Speed Ground Pump Control Valve #1 (+) Pump Control Valve #2 (-) Elec Pump Control Bypass Sw Float Sw Backup Sw Backup Sw Governor Accel Governor Decel Hyd Lock Sol Relay to Grapple and Rotate Sw Rotate CCW Relay to Sol Grapple Close Relay to Sol Grapple Open Relay to Sol Rotate CW Relay to Sol Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Hyd Cont Sw Pump Discharge - Signal Pump Discharge - (+) B Swing Brake Sol - Signal Swing Brake Sol - (+) B Backup Sw - (+) B E/P Controller - RS485 (+) E/P Controller - RS485 (-) Fine Swing Sw - E/P Controller (+) V Sensor Controller RS-232C TX Controller RS-232C RX Elec Pump Control PS Valve (-) Elec Pump Control PS Valve (+) Elec Pump Control to Switch Return Elec Pump Control to Travel Pressure Sw Low Idle Sw Fine Swing Cont Relay to Sol Valve Elec Pump Cont Boom Raise Press Sw Start Aid Cont Lamp 1 Output Trenching Sol Level Finish Sol ©1997 Caterpillar All Rights Reserved Connector Location Real Time Error Codes Code Description of Problems Connector Number Schematic Location Machine Location 1301 Engine oil pressure is too low. 1302 Engine coolant temperature is too high. CONN 1 A-9 21 1303 Hydraulic oil temperature is too high. CONN 2 F-9 D 1304 Air filter is clogged. CONN 3 F-9 D 1305 Battery voltage is not normal. CONN 4 G-9 D 2201 Governor actuator feedback sensor circuit is open or shorted to battery voltage. CONN 5 G-9 D 2202 Governor actuator feedback sensor circuit is shorted to body ground. CONN 6 G-8 D 2301 Governor actuator feedback signal is not stable. CONN 7 G-8 D 2302 Governor actuator feedback signal deviates. CONN 8 G-8 D 2303 Governor actuator does not move. CONN 9 F-8 D 2304 Calibration data error. CONN 10 C-6 5 3201 Monitor RAM is not normal. CONN 11 C-5 5 4101 Electric power supply to the controller is too much (43 volts). CONN 12 C-5 F 4102 Over-current in proportional reducing valve. CONN 13 C-5 F 4103 Proportional reducing valve circuit is open. CONN 14 F-5 C 4105 Over-current in digital output (trenching solenoid). CONN 15 F-5 C 4106 Over-current in digital output (fine control solenoid). CONN 16 F-5 C 4107 Over-current in digital output (travel speed change solenoid). CONN 17 F-5 C 4108 Over-current in digital output (travel alarm). CONN 18 F-4 C 410A Over-current in digital output (swing brake solenoid). CONN 19 F-4 C 4201 Engine speed is not normal. CONN 20 F-4 C 4202 Engine coolant temperature sensor is shorted to body ground. CONN 21 F-4 C 4203 Hydraulic oil temperature sensor is shorted to body ground. CONN 22 H-5 B 4204 PWM sensor of pump delivery pressure is shorted to body ground. CONN 23 H-5 B 4207 PWM sensor of pump delivery pressure is open in circuit. CONN 24 H-5 B 420A Fuel sensor is shorted to body ground CONN 25 H-4 B Harness And Wire Electrical Schematic Symbols A Electrical Schematic Symbols And Definitions Pressure Symbol Title Alternator: SENR9291 SENR9292 Starting Motor: Consist: H-4 B H-4 B Consist: 420D Electric power supply is to high (above 32 volts). CONN 28 H-3 B 420E Engine speed dial is not in one of the 10 specified positions. CONN 29 H-3 B 4301 Data mismatch 1 between alternator and speed sensor (alternator is abnormal). CONN 30 C-3 F 4302 Data mismatch 2 between alternator and speed sensor (speed sensor is abnormal). CONN 31 B-3 7 A-3 22 B-2 23 A202 Monitor takes too much time to respond to controller's signal. CONN 34 D-2 C A203 Communication is abnormal in controller. CONN 35 F-6 C CONN 36 G-5 F CONN 37 G-5 F CONN 38 G-8 F CONN 39 G-8 F CONN 40 G-8 F CONN 41 F-9 F CONN 42 F-9 F CONN 43 G-9 F CONN 44 G-9 F CONN 45 G-9 D CONN 46 H-9 F Off Machine Switch Specification Function Actuate Deactuate Contact Position 38.0 ± 3.0 °C 27 °C MIN Normally Closed (100.4 ± 5.4 °F) (80.6 °F MIN) 90 ± 21 kPa 70 ± 21 kPa A-B, Normally Open 3E-6455 Engine Oil Pressure (13 ± 3.0 psi) (10 ± 3.0 psi) A-C, Normally Closed Implement Pressure 1225.00 ± 98.00 kPa 882.00 kPa MIN 106-0179 Normally Open Travel Pressure (177.67 ± 14.21 psi) (127.92 psi MIN) 2646.00 ± 196.00 kPa 2156.00 ± 196.00 kPa 106-0180 Boom Raise Pressure Normally Open (383.77 ± 28.43 psi) (312.70 ± 28.43 psi) 490.00 ± 49.00 kPa 290.00 kPa MIN 106-0181 Hydraulic Pressure Normally Open (71.07 ± 7.11 psi) (42.06 psi MIN) 275 to 1750 kPa ¹ 114-5333 A/C High/Low Pressure Normally Open ² (40 to 255 psi) ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25psi). 3E-6449 Start Aid Coolant Temperature - ² Contact postion at the contacts of the harness connector. SENR2082 Engine/Pump Control CONN 27 CONN 33 (6V-0512) 6V-0512 SENR3860 6V-5538 3E-6332 Solenoid: Start Aid 3E-7985 Solenoid: Engine Shutdown 3E-9205 Solenoid: Grapple 4I-5394 Sender: Hydraulic Oil Temp Component Part Number Single Wire Connector Normally open switch that will close with an increase of a specific condition (temp-press-etc.). C A A 325-PK-14 Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Normally closed switch that will open with an increase of a specific condition. Circuit Number Identification Wire Gauge Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. Electrical Schematic Symbols And Definitions The circle indicates that the component has screw terminals and a wire can be disconnected from it. FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. No circle indicates that the wire cannot be disconnected from the component. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. This indicates that the component has a wire connected to it that is connected to ground. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Resistance (Ohms)¹ 6 Start (Latch) Coil: 1.55 ± 0.15 Stop (Unlatch) Coil: 10.3 ± 1.03 24.9 6130 to 7500 102-8017 Resistor: Backup 52.0 ± 2.6 111-9916 Solenoid: 11.7 ± 1.2 121-1490 Solenoid: 121-1491 Solenoid: 134-3998 Solenoid: Engine/Pump Control Level Finish Trenching Hydraulic Lock Swing Brake Travel Speed A/C Clutch ¹ At room temperature unless otherwise noted. Pin or Socket Number SENR4975 Resistor, Sender and Solenoid Specifications Component Flow Symbol (6V-5227) CONN 47 H-9 F The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Part No. Level Symbol Form Number (100-5047) Starting and Charging CONN 26 CONN 32 Temperature Symbol Related Electrical Service Manuals Electric power supply is to low (below 23 volts). Monitor communication is not normal. Receptacle Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Wire, Cable, or Harness Assembly Identification Fuel sensor is open or shorted to battery voltage. Engine stalls. Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 2 420B 4303 1 2 1 2 1 T 420C A201 AA Plug Starting Motor: Part No. Printed in U.S.A. 32.0 ± 3.2 32.0 ± 3.2 17.6 ± 0.6 This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Harness Connector Location Chart Connectors 20 Contacts Connector No. And Machine Location CONN3 1C E-134-3323 Monitor C - 134-3305 E-134-3323 C-134-3305 E-134-3323 C-134-3305 F-134-3324 C-134-3305 F-134-3324 F-134-3324 Air Conditioner Switch Panel F-134-3324 A/C Unit B-134-3304 C-134-3305 C-134-3305 G-143-1568 A-134-3303 C-134-3305 C-134-3305 D-134-3313 C-134-3305 D-134-3313 A-134-3303 D-134-3313 F-134-3324 Radio-AM/FM C-134-3305 Governor Controller E-134-3323 Governor Actuator C - 134-3305 E-134-3323 C-134-3305 Governor Controller C-134-3305 H-134-3280 D-134-3313 Hyd Lock Timer D-134-3313 Start Control Relay H-134-3280 J-51-8217 L-143-1567 12V5A Converter F-134-3324 Light Switch CONN5 4G CONN6 3 G CONN19 10G CONN20 9G CONN24 10 D 12 Contacts 9 Contacts 8 Contacts CONN25 17 CONN28 2G CONN32 1 A CONN33 8E CONN34 9 E CONN35 10 E CONN37 7 E CONN18 9D CONN29 19 CONN2 2C CONN4 1G 6 Contacts CONN30 18 CONN31 2 A CONN39 3 E CONN40 6 E CONN60 24 CONN70 6 B 5 Contacts Schematic Location Harness And/or Components CONN9 1 D Connector No. And Machine Location Connectors E-4 CONN10 2D CONN11 3D E-4 CONN12 4D D-4 H-4 J-4 E-8 CONN17 5D CONN38 5 E CONN58 5B CONN65 20 E-8 CONN68 4E D-6 E-5 C-5 4 Contacts CONN8 11 D CONN26 7G CONN55 4B E-8 F-7 3 Contacts J-2 F-134-3324 Wiper Switch F-134-3324 Washer Switch F-134-3324 Travel Speed Switch F-134-3324 Cab Light Switch F-134-3324 Air Bleed Pump Switch F-134-3324 Travel Alarm Cancel Switch F-134-3324 Power Mode Switch D-134-3313 Engine Shutdown Timer G-143-1568 Resistor J -51-8217 Wiper Motor S-134-3331 Travel Alarm Timer F-134-3324 Neutral Start Limit Switch C-134-3305 F-134-3324 G-143-1568 Speaker G-143-1568 Speaker C-134-3305 E-134-3323 F-134-3324 U-134-3329 F-134-3324 T-136-4021 F-134-3324 S-134-3331 C-134-3305 Hyd Lock Solenoid C-134-3305 D-134-3313 A-134-3303 Auto Lubrication Pump A-134-3303 Auto Refrigerant Low Press Switch A-134- 3303 Gov Press Switch CONN14 6D CONN15 7 D CONN16 8D 5 Contacts H-4 CONN59 1 B D-2 C-5 CONN7 5 CONN21 12 G CONN22 11 G CONN23 8G H-6 CONN27 6G E-2 E-3 D-2 2 Contacts D-2 CONN36 11 E CONN41 16 C-2 CONN42 15 J-1 CONN43 8 H-6 Harness And/or Components Schematic Location H-1 Connectors CONN45 13 CONN47 9 CONN50 26 2 Contacts CONN52 4 CONN53 2 CONN54 1 CONN57 3 B 1 Contact Bullet Terminal CONN67 3 CONN69 7 CONN44 14 CONN1 3 C CONN13 12 D CONN46 11 Schematic Location Harness And/or Components A-134-3303 Alternator A-134-3303 Air Conditioner Clutch Solenoid B-134-3304 K-134-3325 B-134-3304 Engine/Pump Control Solenoid B-134-3304 Travel Speed Solenoid B-134-3304 Fuel Sensor G-143-1568 L-143-1567 S-134-3331 Travel Alarm S-134-3331 Travel Press Switch A-134-3303 Alternator E-134-3323 One Touch Low Idle Switch F-134-3324 Horn Switch A-134-3303 Engine Oil Press Switch Connector No. And Machine Location Connectors CONN48 10 CONN49 12 C-8 C-8 A-6 A-6 C-3 A-134-3303 Coolant Temp Sender A-134-3303 Coolant Temp Switch B-134-3304 Hyd Oil Temp Sender G-143-1568 Cigar Lighter H-134-3280 M-116-0243 H-134-3280 M-116-0243 R-128-8940 Cab Lamp R-128-8940 Cab Lamp T-136-4021 Fuel Pump D-134-3313 T-136-4021 D-134-3313 S-134-3331 C-134-3305 U-134-3329 CONN51 6 CONN56 2B CONN61 21 CONN62 25 B-3 A-6 Harness And/or Components Bullet Terminal CONN63 22 CONN64 23 CONN66 5 CONN71 2 E CONN72 1 E A-6 D-7 C-8 F-2 CONN73 3 A G-1 Machine Location 1C Schematic Location Actuator-Governor E-2 Machine Location 35F 2 Alarm - Travel A-6 36B 3 Alternator B-8 Component Relay-Wiper H-9 Resistor - Monitor C-2 37 Sender - Engine Coolant Temp B-8 B-6 4 Antenna H-5 38 Sender - Hydraulic Oil Temp 5 Battery D-9 39 Sensor - Fuel Level A-6 H-1 6E Block - Terminal F-7 40 Solenoid - Air Cond Comp Clutch C-8 J-2 7E Breaker - Alternator F-9 41 Solenoid - Engine Shutdown A-8 8 Cable - Antenna J-4 42G Solenoid - Hydraulic Lock G-4 9 Controller - Governor D-2 43 Solenoid - Travel Speed A-6 H-2 H-2 H-2 H-6 C-3 F-2 J-6 10B Converter - 12V5A 11F Fuse - Block C-2 44 Solenoid - Engine Pump Control A-6 J-7, 8, 9 45B Speaker C-2 12 Horn B-2 46D Switch - Air Bleed Pump H-2 13 Lamp - Boom B-2 47 Switch - Engine Coolant Temp B-8 14 Lamp- Cab E-1, F-1 48 Switch - Disconnect D-9 15 Lamp - Chassis A-3 49 Switch - Engine Oil Press B-8 16 Lamp - Dome B-2 50 Switch - Governor Press D-7 17B Lighter- Cigar C-2 51D Switch- Horn G-1 18D Meter - Service J-2 52D Switch - Light (Boom/Chassis Lamp) J-1 19C J-2 Monitor D-5 53D Switch - Light (Cab Lamp) 20 Motor - Starter A-8 54D Switch - Neutral Start J-1 21 Motor - Washer E-9 55C Switch - One Touch Low Idle F-2 22 Motor - Wiper F-2 56D Switch - Power Mode H-2 23 B-8 57 C-2 Plug - Glow Switch - Refrigerant Low Press D-9 24 Pump - Auto Lubrication D-9 58C Switch - Starter E-2 E-5 25 J-1 D-6 C-2 H-5 H-5 H-5 G-4 E-9 D-9 D-9 D-7 Schematic Location Pump - Fuel A-5 59D Switch - Travel Alarm Cancel H-2 26D Radio J-2 60 Switch - Travel Press D-7 27F Relay - Boom/Chassis Lamp H-9 61D Switch - Travel Speed H-1 28F Relay - Cab Lamp H-8 62D Switch - Washer H-1 29E Relay - Heater G-6 63D Switch - Wiper H-1 30F Relay - Horn H-7 64E Timer - Engine Shutdown H-5 31F Relay - Neutral Start Lock H-7 65E Timer - Hydraulic Lock H-5 32E Relay - Start Control H-5 66E Timer - Travel Alarm J-5 33E Relay - Start G-5 67 Unit - Air Conditioner D-6 34F Relay - Washer/Cigar H-8 68 Unit - Heater D-6 Area A = Inside of Cab,rear Area B = Inside of Cab,rear Area C = Inside of R.H. console Area D = Inside of L.H. console Area E = Around relay panel Area F = Inside of Fuse relay box Area G = Under platform T Pressure Symbol Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 307B Excavator Electrical System Harness And Wire Symbols 55 5I-6587 80 ± 10 kPa (11.6 ± 1.45 psi) 106.0 ± 2.0 °C (222.8 ± 3.7 °F) 1225.00 ± 98.00 kPa (177.67 ± 14.21 psi) B-8 Engine Oil Pressure 085-5121 Engine Coolant Temperature 106-0179 Governor Pressure Travel Pressure E-1 F-1 1 E-1 83 Printed in U.S.A. J-8 C-5 AREA C 21 25 14 26 11 46 63 24 53 52 13 35 4 34 12 47 37 10 41 48 40 9 20 8 60 28 27 54 7 50 11 13 14 24 49 26 1 6 21 38 44 4 16 15 8 2 43 3 5 6 8 5 18 39 3 31 10 12 15 9 25 5 2 9 17 67 68 18 19 30 3 2 4 22 Wire Color 101 RD 103 105 Wire Description Wire Number Wire Color Bat(+) 500 BR Wiper-Front (Park) RD Aux Ckt 501 GN Wiper - Front (Low) RD Key Sw 506 PU Washer - Front 107 RD Eng Shut 508 PU Radio Speaker - Left 109 RD Alt Output (+) Term. 509 WH Radio Speaker - Left (Common) 110 RD Aux Ckt 511 BR Radio Speaker - Right 112 PU Main Power RIy Output 512 GN Radio Speaker - Right (Common) 113 OR Opr Mon Panel B+ Switched 513 OR A/C Compressor/Refrigerant Pressure SW 114 RD Warning Horn (Forward) 515 GY Blower Motor (HI) 115 RD Aux Ckt 516 GN Blower Motor (Medium) 118 RD Aux Ckt 517 BU Blower Motor (Low) 121 YL Back Alarm To Lamp 519 PK Thermostat To Refrigerant Press. SW 124 GN A/C 520 WH Opr A/C SW To Thermostat/Fuse 127 RD Aux Ckt A523 PU Temp Potentiometer Pos 1 129 BU Aux Ckt A524 BR Temp Potentiometer Pos 2 135 BU Aux Ckt A525 GN Temp Potentiometer Pos 3 142 BU Aux Ckt A588 GN Safety Sol Relay To Sol 150 RD Bat (+) 151 GN Aux Ckt 607 PK Flood Lamp - Front 168 GN Aux Ckt 615 YL Cab Flood Lamp/Rops 180 GN Aux Ckt 616 BU Bucket Flood Lamp/Boom Flood Lamp 190 PK Aux Ckt 763 BU Torque Converter SW 786 GN Eng Speed Cont - Hi Press SW 791 PK Eng Speed Cont - Lo Sol Description Power Distribution Circuits 59 1 Wire Number 56 51 20 57 AREA F 11 12 200 BK Control Circuits Main Chassis Basic Machine Circuits 20 D 21 48 2 45 3 12 4 47 6 36 10 24 41 23 54 G 7 50 19 C 9 25 14 12 2 3 2 1 2 43 25 2 7 26 38 5 6 6 6 4 64 A 20 44 33 32 13 60 65 2 29 1 3 8 66 23 24 18 4 22 16 8 40 13 37 49 10 11 53 17 14 9 5 B E 5 3 14 22 16 57 15 45 21 4 4 7 5 1 13 10 9 9 11 12 5 42 8 6 7 1 BR Key SW ACC Position 792 OR Underspeed Proportional Sol 304 WH Starter Relay No. 1 Output 799 WH Sensor PowerLow Idle SW 306 GN Starter Relay Coil B786 BU Low Idle SW 307 OR Key SW To Neutral Start SW H740 OR HEX Governer Motor + 310 PU Start Aid SW To Start Aid Sol H741 WH HEX Governer Motor - 320 RD Horn Relay Coil To SW H742 PU HEX Governor Accel Input 321 BR Travel Alarm H743 YL HEX Governor Decel Input 322 GY Warning Horn (Forward) H744 BU HEX Governor Low Idle 323 WH Fuel Pump Power H745 BR HEX Governor SW Return 327 PK Shutdown Solenoid J703 PK Alt Pulse Sig To Anti-Start Relay 330 YL Neutral Start Relay Coil K776 GN Alternator L terminal 332 BU Shutdown SW To Shutdown Ctrl K777 GY Implement Pressure K778 WH Hydraulic Excavator Pwr Mode Valve 403 GN Alternator (R) Term. 817 WH Back-Up Alarm Relay 405 GY Opr Mon Oil Press. (Low Setting) 877 YL Glow Plug Magnetic SW To Glow Plug 406 PU Opr Mon Coolant Temp D813 OR Low Idle SW HEDC 441 OR Eng Coolant Temp Gauge N933 PU Low Idle Indicator 442 GY Hyd System Temp Gauge 447 PK Fuel Level Gauge G480 GN 12 Volt (Fuel Indicator) G481 WH 12 Volt (Coolant Temperature Indicator) G482 PK 12 Volt (Hydraulic Temperature Indicator) 39 3 AREA A 303 Monitoring Circuits 8 10 11 15 3 Description Accessory Circuits (Continued) Lighting Circuits Ground Circuits AREA D 1 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. 1 2 J-7 ¹ At room temperature 17 200-BK-14 © 1998 Caterpillar All Rights Reserved 2 A-5 Resistor, Sender and Solenoid Specifications 32.0 ± 3.2 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 E-1 Normally Open Solenoid - Hydraulic Lock Plug C-2 23 121-1491 Receptacle Pin or Socket Number Normally Closed Resistance (Ohms)¹ 105-9344 1 A-6 Normally Open Component Description Fuse AA Wire Gauge Ground Connection 7 Part No. Circuit Number Identification B-8 Contact Position 50 ± 10 kPa (7.3± 1.4 psi) 90 °C (194 °F) 882.00 kPa MIN (127.92 psi MIN) Wire Color Single Wire Connector Component Part Number Wire, Cable, or Harness Assembly Identification 325-PK-14 58 16 Deactuate Socket 19 22 23 Actuate Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. 62 Function T 5CW1-UP 61 Part No. Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. A 1 Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Pin B-8 Off Machine Switch Specification Electrical Schematic Symbols And Definitions RENR1092 May 1998 Schematic Location Component H-1 Harness Connector Location Chart Connector No. And Machine Location Component Location Related Electrical Service Manuals AREA B AREA G AREA E Title Form Number Electrical and Electronic Systems RENR2978
Wire Description Wire Number Wire Color Wire Number Description Wire Color Power Circuits Description Accessory Circuits (Continued) 101 RD Bat (+) 513 OR A/C Compressor/Refrigerant Pressure SW 103 RD Dome Lamp 519 PK Refrigerant Pressure Sw to A/C Unit 105 BR Key Sw 524 BU Wiper Cont. to Lower Wiper Motor 109 OR Alt Output (+) Term. 111 RD Power to Eng / Pump Control 112 PU Main Power Relay Output 113 OR Opr Mon Switch Panel B (+) 114 GN 115 PK 524 GN Lower Wiper Motor 590 GY Intermittent Sw to Wiper Cont. A537 PK Seat Heater A586 OR Wash Sw to Wiper Cont. Warning Horn (Forward) A588 GN Hyd. Lock Solenoid Cab/Chassis Lamps C537 GN A/C Photo Sensor (+) 118 GY Washer/Wiper C576 BU Med. Pressure Sw 1 to Med. Pressure Valve 120 YL Converter C577 GY Med. Pressure Sw 2 to Med. Pressure Valve 124 GN A/C C578 YL Radio Sw 129 BU Cigar Lighter C588 BR Blade Sw to Blade Relay 135 BU 12V Socket C589 GY Blade Relay To Solenoids 12V Radio Memory C591 PK Floating Blade Relay To Floating Blade Sol. 140 BU Auto Lubrication Pump C592 WH Diodes to Relays 147 PU Seat Heater C599 OR Blade Floating Sw to Blade Floating Relay 149 PU Boom Lamp E500 YL Blade Floating Relay to Blade Relays 150 RD Hyd. Lock Sw E501 PU Blade Relay to Blade Floating Relay BU Aux. Ckt 607 PK Chassis Lamp 154 RD Neutral Start Limit Sw 615 YL Cab Lamps 168 RD Refueling Pump 616 BU Boom Lamps 172 RD Engine Gov. Actuator 633 BU Attach Lighting Ckt Aux. Ckt 638 WH 763 BU Travel Speed Sol. 185 YL Backup 779 WH Coupler Close Sol 189 RD Aux. Ckt 780 PU Coupler Open Sol 191 WH Aux. Ckt 786 GN Boom Lamp Relay 788 YL Engine Sped Sensor (+) 791 PK Chassis Lamp Relay Ground Circuits Main Chassis 201 BK Operator Monitor Return A755 PK Throttle Sw #1 210 BK Converter Output Gnd. A756 BU Throttle Sw #2 235 BK Eng/Pump Control Gnd. A757 GY Throttle Sw #3 Basic Machine Circuits A758 BR Throttle Sw #4 1 16 1 4 PU Engine Gov Actuator Feedback 306 GN Start Relay Coil A762 PU Engine Speed Sensor (-) 307 OR Key Start Sw A768 BU Eng/Pump Cont. Sol (+) 308 YL Main Power Relay Coil A769 GY Eng/Pump Cont. Sol (-) 310 PU Start Aid SW To Start Aid Relay A770 PK Electronic Pump Control Bypass Sw to Resistor 311 WH Start Aid Sw to Key Sw A771 PU Implement Pressure Sw 320 OR Horn Relay Coil F771 OR Governor Actuator (A) 321 BR Travel Alarm F772 WH Governor Actuator (B) 322 GY Warning Horn (Forward) F773 OR Governor Accel 323 WH Fuel Pump Power F774 WH Governor Decel 325 PK Refueling Stop Sw K779 PU Alternator D Terminal 327 PK Fuel Pump Solenoid 877 YL Air Heater Indicator 334 BU Air Heater Resistor 878 OR Start Aid Sol 365 YL Refueling Relay Coils to Sw 954 GN Hammer Pressure Sw 376 GN Coolant Temp Sw 955 BU Hammer Sol 399 OR Cold Advance solenoid K904 GN Discharge Pump Pressure Sensor K905 RD Eng / Pump Control Power 9 K906 GN Swing Brake Sol 405 GY Opr Mon Oil Press. (Low Setting) K907 BU Swing Brake Sol Signal From Eng/Pump Cont. 412 BU Opr Mon Coolant Level K909 BU Backup Sw 430 BU Opr Mon Air Filter K911 PK E/P Controller - RS 485 (+) E/P Controller - RS 485 (-) 491 PK Hyd. Oil Temp Sensor K997 BU Monitor +B Output 492 GY Coolant Temp Sensor L908 OR E/P Controller RS-232C (TX) Fuel Level Sensor L909 Hyd. Oil Level Sw L968 BU E/P Controller RS-232C (RX) OR EPR Valve (-) C468 BU Engine Oil Level L969 WH EPR Valve (+) H414 YL Overload Warning Switch to Buzzer L970 GY Aux. Hyd. Pressure Sw H415 BR Overload Warning Pressure Switch to Buzzer L971 GN Travel Pressure Sw L972 BU Low Idle and Pressure Raise Sw Accessory Circuits 3 15 B-7 1 Air Heater C-8 Alarm - Travel D-9 Alternator B-8 18 Solenoid - Blade C-7 22 Buzzer - Overload Warning F-5 A Solenoid - Cold Advance B-9 18 Buzzer - Quick Coupler Warning H-3 C Solenoid - Eng/Pump Control A-7 23 Control - Eng/Pump C-4 6 Solenoid - Fuel Pump B-9 18 Control - Wiper E-2 E Solenoid - Hammer G-2 F B-5 G-7, H-7, I-6, I-9 7 Solenoid - Hyd. Lock G-2 D Solenoid - Level Finish A-7 Converter - 24V to 12V PU Radio Speaker - Left L978 GY Trenching Sol 509 WH Radio Speaker - Left (Common) P975 OR Quick Coupler Warning Buzzer 511 BR Radio Speaker - Right P976 BR 512 GN Radio Speaker - Right (Common) 8630 BU Resistor - Fuel Pump 102 - 8016 Resistor - Backup 111 - 9916 Solenoid - Engine/Pump Control H-9 D CONN. 2 G-9 D CONN. 3 G-8 D CONN. 4 G-8 D F CONN. 5 G-8 D 23 CONN. 6 E-8 D CONN. 7 E-8 D CONN. 8 E-8 D A-6 A Solenoid - Quick Coupler HP Close A-2 8 CONN. 9 D-8 D Ground - Cab D-2 E Solenoid - Quick Coupler HP Open A-2 8 CONN. 10 G-7 D Quick Coupler Sol Ground - Chassis B-3 8 Solenoid - Quick Coupler LP G-2 F CONN. 11 F-6 F Rotating Beacon Sw Ground - Chassis B-8 4 Solenoid - Start Aid F-9 24 CONN. 12 F-6 F Ground - Platform D-5, G-3, G-6 F Solenoid - Swing Brake A-2 22 CONN. 13 E-6 F CONN. 14 E-6 F CONN. 15 E-6 F Contact Position Normally Closed Normally Open Normally Open Normally Open Normally Open Normally Open Resistance (Ohms)1 17.6 ± 0.6 6.0 Ground - Relay Panel H-9 D Solenoid - Travel Speed A-7 23 Ground Strap - Chassis G-9 D Solenoid - Trenching A-7 23 CONN. 16 C-6 10 Ground Strap - Chassis to Engine A-8 9 Switch - Air Cleaner F-8 D CONN. 17 C-6 10 Ground Strap - Chassis to Platform G-6 10 Switch - Air Heater/ Start Aid E-4 C CONN. 18 C-5 10 Horn C-2 8 Switch - Aux. E-5 C CONN. 19 C-5 10 Indicator - Hyd. Oil Filter A-7 11 Switch - Backup EPR Valve D-4 C CONN. 20 B-5 F CONN. 21 B-5 F CONN. 22 C-5 F CONN. 23 C-5 27 Joystick - Multiswitch LH I-2 B Switch - Backup Gov. D-5 C Joystick - Multiswitch RH F-3 C Switch - Blade Floating F-3 C Meter - Service F-2 E Switch - Boom Raise Pressure C-7 22 CONN. 24 H-5 F Monitor F-2 E Switch - Coolant Level E-9 25 CONN. 25 H-5 F Motor - Lower Wiper H-2 12 Switch - Coolant Temp B-9 18 CONN. 26 H-4 F Motor - Starter A-8 9 Switch - Coolant Temp (Start Aid) C-8 18 CONN. 27 H-4 F CONN. 28 I-3 C CONN. 29 D-3 F CONN. 30 B-3 16 Motor - Upper Wiper G-1 13 Switch - Disconnect G-9 D Motor - Washer E-9 D Switch - Engine Oil Level B-8 26 Pickup - Engine Speed B-9 14 Switch - Engine Oil Pressure A-9 18 CONN. 31 A-2 20 Pump - Auto Lubrication E-9 15 Switch - Hammer Pressure G-2 F CONN. 32 B-2 16 Pump - Refueling B-2 16 Switch - Hyd. Oil Level B-7 19 CONN. 33 B-2 16 Relay - Air Heater I-7 D Switch - Implement Pressure B-7 22 C I-9 D Switch - Key Start E-3 Relay - Blade I-7, I-9 D Switch - Neutral Start Limit I-2 B Relay - Blade Floating I-7, I-8 D Switch - Overload Warning E-4 C Relay - Boom Lamp J-8 D Switch - Overload Warning Pressure D-2 F Relay - Cab/Chassis Lamp I-9 D Switch - Quick Coupler I-3 C Relay - Fan I-7 D Switch - Radio E-4 C Relay - Horn I-9 D Switch - Refrigerant Low Pressure B-9 18 Relay - Hyd. Lock Sol I-8 D Switch - Refueling A-2 16 Relay - Main H-7 D Switch - Refueling Start B-2 16 6130 to 7500 Relay - Neutral Start I-7 D Switch - Refueling Stop B-3 16 4.0 ± 0.2 Relay - Refueling 1 B-2 17 Switch - Rotating Beacon E-5 C 47.00 ± 2.35 Relay - Refueling 2 B-2 17 Switch - Seat Heater E-4 C Relay - Start H-7 D Switch - Throttle Position E-3 C 11.7 ± 1.2 112 - 4009 Sender - Coolant Temp 20824 - 25451 @ 0 C (32 F) 6134 - 7496 @ 25 C (77 F) 475 - 522 @ 100 C (212 F) 121 - 1490 Solenoid - Level Finish Solenoid-Trenching 32.0 ± 3.2 121-1491 Solenoids -Hydraulic Lock Solenoid - Swing Brake Solenoid - Travel Speed 32.0 ± 3.2 140 - 2238 Resistor Coolant Temp Governor actuator does not move. 2304 Calibration data error. 3201 Monitor RAM is not normal. 4101 Electric power supply to the controller is too much (43 volts). 4102 Over-current in proportional reducing valve. 4103 Proportional reducing valve circuit is open. 4104 Monitor power supply (digital output) over current. 4105 Over-current in digital output (trenching solenoid). 4106 Over-current in digital output (fine control solenoid). 4107 Over-current in digital output (travel speed change solenoid). 4108 Over-current in digital output (travel alarm). 410A Over-current in digital output (swing brake solenoid). 4201 Engine speed is not normal. 4202 Engine coolant temperature sensor is shorted to body ground. 4203 Hydraulic oil temperature sensor is shorted to body ground. 4204 PWM sensor of pump delivery pressure is shorted to body ground. 4207 PWM sensor of pump delivery pressure is open in circuit. 420A Fuel sensor is shorted to body ground. 420B Fuel sensor is open or shorted to battery voltage. 420C Electric power supply is to low (below 23 volts). 420D Electric power supply is to high (above 32 volts). 420E Engine speed dial is not in one of the 10 specified positions. 4301 Data mismatch 1 between alternator and speed sensor (alternator is abnormal). 4302 Data mismatch 2 between alternator and speed sensor (speed sensor is abnormal). 4303 Engine stalls. A201 Monitor communication is not normal. A202 Monitor takes too much time to respond to controller's signal. A203 Communication is abnormal in controller. 25.00 ± 0.25 Title Alternator: Switch - Travel Pressure B-7 22 Resistor - Air Heater H-7 D Switch - Windshield E-2 A Engine/Pump Control: Resistor - Backup I-9 D Switch Panel F-3 C Starting and Charging: Resistor - Coolant Temp H-7 D Unit - A/C H-6 7 Resistor - Fuel Pump H-7 D D = Located in relay panel area. E = Located in dash area. F = Located under cab floor plate. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols Socket Wire Color Single Wire Connector Circuit Number Identification SENR3685 132 - 7834 SENR9291 Ground Connection Fuse AA 105-9344 1 Receptacle Wire Gauge Form Number 109 - 2362 Component Part Number Wire, Cable, or Harness Assembly Identification 325-PK-14 D B = Located in operator's left hand console area. Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. A Related Electrical Service Manuals Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp, press, etc...). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Pin I-7 Machine locations are repeated for components located close together. Printed in U.S.A. T Pressure Symbol CONN. 34 C-2 8 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Relay - Timer C = Located in operator's right hand console area. At room temperature unless otherwise noted. CONN. 1 - S.I.S. Connector Ground - Cab A = Located in operator's compartment. 1 Machine Location 22 Resistor, Sender and Solenoid Specifications 5L - 2854 Schematic Location Connector Number A-2 Relay - Aux. Hyd. 41 - 5394 Governor actuator feedback signal deviates. 2303 Connector Location Solenoid - Medium Pressure Valve With increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kPa (25 psi). Solenoid - Start Aid Governor actuator feedback signal is not stable. 2302 Electrical Schematic Symbols And Definitions B 1 Sender - Hydraulic Oil Temp Governor actuator feedback sensor circuit is shorted to body ground. 2301 ©2001 Caterpillar All Rights Reserved I-4, I-5, I-6 Off Machine Switch Specification 3E - 6332 E D 508 Solenoid - A/C Clutch F-2 G-9 Fuses - 10A & 15A 3E - 1906 Sensor - Provision For A/C Photo Breaker - Main Level Finish Sol Component Description 20 4 21 YL Part No. 19 A-2 A-9 L977 Refrigerant Hi/Lo Pressure B-7 Sensor - Fuel A-9 Washer - Front 113-3444 Sender - Hyd. Oil Temp 3 Solenoid - A/C Compr Clutch PU Engine Oil Pressure 2 Sensor - Pump Discharge Pressure 506 107-0611 Machine Location 18 5 Diodes Hammer Pressure Sender - Coolant Temp Schematic Location B-8 Component D Refueling Start Sw to Refueling Relays 1 & 2 26.7 C MIN (80 F MIN) 882.0 kPa MIN (127.92 psi MIN) 2156.0 ± 196.0 (312.7 ± 28.43 psi) 290.0 kPa MIN (42.06 psi MIN) 70.0 ± 21.0 kPa (10.15 ± 3.05 psi) _ _ Governor actuator feedback sensor circuit is open or shorted to battery voltage. 2202 F F-9 Boom Raise Pressure Sw 106-0181 16 G-9 GN Boom Raise Pressure 17 Breaker - Alternator GN 106-0180 6 Batteries L976 106-0179 27 Actuator - Engine Gov. L974 Implement Pressure Travel Pressure 23 Machine Location Wiper - Front (Low) 37.8 ± 2.8 C (100 ± 5 F) 1225.0 ± 98.0 kPa (177.67 ± 14.21 psi) 2646.0 ± 196.0 kPa (383.77 ±28.43 psi) 490.0 ± 49.0 kPa (71.07 ± 7.11 psi) 93.0 ± 21.0 kPa (13.49 ± 3.05 psi) 196 to 3140 kPa1 (28.4 to 455.4 psi) Battery voltage is not normal. 2201 12 10 Schematic Location Wiper - Front (Park) Deactuate Air filter is clogged. 1305 E C B Component BR Actuate Hydraulic oil temperature is too high. 1304 8 D 5 GN Coolant Temperature 20 19 25 501 8N-1693 11 14 500 Function Engine coolant temperature is too high. 1303 22 18 Component Location Alternator (R) Term. GN 1302 Machine Harness Connector And Component Locations GN K912 312B L: 9FS1-UP 2KW1-UP Engine oil pressure is too low. 24 26 403 Hyd. Oil Filter Indicator 312B: 6SW1-UP 9NW1-UP Description of Problems 1301 7 A761 Monitoring Circuits 312B and 312B L Excavator Electrical System 21 Starter Relay No. 1 Output Part No. 23 21 2 WH WH 11 13 304 496 17 9 A Aux. Ckt GN 14 19 Control Circuits Main Breaker GN 495 8 Rotary Beacon 180 OR 22 2 Lighting Circuits Hyd. Lock Coil Relay 152 487 E 20 OR BK C 6 10 26 139 200 Code 12 4 A/C Photo Sensor (-) RD Real Time Error Codes 13 18 OR 177 F A 3 C538 YL 7 D 27 Fan Relay 176 B 25 BR GN 5 15 116 151 RENR1115-02 April 2001 24 Plug 2 200-BK-14 Pin or Socket Number SENR9292 1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.
Component Location Schematic Machine Location Component Location Actuator - Eng Governor D-9 27 Resistor - Main Relay Air Heater B-9 3 Seat With Seat Heater Alarm - Travel D-9 3 Sender - Coolant Temp Alternator C-8 4 Sender - Hydraulic Oil Temp Antenna A-6 5 Sensor - A/C Photo Battery E-9, F-9 6 Sensor - AIH Coolant Temp Block - Terminal G-7 D Sensor - Engine Speed Pickup Breaker 1 G-9 D Sensor - Fuel Level Breaker 1 - Bat G-9 D Sensor - Pump Discharge Press Breaker 2 G-9 D Solenoid - Air Conditioner Clutch Breaker 2 - Bat H-9 D Solenoid - Eng/Pump Cont Breaker 3 H-9 D Solenoid - Engine Shutdown Control - Eng/Pump B-4, C-4 7 Solenoid - Hydraulic Lock Control - Power Window B-6 15 Solenoid - Level Finish Control - Wiper E-2 A Solenoid - Swing brake Converter J-3 8 Solenoid - Travel Speed Converter - 12V 5A H-5 9 Solenoid - Trenching Fuse - Block J-4, J-5, J-6 C Speaker Glow Plug A-9, B-9 2 Switch - Air Cleaner Horn C-2 10 Switch - Aux Hydraulic Indicator - Hydraulic oil Filter B-7 E Switch - Backup EPR Valve Lamp - Boom C-1 11 Switch - Backup Gov Lamp - Cab G-1, H-1 12 Switch - Boom Raise Press Lamp - Chassis B-2 13 Switch - Coolant Level Lamp - Dome A-6 A Switch - Disconnect Lighter - Cigar F-2 A Switch - Engine Oil Level Meter - Service F-2 A Switch - Engine Oil Pressure Monitor F-2 A Switch - Hammer Press Motor - Lower Washer F-9 40 Switch - Horn Motor - Lower Wiper G-2 G Switch - Hydraulic Oil Level Motor - Starter B-8 14 Switch - Implement Swing Press Motor - Upper Wiper E-2 A Switch - Key Motor - Washer F-9 1 Switch - Lower Washer Pump - Auto Lubrication E-9 16 Switch - Lower Wiper Pump - Refueling B-2 17 Switch - Neutral Start Limit Radio J-3 C Switch - One Touch Low Idle Relay - Air Heater G-6 D Switch - Panel Relay - Boom Lamp J-9 D Switch - Power Window Relay - Chassis/Cab Lamp J-9 D Switch - Power Window Limit Relay - Fan J-7 D Switch - Refrigerant Low Press Relay - Heater H-7 D Switch - Refueling Level Relay - Horn J-9 D Switch - Refueling Start Relay - Hydraulic Lock Solenoid J-9 D Switch - Refueling Stop Relay - Main H-7 D Switch - Seat Heater Relay - Neutral Start J-7 D Switch - Throttle Position Relay - Refueling 1 B-2 19 Switch - Travel Press Relay - Refueling 2 B-2 20 Switch - Window Limit Relay - Start H-7 D Timer - Engine Shutdown Relay - Start Cont J-8 D Unit - Air Conditioner Relay - Timer J-7 D Unit - Air Heater Control Resistor - Backup J-9 D Unit - Air Heater Control ATCH Machine locations are repeated for components located close together. A Located in the cab B Located in the lefthand console C Located in the righthand console D Located on or near relay panel E Located near hydraulic oil tank F Located near pilot manifold G Located on or near bottom platform Component Electrical Schematic Symbols And Definitions Schematic Location Machine Location H-9 F-5 C-8 B-7 F-2 C-8 B-8 A-2 A-7 B-8 A-7 A-9 H-2 A-7 A-3 A-7 A-7 B-6 D-8 G-2 D-4 D-5 C-7 E-9 G-9 A-9 B-8 G-2 H-1 B-7 C-7 E-3 E-4 E-4 H-2 F-3 F-3 E-4 A-6, G-2 E-9 A-2 B-2 B-3 D-5 E-3 B-7 G-2 H-7 H-6 J-8 H-6 D 28 22 E A 21 25 23 24 26 F 27 G F 32 F F 33 35 G C B 34 36 D 37 38 G C E 39 B B B C B B B A 36 41 29 30 B B 31 A D 18 D D RENR1132-01 October 1999 T Pressure Symbol Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T 315B and 315B L Excavators Electrical System 315B: 1SW1-UP 2DW1-UP Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. 315B L: 3AW1-UP Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols Pin Socket Wire Color A Circuit Number Identification 105-9344 Receptacle Wire Gauge Ground Connection Fuse AA 1 325-PK-14 Single Wire Connector Component Part Number Wire, Cable, or Harness Assembly Identification Plug 2 200-BK-14 Pin or Socket Number 1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. ©1999 Caterpillar All Rights Reserved Printed in U.S.A. Wire Description Related Electrical Service Manuals Title Form Number Engine / Pump Control RENR1998 Starting and Charging RENR1044 Off Machine Switch Specification Part No. Function Implement Pressure 106-0179 Travel Pressure Actuate 1520 ± 98 kPa (220.4 ± 14 psi) 2646 ± 196 kPa (383.8 ± 28.4 psi) 490 ± 49 kPa (71.1 ± 7.1 psi) 106-0180 Boom Raise Pressure 106-0181 Aux Hydraulic Pressure Hammer Pressure Deactuate 1127 kPa MIN (163.5 psi MIN) 2156 ± 196 kPa (312.7 ± 28.4 psi) 290 kPa MIN (42.1 psi MIN) CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN CONN 1 2 3 SIS Connector 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 163-6616 Normally Open Normally Open 15 Connector Location Connector Number Normally Open 12 33 Schematic Location B-4 C-4 H-9 G-9 G-8 G-8 D-8 D-8 D-7 G-7 F-6 E-6 E-6 E-6 B-6 B-6 B-6 B-5 B-5 C-5 C-5 C-5 H-5 H-5 H-5 H-5 H-4 H-4 A-3 B-3 H-3 J-3 C-2 B-2 B-2 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Machine Location 7 7 D D D D D D D D G G G G A A A A G G G 7 43 G G G G G 41 29 G 42 32 17 19 Part No. 102-8015 Contact Position Resistor, Sender and Solenoid Specifications Component Description Resistor: Backup Resistor: Main Relay 4I-5394 111-9916 Sender: Hydraulic Oil Temperature Solenoid: Engine / Pump Control Level Finish 121-1490 Solenoid: Trenching Hydraulic Lock 121-1491 Solenoid: Swing Brake Travel Speed ¹ At room temperature unless otherwise noted. 11 5 2 3 36 21 22 24 27 4 14 16 25 9 41 32 35 31 26 28 23 34 38 18 8 39 42 30 29 43 7 44 Real Time Error Codes 19 10 45 Code 20 37 13 6 3 17 40 1 36 16 33 40 6 43 12 1 9 18 28 42 8 7 35 3 22 15 12 5 33 21 10 45 11 4 39 26 38 27 32 3 31 14 37 10 34 11 23 13 2 25 24 41 29 17 44 30 20 19 Machine Harness Connector And Component Locations Description of Problems 1301 Engine Oil Pressure Is Too Low 1302 Engine Coolant Temperature Is Too High 1303 Hydraulic Oil Temperature Is Too High 1304 Air Filter Is Clogged 1305 Battery Voltage Is Not Normal 2201 Governor Actuator Feedback Sensor Circuit Is Open Or Shorted To Battery Voltage 2202 Governor Actuator Feedback Sensor Circuit Is Shorted To Body Ground 2301 Governor Actuator Feedback Signal Is Not Stable 2302 Governor Actuator Feedback Signal Deviates 2303 Governor Actuator Does Not Move 2304 Calibration Data Error 3201 Monitor RAM Is Not Normal 4101 Electric Power Supply To The Controller Is Too High (43Volts) 4102 Over-Current In The Proportional Reducing Valve 4103 Proportional Reducing Valve Circuit Is Open 4105 Over-Current In The Digital Output (Trenching Solenoid) 4106 Over-Current In The Digital Output (Fine Control Solenoid) 4107 Over-Current In The Digital Output (Travel Speed Change Solenoid) 4108 Over-Current In The Digital Output (Travel Alarm) 410A Over-Current In The Digital Output (Swing Brake Solenoid) 4201 Engine Speed Is Not Normal 4202 Engine Coolant Temperature Sensor Is Shorted To Body Ground 4203 Hydraulic Oil Temperature Sensor is Shorted To Body Ground 4204 PWM Sensor Of Pump Delivery Pressure Is Shorted To Body Ground 4207 PWM Sensor Of Pump Delivery Pressure Is Open In Circuit 420A Fuel Sensor Is Shorted To Body Ground 420B Fuel Sensor Is Open Or Shorted To Battery Voltage 420C Electric Power Supply Is Too Low (Below 23 Volts) 420D Electric Power Supply Is Too High (Above 32 Volts) 420E Engine Speed Dial Is Not One Of The Specified 10 4301 Data Mismatch 1 Between The Alternator And The Speed Sensor (Alternator Is Abnormal) 4302 Data Mismatch 2 Between The Alternator And The Speed Sensor (Speed Sensor Is Abnormal) 4303 Engine Stalls A201 Monitor Communications Is Not Normal A202 Monitor Takes Too Much Time To Respond To The Controller's Signal A203 Communication Is Abnormal In The Controller Wire Number Resistance (Ohms)¹ 41 ± 2.1 (1) 48 ± 2.4 (2) 48 ± 2.4 6134 to 7496 11.7 ± 1.2 32.0 ± 3.2 32.0 ± 3.2 Wire Color 101 103 105 109 110 111 112 113 115 118 120 124 129 135 140 147 149 150 151 152 154 169 168 172 173 175 176 177 178 179 180 185 189 191 196 RD RD RD RD RD RD PU OR RD GY YL RD BU BU BU PU PU RD GN BU RD RD RD RD YL RD YL RD GN BU GN YL RD WH BU 200 201 235 BK BK BK 304 306 307 308 309 310 320 321 322 323 325 327 330 365 WH GN OR YL GY PU RD BR GY WH PK PK YL YL 403 405 412 430 487 491 492 495 496 C468 GN GY BU BU OR PK GY GN WH BU 501 506 508 509 511 512 GN PU PU WH BR GN Description Power Distribution Circuits Bat (+) Aux Ckt Key Sw Alt Output (+) Term. Aux Ckt Aux Ckt Main Power Rly Output Opr Mon Panel B (+) Switched Aux Ckt Aux Ckt Aux Ckt A/C Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Bat (+) Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Main Brkr Main Brkr Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Ground Circuits Main Chassis Operator Monitor Return Electronic Pump Ctrl Gnd Basic Machine Circuits Starter Relay No. 1 Output Starter Relay Coil To Neut Start Key SW To Neut Start Main Power Relay Coil Alternator Regulator Term. Start Aid SW To Start Aid Sol Horn Relay Coil To SW Travel Alarm Warning Horn (Forward) Fuel Pump Power Fuel Pump Relay Cut-Out Shutdown Sol Neut Start Relay Coil Fuel Pump Relay To Switch Monitoring Circuits Alternator (R) Term. Opr Mon Oil Press. (Low Setting) Opr Mon Cool Flow Opr Mon Air Filter Hyd Oil Flow SW Hyd Oil Temp Sensor Coolant Temp Sensor Signal Fuel Level Signal Opr Mon Panel Hyd Oil Level Engine Oil Level Accessory Circuits Wiper - Front (Low) Washer - Front Radio Speaker - Left Radio Speaker - Left (Commom) Radio Speaker - Right Radio Speaker - Right (Common) Wire Number Wire Color 513 519 530 575 576 578 579 590 592 A537 A513 A579 A580 A581 A582 A583 A584 A586 A587 A588 A589 A590 A591 C537 C538 OR PK OR YL PK BU BR GY BU PK RD OR BR GN PU YL BU OR YL GN OR BU PU GN OR 607 615 616 PK YL BU 763 786 788 791 A718 A755 A756 A757 A758 A761 A762 A768 A769 A770 A771 F771 F772 F773 F774 J703 877 954 K904 K905 K906 K907 K909 K911 K912 K997 L908 L909 L968 L969 L970 L971 L972 L974 L975 L976 L977 L978 BU GN YL RD PU PK BU GY BR PU PU BU GY PK PU OR WH OR WH PK YL GN GN RD GN BU BU PK GN BU OR BU OR WH GY GN BU GN PK GN YL GY Description Accessory Circuits (cont'd) A/C Compressor/Refrigerant Press SW Thermostat To Refrigerant Press SW Washer Right Wiper - Aux (Park) Wiper - Aux (Low) Washer - Aux A/C Blower Motor No. 1 Wiper SW To Intermittent Module DC/DC Converter Power Output Seat Heater (Resistive Element In Cushion) DC/DC Converter Memory Output Wiper Motor (+) Wiper Motor (-) Wiper Motor Raise Wiper Motor Stop Power Window Interlock To Wiper Cont Front Window Limit SW To Wiper Cont Wiper SW To Wiper Cont Power Window Cont To Safety Sol Relay Safety Sol Relay To Sol Power Window Up Power Window Down Rear Window Limit SW A/C Photo Sensor (+) Sig A/C Photo Sensor (-) Sig Lighting Circuits Flood Lamp - Front Cab Flood Lamp Boom Flood Lamp Control Circuits Torque Converter SW Eng Speed Cont - Hi Press SW Eng Speed (+) Eng Speed Cont - Lo Sol Start Aid Coolant Sensor Signal Throttle SW #1 Throttle SW #2 Throttle SW #3 Throttle SW #4 Electronic Pump Cont Electronic Pump Cont Pump Control Valve #1 (+) Pump Control Valve #2 (-) Electronic Pump Control Bypass SW To Resistor Float SW Backup SW Backup SW Governor Accel Governor Decel Alt Pulse Sig To Anti-Start Relay Glow Plug Magnetic SW To Glow Plug Hammer SW A Pump Discharge Signal Pump Discharge (+) Swing Brake Sol Signal Swing Brake Sol (+) Backup SW (+) E/P Controller RS485 (+) E/P Controller RS485 (-) (+) V Sensor Controller RS-232C Tx Controller RS-232C Rx Electronic Pump Control Ps Valve (-) Electronic Pump Control Ps Valve (+) Electronic Pump Control To Switch Common RTN Electronic Pump Control To Travel Pressure SW Low Idle SW Electronic Pump Ctrl Boom Raise Press SW Start Aid Cont Lamp 1 Output Excavator Fuel Pump Switch Trenching Sol Level Finish Sol
Wire Description Component Location Component Schematic Machine Location Location Component Schematic Machine Location Location A/C Unit H-6 1 Relay - Timer J-7 D Actuator - Eng Gov B-7 2 Resistor - Air Heater J-7 D Air Heater C-9 3 Resistor - Backup H-9 D Alarm - Travel C-9 4 Resistor - Fuel Pump J-7 D Alternator B-8 5 Sender - Coolant Temp B-8 21 Batteries F-9 6 Sender - Hyd Oil Temp B-7 13 Breaker - 1 H-9 D Sensor - A/C Photo F-2 E Breaker - 2 H-9 D Sensor - Fuel Level A-2 22 Breaker - 3 H-9 D Sensor - Pump Discharge Press A-7 23 Breaker - Battery H-9 D Solenoid - A/C Compr Clutch B-8 5 Control - Wiper E-2 E Solenoid - Cold Advance B-9 24 Controller - Engine/Pump C-4 Converter - Voltage Fuses 7 Solenoid - Eng/Pump Cont A-7 25 B-5 8 Solenoid - Fuel Pump B-9 24 J-4,5,6 B Solenoid - Hammer G-2 F Ground - Cab A-6 A Solenoid - Hyd Lock G-2 F Ground - Chassis B-3 9 Solenoid - Level Finish A-7 25 Ground - Platform D-5 Ground - Platform F G-3 Solenoid - Start Aid F E-9 Solenoid - Swing Brake A-2 26 27 Ground - Platform G-6 F Solenoid - Travel Speed A-7 25 Ground - Relay Panel H-8 D Solenoid - Trenching A-7 25 Ground Strap - Chassis to Platform G-6 10 Solenoid - Medium Press Valve B-7 28 Ground Strap - Disconnect to Switch to Chassis G-9 D Switch - Air Cleaner F-8 29 Ground Strap - Engine to Chassis A-8 11 Switch - Aux E-4 F Heater H-6 1 Switch - Backup EPR Valve D-4 C Horn - Forward C-2 12 Switch - Backup Gov D-5 C Indicator - Hydraulic Oil Filter B-7 13 Switch - Boom Raise Press C-7 13 Joystick - Multiswitch (LH) H-2 B Switch - Coolant Level E-9 26 Joystick - Multiswitch (RH) F-3 C Switch - Coolant Temp B-9 24 Meter - Service F-2 E Switch - Coolant Temp C-9 24 Monitor F-2 E Switch - Disconnect G-9 D Motor - Lower Wiper H-2 14 Switch - Eng Oil Level A-8 30 Motor - Starter A-8 15 Switch - Eng Oil Press B-9 31 Motor - Upper Wiper G-1 16 Switch - Hammer Press G-2 F Motor - Washer F-9 Panel - Switch D F-3 Pickup - Engine Speed Switch - Heater/Start Aid C A-9 Switch - Hyd Oil Lever 17 Switch - Implement Press E-4 B-7 C-7 C 32 E-9 18 Switch - Key Start E-3 C Pump - Refueling B-2 19 Switch - Neutral Start Limit J-2 B Relay - Air Heater J-8 D Switch - Overload Warning E-5 C Relay - Aux Hydraulic J-8 D Switch - Overload Warning Pressure D-2 F Relay - Boom Lamp J-9 D Switch - Radio E-4 C Relay - Cab/Chassis lamp J-9 D Switch - Refrigerant Low Press B-9 26 J-7 D Switch - Refueling A-2 33 Relay - Horn J-9 D Switch - Refueling Start (NO) B-2 34 Relay - Hydraulic Lock Solenoid J-9 D Switch - Refueling Stop (NC) B-2 34 Relay - Main H-7 D Switch - Rotating Beacon E-5 C Relay - Neutral Start J-8 D Switch - Seat Heater E-4 C Relay - Refueling 1 B-2 20 Switch - Throttle E-3 C Relay - Refueling 2 B-2 20 Switch - Travel Pressure C-7 28 Relay - Start H-7 D Switch - Windshield E-2 A Machine locations are repeated for components located close together. A = Located inside of cab. B = Located inside of right console. C = Located inside of left console. D = Located around relay panel. E = Located around hydraulic oil tank. F = Located around pilot manifold. G = Located under platform. 16 A 23 3 33 13 5 11 31 28 D 17 30 7 9 22 35 6 E 36 27 15 18 1 8 29 32 26 24 2 21 B C 25 19 4 20 Wire Number Wire Color Power Distribution Circuits 508 PU Radio Speaker - Left 103 RD Aux Ckt 509 WH Radio Speaker - Left(Common) 105 RD Key Sw 511 BR Radio Speaker - Right 109 RD Alt Output (+) Term. 512 GN Radio Speaker - Right (Common) 110 RD Aux Ckt 513 OR A/C Compressor/Refrigerant Press SW 111 RD Aux Ckt 519 PK Thermostat To Refrigerant Press SW 112 PU Main Power Rly Output 524 BU Wiper Motor - Lower 113 OR Opr Mon B+ Switched 524 GN Wiper Motor - Upper 114 RD Warning Horn (Forward) 579 BR A/C Blower Motor No1 115 PK Aux Ckt 590 GY Wiper Switch To Intermittent Module 118 GY Aux Ckt A537 PK Seat Heater (Resistive Element In Cushion) 120 YL Aux Ckt A586 OR Wiper Switch To Wiper Control 124 RD A/C A588 GN Safety Sol Relay To Sol 129 BU Aux Ckt C537 GN A/C Photo Sensor (+) Sig 135 BU Aux Ckt C538 OR A/C Photo Sensor (-) Sig 139 OR Aux Ckt C576 BU Switch #1 To Medium Pressure Sol #1 140 BU Aux Ckt C577 GY Switch #1 To Medium Pressure Sol #2 149 PU Aux Ckt C578 YL Radio Switch To Radio 150 RD Bat (+) C583 OR +24 Volt Relay To A/C Control Module 151 GN Aux Ckt C592 WH Diode To Blade Relay 152 BU Aux Ckt 154 RD Aux Ckt 607 PK Flood Lamp - Front 168 RD Aux Ckt 615 YL Cab Flood Lamp 172 RD Aux Ckt 616 BU Boom Flood Lamp 173 YL Aux Ckt 633 BU Attach Lighting Ckt 176 YL Aux Ckt 638 WH Rotary Beacon 177 RD Main Brkr 178 GN Main Brkr 763 BU Torque Converter SW 179 BU Aux Ckt 786 GN Eng Speed Cont - Hi Press SW 180 GN Aux Ckt 788 YL Eng Speed (+) 185 YL Aux Ckt 779 WH Coupler Engage Sol 189 RD Aux Ckt 780 PU Coupler Disengage Sol 191 WH Aux Ckt 791 PK Eng Speed Cont - Lo Sol 196 BU Aux Ckt A755 PK Throttle SW #1 A756 BU Throttle SW #2 14 F T Pressure Symbol Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Lighting Circuits Control Circuits Ground Circuits 200 BK Main Chassis A757 GY Throttle SW #3 201 BK Operator Monitor Return A758 BR Throttle SW #4 210 BK Converter Output (24/12 Volt) A761 PU Electronic Pump Cont Throttle Ground 235 BK Electronic Pump Ctrl Gnd A762 PU Electronic Pump Cont Eng Speed Ground A768 BU Pump Cont Valve #1 (+) GY Pump Cont Valve #2 (-) Basic Machine Circuits 304 WH Starter Relay No. 1 Output A769 306 GN Starter Relay Coil To Key Neut Start A770 PK Electronic Pump Control Bypass SW To Resistor 307 OR Key Switch Neut Start A771 PU Float SW 308 YL Main Power Relay Coil F771 OR Backup SW 310 PU Start Aid SW To Start Aid Sol F772 WH Backup SW 311 WH Start Aid Sol To Temp SW F773 OR Governor Accel 315 GN Start Aid Breaker To Start Aid Sol F774 WH Governor Decel 317 YL Start Aid Relay To Start Sol K779 PU Alternator D Terminal 320 RD Horn Relay Coil To SW 877 YL Glow Plug Magnetic SW To Glow Plug 321 BR Travel Alarm 954 GN Hammer SW A 322 GY Warning Horn (Forward) 955 BU Hammer Sol A 323 WH Fuel Pump Power K904 GN Pump Dicharge Signal 325 PK Fuel Pump Relay Cut-Out K905 RD Pump Discharge (+) B 327 PK Shutdown Solenoid K906 GN Swing Brake Sol Signal 365 YL Fuel Pump Relay To Switch K907 BU Swing Brake Sol (+) B 399 OR Cold Start Advance Motor K909 BU Backup SW (+) B Monitoring Circuits K911 PK E/P Controller - RS485 (+) 403 GN Alternator (R) Term. K912 GN E/P Controller - RS485 (-) 405 GY Opr Mon Oil Press (Low Setting) K997 BU (+) V Sensor 412 BU Opr Mon Cool Flow L908 OR Controller RS - 232C Tx 430 BU Opr Mon Air Filter L909 BU Controller RS - 232C Rx 487 OR Hyd Oil Flow SW L968 OR Electronic Pump Control Ps Valve (-) 491 PK Hyd Oil Temp Sensor L969 WH Electronic Pump Control Ps Valve (+) 492 GY Coolant Temp Sensor Signal L970 GY Electronic Pump Control To SW Common Return 495 GN Fuel Level Signal L971 GN Electronic Pump Control To Travel Pressure SW Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols Pin Single Wire Connector 1 2 BU Engine Oil Level L974 GN Electronic Pump Ctrl Boom Raise Press SW 8N-1693 H414 YL Warning Switch To Alarm L976 GN Excavator Fuel Pump SW H415 BR Alarm To Warning Pressure Switch L977 YL Trenching Sol L978 GY Level Finish Sol GN Wiper - Front (Low) R984 YL E/P Controller to Aux/Hyd Cotroller (RS485 -) 506 PU Washer - Front 8630 BU Lamp Relays Function Atch Coolant Temperature 106-0179 Implement Pressure Travel Pressure 106-0180 Boom Raise Pressure 106-0181 Hammer Pressure B 6 8 F D 16 A 1 14 21 4 35 29 10 24 2 E C 7 32 5 36 3 28 31 15 30 11 17 23 27 12 9 13 22 33 34 19 25 20 Machine Harness Connector And Component Locations 107-0611 Connector Schematic Machine Number Plug 2 200-BK-14 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Printed in U.S.A. Off Machine Switch Specification C468 501 Receptacle Wire Gauge ©2000 Caterpillar All Rights Reserved Low Idle SW E/P Controller to Aux/Hyd Cotroller (RS485 +) 105-9344 Pin or Socket Number BU GN Circuit Number Identification Fuse AA 1 Ground Connection L972 R983 Wire Color 325-PK-14 Opr Mon Panel Hyd Oil Level Wiper - Front (Park) Socket Component Part Number Wire, Cable, or Harness Assembly Identification A WH BR Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. 5SW1-UP 496 500 Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T 315B Excavator Electrical Schematic Part No. Connector Location¹ 18 Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Actuate Deactuate Contact Position 37.8 ± 2.8° C 26.7° C MIN Normally (100 ± 5° F) (80° F MIN) Closed 1225.00 ± 98.00 kPa 882.00 kPa MIN Normally (177.67 ± 14.21 psi) Engine Oil Presure (127.92 psi MIN) Open 2156.00 ± 196.00 kPa Normally (383.77 ± 28.43 psi) (312.70 ± 28.43 psi) Open 490.00 ± 196.00 kPa 93.00 ± 21.00 kPa (13.49 ± 3.05 psi) Real Time Error Codes Code 2646.00 ± 196.00 kPa (71.07 ± 7.11 psi) 26 Electrical Schematic Symbols And Definitions RENR1149-02 April 2000 Accessory Circuits (cont'd) Bat (+) Accessory Circuits 34 Description RD 12 10 Description 101 13 Pump - Auto Lubrication Relay - Heater Wire Number Wire Color 290.00 kPa MIN Normally (42.06 psi MIN) Open 70.00 ± 21.00 kPa Normally (10.15 ± 3.05 psi) Open Description Of Problems 1301 Engine oil pressure too low 3102 Engine coolant temperature is too high 1303 Hydraulic oil temperature is too high 1304 Air filter is clogged 1305 Battery voltage is not normal 2201 Governor actuator feeback sensor circuit is open or shorted battery voltage 2202 Governor actuator feedback sensor is shorted to body ground 2301 Governor actuator feedback signal is not stabe 2302 Governor actuator feedback signal deviates 2303 Governor actuator does not move 2304 Calibration data error 3201 Monitor RAM is not normal 4101 Electric power supply to the controller is too much(43 volts) 4102 Over-current in proportional reducing valve Location Location CONN 1 Service H-9 D CONN 2 D-9 D CONN 3 D-8 D CONN 4 D-8 D CONN 5 D-7 D 4103 Proportional reducing valve circuit is open CONN 6 G-8 D 4105 Over-current in digital output (trenching solenoid) CONN 7 G-8 D 4106 Over-current in digital output (fine control solenoid) CONN 8 G-8 D 4107 Over-current in digital output (Travel speed change solenoid) CONN 9 G-7 D 4108 Over-current in digital output (travel alarm) CONN 10 C-6 D 410A Over-current in digital output (swing brake solenoid) CONN 11 C-6 F 4201 Engine speed is not normal CONN 12 C-5 F 4202 Engine coolant temperature sensor is shorted to body ground CONN 13 C-5 F 4203 Hydraulic oil temperature sensor is shorted to body ground CONN 14 E-6 F 4204 PWM sensor of pump delivery pressure is open in circuit CONN 15 E-6 F 3E-1906 PWM sensor of pump delivery pressure is open in circuit CONN 16 E-6 10 3T-9493 Solenoid - Start Aid 4207 1.5 Fuel sensor is shorted to ground E-6 10 4I - 5394 Sender - Hydraulic Oil Temp 420A CONN 17 6130 to 7500 420B Fuel sensor is open or shorted to battery voltage CONN 18 F-6 10 7T-4003 420C Electric power supply is too low (below 23 volts) CONN 19 B-5 10 102-8015 420D Electric power supply is too high (above 32 volts) CONN 20 B-5 F 420E Engine speed dial is not one of the specified 10 CONN 21 C-5 F 111-9916 112-4009 4301 Data mismatch 1 between alternator and speed sensor (alternator is abnormal) CONN 22 C-5 F 6134 - 7496 @ 25° C (77° F) 4302 Data mismatch 2 between alternator and speed sensor (speed sensor is abnormal) CONN 23 H-5 27 475 - 522 @ 100° C (212° F) 4303 Engine stalls CONN 24 H-5 F A201 Monitor communication is not normal CONN 25 H-5 F A202 Monitor takes to much time to respond to controller's signal CONN 26 H-4 F A203 Communication is abnormal in controller CONN 27 H-4 F CONN 28 D-3 C CONN 29 A-2 F CONN 30 B-2 16 CONN 31 B-2 20 CONN 32 B-2 16 CONN 33 C-2 16 CONN 34 D-2 8 ¹The connectors shown in this chart are harness to harness and special use connectors. Connectors which join a harness to a component are generally located at or near the component. See the component location chart Related Electrical Service Manuals Title Form Number Alternator: 109-2362 SENR3685 Engine/Pump Control RENR1998 Starting And Charging RENR1044 AC Pressure 114-5333 275 to 1750 kpa¹ (40 to 255 psi) -- Normally ² Open ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). ² Contact position at the contacts of the harness connector. Resistor, Sender, and Solenoid Specifications Part No. 121-1490 Component solenoid - A/C Clutch Resistor - Fuel Pump Resistor - Backup Solenoid - Eng/Pump Control Sender - Coolant Temperature Slonoid - Level Finish Trenching 121-1491 17.6 ± 0.6 10.0 ± 0.5 41.0 ± 2.0 11.7 ± 1.2 20824 - 25451 @ 0° C (32° F) 221 - 269 @ 125° C (257° F) 14.4 ± 0.6 solenoids - Hydraulic Lock Swing Brake Travel Speed ¹ At room temperature. Resistance (Ohms)¹ 32.0 ± 3.2
Component Location Machine Location Component Schematic Location Machine Location RENR1156 March 1998 Alarm - Travel F-9 1 Solenoid - Stabilizer Lockout (Left Front) F-1 18 Alternator C-8 2 Solenoid - Stabilizer Lockout (Left Rear) F-6 27 Battery - F-8 3 Solenoid - Stabilizer Lockout (Right Front) F-1 18 Part No. BB3 C-7 A Solenoid - Stabilizer Lockout (Right Rear) F-6 27 3E-6429 Beacon E-1 A Solenoid - Start Aid B-9 30 Control - Engine C-8 A Solenoid - Swing Brake E-9 16 Control - Engine/Pump C-7 A Solenoid - Swing Pump Prv E-8 16 Control - Suppl Steer F-8 4 Solenoid - Transmission Speed E-8 11 Converter - 24V-12V C-2 A Solenoid - Travel Activation E-9 16 Diode - Brake D-4 D Solenoid - Travel Lock F-2 16 Diode - Temp D-4 D Starter C-8 5 Diode AEC Aux Hyd D-5 D Stick Travel Lamp As C-1 19 Diode Stop Lamp D-5 D Switch - A/C B-7 C Engine Speed Dial B-1 C Switch - A/C Pressure D-8 8 Flasher E-4 C Switch - AEC B-6 C 117-0651 AEC Implement/Travel Press Fuse - Alternator C-9 5 Switch - AEC Boom-Cylinder E-9 19 Fuse - Block A Black E-6 D Switch - AEC Implement Travel Switch D-9 19 118-5501 Overload Warning Press Fuse - Block B Yellow E-6 D Switch - AEC Stick-Cylinder E-9 19 119-3399 Engine Coolant Temp Fuse - Block C Green D-6 D Switch - AEC Swing D-9 16 Fuse - Block D Red D-6 D Switch - Air Filter Clog C-9 20 Fuse - Main E-5 D Switch - Air Horn E-2 A Governor Actr C-8 6 Switch - Aux Hyd (CCW Rotation) D-2 B Horn - Compressed Air D-1 7 Switch - Aux Hyd (CW Rotation) 0-2 C Horn - Forward C-1 7 Switch - Backup B-7 C Hour Meter D-3 D Switch - Beacon B-3 C Monitor Panel B-2 C Switch - Brake Light F-3 21 Motor - A/C Fan D-8 8 Switch - Brake Light Cutoff D-2 B Motor - Fuel Pump F-8 9 Switch - Cab Riser B-5 C Motor - Heater Fan B-5 10 Switch - Cab Riser (Down) C-3 C Motor - Suppl Steer F-7 4 Switch - Cab Riser (Up) C-3 C Motor - Washer (Lower) E-8 11 Switch - Coolant Temp C-8 2 C Motor - Washer (Upper) E-8 3 Switch - Creeper Speed C-4 Motor - Wiper (Lower) D-1 12 Switch - Disconnect F-8 3 Motor - Wiper (Upper) D-2 A Switch - Dome Light E-2 A Regulator - A/C Temp B-6 10 Switch - Engine Oil Pressure C-8 8 Relay - A/C Clutch D-8 D Switch - Forward/Reverse Travel Alarm (2) F-4 21 Relay - A/C Fan D-8 D Switch - Front Flood Lamp C-3 C Relay - AEC Aux Hyd E-5 D Switch - Hammer B-5 C Relay - Air Horn D-4 D Switch - Hazard B-3 C Relay - Alarm Cab Riser E-3 C Switch - Head Lamp C-3 C Relay - Brake E-4 D Switch - Heater Fan B-6 Relay - Brake/Travel Cutoff D-3 D Switch - Heavy Lift Relay - Main Power E-4 D Switch - Horn/Turn/High Beam Relay - Pilot Pressure Enable E-4 D Relay - Power Mode E-4 Relay - Start Relay - Start/Stop Off Machine Switch Specifications Function Actuate Supplemental Steering Oil Flow Deactuate Contact Position 4 grams (.14 oz) 90 ± 21 kPa (13 ± 3.0 psi) 187.5 mm Hg (7.4 in Hg) 1.5 grams (.05 oz) 70 ± 21 kPa (10 ± 3.0 psi) NA A-B, Normally Open A-C, Normally Closed 10000 kPa (1450 psi) NA Normally Open NA Normally Open Normally Open 3E-6455 Engine Oil Pressure 5W-9934 Air Filter Clog 5W-9972 Low Brake Oil Press 8U-2158 Brake Light Press 500 kPa (72.5 psi) 8U-9306 Low Trans Clutch Press 2500 kPa (362 psi) NA Normally Open 517 ± 34.5 kPa (75.0 ± 5.0 psi) 414 ± 34.5 kPa (60.1 ± 5.0 psi) Normally Open Normally Open Normally Open T Travel Press 116-4710 High Hydraulic Oil Temp 94°C (201°F) NA 116-8514 Hydraulic Oil Filter Press 250 kPa (36.3 psi) NA Normally Open 1500 kPa (218 psi) NA 1-2 Normally Closed 1-3 Normally Open 16000 kPa (2320 psi) NA Normally Open Low Hydraulic Oil Temp 127-0925 AEC Swing/Stick/Boom Press 100°C (212°F) NA Normally Open Closes On Decreasing Temperature 11°C (52°F) Opens On Increasing Temperature 17°C (63°F) Normally Closed 500 kPa (72.5 psi) NA 1-4 Normally Closed 1-2 Normally Open Part No. Solenoid - A/C Clutch Solenoid - Engine Start/Stop 8C-3663 8U-6424 19 C Solenoid - Heavy Lift, Hammer, Park Brake, Trans Speed, Swing Brake, Creeper Speed, Travel Actuator, Implement Actuator, Aux Hyd CCW, Aux Hyd CW, Blade Front, Right Front Stabilizer, Left Front Stabilizer B-6 C Resistor - Heater Fan 122-2373 47 F-2 A Resistor - Backup 124-0329 Overall - 6.0; Tap 1.5 or 4.5 Switch - Hydraulic Oil Filter Clog D-9 24 D Switch - Hydraulic Oil High Temp Sender D-9 23 Sender - Engine Coolant Temp 8U-1516 C-9 5 Switch - Hydraulic Oil Low Temp D-9 23 D-4 D Switch - Key Start C-4 C Sender - Fuel Level 112-7178 Relay - Stop Lamp D-4 D Switch - Low Brake Pressure F-3 21 Sender - Hydraulic Oil Temp 116-4710 Relay - Suppl Steer E-8 D Switch - Low Transmission Clutch Pressure E-8 11 Relay - Suppl Steer F-8 4 Switch - Overload Warning Device B-3 25 Solenoid - Pump PRV 123-0156 Relay - Temp D-4 D Switch - Overload Warning Device B-5 C Relay - Trans Speed E-4 D Switch - Parking Brake B-3 C Relay - Travel Alarm E-3 D Switch - Pilot Control Lock B-3 B Relay - Travel Cutoff D-3 D Switch - Power Mode C-4 C Resistor (Backup) - Main Pump Prv D-6 D Switch - Primary Steering Flow F-3 21 Resistor (Backup) - Swing Pump Prv D-6 D Switch - Rear Flood Lamp C3 C Resistor - Heater Fan D-6 10 Switch - Refueling Pump E-3 D Reverse Steer Light F-2 A Switch - Reverse Steer Prox B-3 26 Sender - Coolant Temp C-8 2 Switch - Stabilizer Lockout (Left Front) B-5 C Sender - Fuel Level E-9 13 Switch - Stabilizer Lockout (Left Rear) B-5 C Sensor - Engine Speed C-9 14 Switch - Stabilizer Lockout (Right Front) B-6 C Solenoid - A/C Clutch D-8 15 Switch - Stabilizer Lockout (Right Rear) B-6 C Solenoid - Aux Hyd (CCW) F-9 16 Switch - Start Aid B-6 C Solenoid - Aux Hyd (CW) F-9 16 Switch - Starting/Pilot Press Enable D-3 B Solenoid - Blade Front E-1 27 Switch - Step Door Safety B-4 A Solenoid - Blade Rear F-6 17 Switch - Swing Brake B-3 A Solenoid - Cab Riser (Down) E-9 D Switch - Trans Speed C-4 C Solenoid - Cab Riser (Up) E-9 D Switch - Travel Alarm Cancel B-3 C Solenoid - Creeper Speed E-9 16 Switch - Travel Lock B-4 C Solenoid - Engine Start/Stop D-8 6 Switch - Travel Pedal F-2 A Solenoid - Hammer D-8 16 Switch - Windshield (Lower) D-2 A Solenoid - Heavy Lift D-9 16 Switch - Windshield (Upper) D-2 A Solenoid - Implement Activation E-9 16 Switch - Wiper (Lower) B-4 C Solenoid - Main Pump Prv E-8 16 Switch - Wiper (Upper) B-4 C Solenoid - Parking Brake E-8 11 Swivel F-5 22 The circle indicates that the component has screw terminals and a wire can be disconnected from it. This indicates that the component has a wire connected to it that is connected to ground. 60°C (1 40°F) - 134 90°C(194°F)- 51.2 100°C (21 2°F) - 38.5 Empty -70.6; Full 0.4 60°C (140°F) - 134 90°C (1 94°F) - 51.2 100°C (212°F) - 38.5 This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. 27² ¹ At room temperature. ² At operating temperature. Harness And Wire Electrical Schematic Symbols System Faults Detected by the Controller Error Message 7 5 30 2 15 23 12 21 10 A 17 13 11 8 1 3 D 29 4 Logged CONN 1 C-7 28 CONN 2 C-7 29 CONN 3 D-7 29 CONN 4 E-7 29 CONN 5 D-6 29 CONN 6 C-6 29 CONN 7 C-6 28 ¹ The connectors shown in this chart are for harness to harness connectors with a minimum of four contacts and other special connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Possible Causes No • Main pump set to minimum output. Low Voltage No • None. RPM Setting Diff No RPM Setting High No • Engine operates at high idle (no effect on AEC or Heavy Lift operation). • Low idle speed too low. • Engine stall speed too high or low. RPM Setting Low No Swing Pump No Low Engine Speed No 9 B Connector Number Result of Fault Main Pump Circt 27 24 28 C 20 26 22 25 18 14 6 16 Machine Location Printed in U.S.A. © 1998 Caterpillar All Rights Reserved 19 Schematic Location Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. No circle indicates that the wire cannot be disconnected from the component. 17.6 ± 0.6 1.55 ± 0.15 10.3 ± 1.03 Connector Location¹ Normally closed switch that will open with an increase of a specific condition. Resistance (Ohms)¹ 3E-1906 Machine locations are repeated for components located close together. A = Operator Compartment B = Operator Compartment - Left Console C = Operator Compartment - Right Console D = Operator Compartment - Behind Operator Compartment Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. 8SS1-UP 9PS1-UP Resistor, Sender and Solenoid Specifications Flow Symbol Level Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). M318 and M320 Wheeled Excavator Electrical System Component Description Temperature Symbol Pressure Symbol 9D-7032 119-3400 Electrical Schematic Symbols And Definitions • Main pump PRV solenoid faulty. • Open in harness wiring for main PRV solenoid. • Harness wiring for main PRV solenoid shorted to ground. • Battery voltage below 17 DCV. • Engine speed requested does not match the actual governor actuator position. • Governor actuator position signal too high. • Open or shorted supply voltage circuit. • Low idle stop passed. • High idle speed too high. • Governor actuator position signal too low. • Engine stall speed too high or low. • Open or shorted supply voltage circuit. • High idle stop passed or engine speed adjustment is loose. • Swing pump set to minimum • Swing pump PRV solenoid faulty. output. • Open in harness wiring for swing PRV solenoid. • Harness wiring for swing PRV solenoid shorted to ground. • Hydraulic pump outputs are • Signal from engine speed sensor indicates engine speed is below 750 ± 25rpm. reduced. • Engine speed sensor is not adjusted properly or is faulty. • Open in harness wiring from engine speed sensor to controller. • Harness wiring for engine speed sensor is shorted to ground. • Incorrect number of flywheel teeth specified in parameter settings. High Engine Speed Yes • Engine overload. • Engine stalls. RPM Dial Setting Yes • Engine speed set to high idle (No effect on AEC or Heavy Lift operation). Heavy Lift Circt Yes • Heavy lift does not operate correctly. Mode Sw Open Yes • Power mode 1 selected no matter what the position of the power mode switch. Mode Sw Short Yes • Power mode 1 selected no matter what the position of the power mode switch. • Signal from engine speed sensor indicates engine speed is above 2150 ±200 rpm • Incorrect number of flywheel teeth specified in parameter settings. • Engine speed dial is faulty. • Engine speed dial signal circuit has an open. • Engine speed dial supply voltage circuit has an open or is shorted to ground. • Engine speed dial signal circuit is shorted to ground. • Heavy lift solenoid is faulty. • Open in harness wiring for heavy lift solenoid. • Harness wiring for heavy lift solenoid is shorted to ground. • Mode switch is faulty. • Open in harness wiring for mode switch. • Mode switch supply voltage circuit has an open or is shorted to ground. • Mode switch is faulty. • Short to ground in harness wiring for mode switch. 1 Receptacle Plug C * C-C4* AG-C3 130-6795 130-6795 19 8 325-A135 PK-14 2 16 B 28 12 26 21 7 10 4 23 30 14 D 5 29 * Harness identification letter(s) and a serializing code. The "C" stands for connector and the number indicates which connector in the harness. 9 27 Title Alternator: 9W-3043 2 200-L32 BK-14 Circuit Number Identification Wire Color Wire Gauge 17 E32958 REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Form Number SENR3685 SENR6265 Starting Motor: 8C-4774 Machine Harness Connector And Component Locations Harness identification code This example indicates wire 32 in harness "L'. Electrical Schematic Symbols And Definitions Related Service Manuals Electronic Control Systems 18 1 Socket Single Wire Connector 20 1 3 11 6 L-C12* 3E-5179 AG-C4* 111-7898 9X-1123 FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. 13 24 15 22 Wire, Cable, or Harness Assembly Identification Pin or Socket Number A 25 Component Part Number 2 Pin Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. L-C12 * 3E-5179 AG-C4 * 111-7898 1 2 1 2 Part Numbers For Connector Assembly 325-L25 PK-14 Component Schematic Location Consist: 8C-4773 SENR3559 Consist: 3E-1944 SENR3581 Consist: 106-8558 SENR3559 T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work.
Component Location Schematic Location Machine Location Alarm - Travel F-9 1 Alternator C-8 Component Schematic Location Machine Location Solenoid - Stabilizer Lockout (Left Front) F-1 18 2 Solenoid - Stabilizer Lockout (Left Rear) F-6 27 Component Part No. 3E-6429 Off Machine Switch Specifications Function Actuate Supplemental Steering Oil Flow Deactuate Contact Position 4 grams (.14 oz) 90 ± 21 kPa (13 ± 3.0 psi) 187.5 mm Hg (7.4 in Hg) 1.5 grams (.05 oz) 70 ± 21 kPa (10 ± 3.0 psi) NA A-B, Normally Open A-C, Normally Closed Normally Open F-8 3 Solenoid - Stabilizer Lockout (Right Front) F-1 18 3E-6455 Engine Oil Pressure BB3 C-7 A Solenoid - Stabilizer Lockout (Right Rear) F-6 27 5W-9934 Air Filter Clog Beacon E-1 A Solenoid - Start Aid B-9 30 5W-9972 Low Brake Oil Press 10000 kPa (1450 psi) NA Normally Open Control - Engine C-8 A Solenoid - Swing Brake E-9 16 8U-21 58 Brake Light Press 500 kPa (72.5 psi) NA Normally Open Low Trans Clutch Press 2500 kPa (362 psi) NA Normally Open 517 ± 34.5 kPa (75.0 ± 5.0 psi) 414 ± 34.5 kPa (60.1 ± 5.0 psi) Normally Open Control - Engine/Pump C-7 A Solenoid - Swing Pump Prv E-8 16 8U-9306 Control - Suppl Steer F-8 4 Solenoid - Transmission Speed E-8 11 9D-7032 Travel Press Converter - 24V-12V C-2 A Solenoid - Travel Activation E-9 16 Diode - Brake D-4 D Solenoid - Travel Lock F-2 16 116-4710 High Hydraulic Oil Temp 94°C (201°F) NA Normally Open Diode - Temp D-4 D Starter C-8 5 116-8514 Hydraulic Oil Filter Press 250 kPa (36.3 psi) NA Diode AEC Aux Hyd D-5 D Stick Travel Lamp As C-1 19 117-0651 AEC Implement/Travel Press 118-5501 Overload Warning Press Normally Open 1-2 Normally Closed 1-3 Normally Open Normally Open 119-3399 Engine Coolant Temp Low Hydraulic Oil Temp D-5 D Switch - A/C B-7 C Engine Speed Dial B-1 C Switch - A/C Pressure D-8 8 Flasher E-4 C Switch - AEC B-6 C 119-3400 Fuse - Alternator C-9 5 Switch - AEC Boom-Cylinder E-9 19 127-0925 Fuse - Block A Black E-6 D Switch - AEC Implement Travel Switch D-9 19 Fuse - Block B Yellow E-6 D Switch - AEC Stick-Cylinder E-9 19 Fuse - Block C Green D-6 D Switch - AEC Swing D-9 16 Fuse - Block D Red D-6 D Switch - Air Filter Clog C-9 20 Fuse - Main E-5 D Switch - Air Horn E-2 A Governor Actr C-8 6 Switch - Aux Hyd (CCW Rotation) D-2 B Horn - Compressed Air D-1 7 Switch - Aux Hyd (CW Rotation) 0-2 C Horn - Forward C-1 7 Switch - Backup B-7 C Hour Meter D-3 D Switch - Beacon B-3 C Monitor Panel B-2 C Switch - Brake Light F-3 21 Motor - A/C Fan D-8 8 Switch - Brake Light Cutoff D-2 B Motor - Fuel Pump F-8 9 Switch - Coolant Temp C-8 2 Motor - Heater Fan B-5 10 Switch - Creeper Speed C-4 C Motor - Suppl Steer F-7 4 Switch - Disconnect F-8 3 Motor - Washer (Lower) E-8 11 Switch - Dome Light E-2 A Motor - Washer (Upper) E-8 3 Switch - Engine Oil Pressure C-8 8 Motor - Wiper (Lower) D-1 12 Switch - Forward/Reverse Travel Alarm (2) F-4 21 Motor - Wiper (Upper) D-2 A Switch - Front Flood Lamp C-3 C Regulator - A/C Temp B-6 10 Switch - Hammer B-5 C Relay - A/C Clutch D-8 D Switch - Hazard B-3 C Relay - A/C Fan D-8 D Switch - Head Lamp C-3 C Relay - AEC Aux Hyd E-5 D Switch - Heater Fan B-6 C Relay - Air Horn D-4 D Switch - Heavy Lift B-6 C Relay - Brake E-4 D Switch - Horn/Turn/High Beam F-2 A Relay - Brake/Travel Cutoff D-3 D Switch - Hydraulic Oil Filter Clog D-9 24 Relay - Main Power E-4 D Switch - Hydraulic Oil High Temp Sender D-9 23 Relay - Pilot Pressure Enable E-4 D Switch - Hydraulic Oil Low Temp D-9 23 Relay - Power Mode E-4 D Switch - Key Start C-4 C Relay - Start C-9 5 Switch - Low Brake Pressure F-3 21 Relay - Start/Stop D-4 D Switch - Low Transmission Clutch Pressure E-8 11 Relay - Stop Lamp D-4 D Switch - Overload Warning Device B-3 Relay - Suppl Steer E-8 D Switch - Overload Warning Device Relay - Suppl Steer F-8 4 Switch - Parking Brake Relay - Temp D-4 D Relay - Trans Speed E-4 Relay - Travel Alarm Relay - Travel Cutoff Resistor (Backup) - Main Pump Prv D-6 Resistor (Backup) - Swing Pump Prv Resistor - Heater Fan AEC Swing/Stick/Boom Press 1500 kPa (218 psi) NA 16000 kPa (2320 psi) NA 100°C (212°F) Closes On Decreasing Temperature 11°C (52°F) NA Opens On Increasing Temperature 17°C (63°F) 500 kPa (72.5 psi) NA Normally Closed Resistor, Sender and Solenoid Specifications 8C-3663 Solenoid - Heavy Lift, Hammer, Park Brake, Trans Speed, Swing Brake, Creeper Speed, Travel Actuator, Implement Actuator, Aux Hyd CCW, Aux Hyd CW, Blade Front, Right Front Stabilizer, Left Front Stabilizer 8U-6424 Resistor - Backup 122-2373 47 Resistor - Backup 124-0329 Sender - Engine Coolant Temp 8U-1516 Sender - Fuel Level 112-7178 25 Sender - Hydraulic Oil Temp 116-4710 B-5 C Solenoid - Pump PRV 123-0156 Overall - 6.0; Tap 1.5 or 4.5 60°C (1 40°F) - 134 90°C(194°F) - 51.2 100°C (21 2°F) - 38.5 Empty -70.6; Full - 0.4 60°C (140°F) - 134 90°C (1 94°F) - 51.2 100°C (212°F) - 38.5 27² B-3 C ¹ At room temperature. Switch - Pilot Control Lock B-3 B ² At operating temperature. D Switch - Power Mode C-4 C E-3 D Switch - Primary Steering Flow F-3 21 D-3 D Switch - Rear Flood Lamp C3 C D Switch - Refueling Pump E-3 D D-6 D Switch - Reverse Steer Prox B-3 26 B-5 10 Switch - Stabilizer Lockout (Left Front) B-5 C Reverse Steer Light F-2 A Switch - Stabilizer Lockout (Left Rear) B-5 C Sender - Coolant Temp C-8 2 Switch - Stabilizer Lockout (Right Front) B-6 C Sender - Fuel Level E-9 13 Switch - Stabilizer Lockout (Right Rear) B-6 C Sensor - Engine Speed C-9 14 Switch - Start Aid B-6 C Solenoid - A/C Clutch D-8 15 Switch - Starting/Pilot Press Enable D-3 B Solenoid - Aux Hyd (CCW) F-9 16 Switch - Swing Brake B-3 A Solenoid - Aux Hyd (CW) F-9 16 Switch - Trans Speed C-4 C Solenoid - Blade Front E-1 27 Switch - Travel Alarm Cancel B-3 C Solenoid - Blade Rear F-6 17 Switch - Travel Lock B-4 C Solenoid - Creeper Speed E-9 16 Switch - Travel Pedal F-2 A Solenoid - Engine Start/Stop D-8 6 Switch - Windshield (Lower) D-2 A Solenoid - Hammer D-8 16 Switch - Windshield (Upper) D-2 A Solenoid - Heavy Lift D-9 16 Switch - Wiper (Lower) B-4 C Solenoid - Implement Activation E-9 16 Switch - Wiper (Upper) B-4 C Solenoid - Main Pump Prv E-8 16 Swivel F-5 22 Solenoid - Parking Brake E-8 11 Component Description This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Error Message Main Pump Circt 7 22 25 14 6 15 23 28 24 10 A 21 12 4 B 27 17 11 13 8 D 1 3 29 29 D-7 29 CONN 4 E-7 29 CONN 5 D-6 29 CONN 6 C-6 29 CONN 7 D-1 28 1 The connectors shown in this chart are for harness to harness connectors with a minimum of four contacts and other special connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Result of Fault Possible Causes • Main pump set to minimum output. • Main pump PRV solenoid faulty. • Open in harness wiring for main PRV solenoid. • Harness wiring for main PRV solenoid shorted to ground. Low Voltage No • None. • Battery voltage below 17 DCV. RPM Setting Diff No • Engine operates at high idle (no effect on AEC or Heavy Lift operation). • Engine speed requested does not match the actual governor actuator position. RPM Setting High No RPM Setting Low No Swing Pump No • Low idle speed too low. • Governor actuator position signal too high. • Engine stall speed too high or low. • Open or shorted supply voltage circuit. • Low idle stop passed. • High idle speed too high. • Governor actuator position signal too low. • Engine stall speed too high or low. • Open or shorted supply voltage circuit. • High idle stop passed or engine speed adjustment is loose. • Swing pump set to minimum • Swing pump PRV solenoid faulty. output. • Open in harness wiring for swing PRV solenoid. • Harness wiring for swing PRV solenoid shorted to ground. Low Engine Speed No 9 1 C-7 No 20 26 19 Logged 18 5 2 C CONN 3 Harness And Wire Electrical Schematic Symbols System Faults Detected by the Controller 16 CONN 2 Printed in U.S.A. © 2001 Caterpillar All Rights Reserved 18 28 The circle indicates that the component has screw terminals and a wire can be disconnected from it. 19 19 C-7 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. No circle indicates that the wire cannot be disconnected from the component. 17.6 ± 0.6 1.55 ± 0.15 10.3 ± 1.03 CONN 1 Normally closed switch that will open with an increase of a specific condition. 6WL1-468 3E-1906 Machine Location Normally open switch that will close with an increase of a specific condition (temp-press-etc.). M320 Excavator Electrical System Solenoid - Engine Start/Stop Schematic Location Flow Symbol Level Symbol Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Solenoid - A/C Clutch Connector Number Temperature Symbol Pressure Symbol 1-4 Normally Closed 1-2 Normally Open Resistance (Ohms)¹ Connector Location T Normally Open Part No. Machine locations are repeated for components located close together. A = Operator Compartment B = Operator Compartment - Left Console C = Operator Compartment - Right Console D = Operator Compartment - Behind Operator Compartment Electrical Schematic Symbols And Definitions Normally Open Battery - Diode Stop Lamp RENR1166-01 January 2001 • Hydraulic pump outputs are reduced. Yes • Engine overload. • Engine stalls. • Signal from engine speed sensor indicates engine speed is above 2150 ±200 rpm • Incorrect number of flywheel teeth specified in parameter settings. RPM Dial Setting Yes • Engine speed set to high idle (No effect on AEC or Heavy Lift operation). • Engine speed dial is faulty. • Engine speed dial signal circuit has an open. • Engine speed dial supply voltage circuit has an open or is shorted to ground. • Engine speed dial signal circuit is shorted to ground. Heavy Lift Circt Yes • Heavy lift does not operate correctly. • Heavy lift solenoid is faulty. • Open in harness wiring for heavy lift solenoid. • Harness wiring for heavy lift solenoid is shorted to ground. Mode Sw Open Yes • Power mode 1 selected no matter what the position of the power mode switch. • Power mode 1 selected no matter what the position of the power mode switch. • Mode switch is faulty. • Open in harness wiring for mode switch. • Mode switch supply voltage circuit has an open or is shorted to ground. Yes 15 25 C 12 18 22 B 21 8 2 28 10 26 13 24 3 11 6 16 4 D 19 29 20 14 Related Service Manuals 5 9 Title 27 7 SENR3685 Wire, Cable, or Harness Assembly Identification D97416 Component Part Number Single Wire Connector C A A 325-PK-14 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. SENR6265 Starting Motor: 8C-4774 17 Machine Harness Connector and Component Locations Alternator: 9W-3043 Electronic Control Systems Form Number Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number T 23 18 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 2 • Mode switch is faulty. • Short to ground in harness wiring for mode switch. 1 1 2 1 2 Receptacle Plug A 19 AA 1 • Signal from engine speed sensor indicates engine speed is below 750 ± 25rpm. • Engine speed sensor is not adjusted properly or is faulty. • Open in harness wiring from engine speed sensor to controller. • Harness wiring for engine speed sensor is shorted to ground. • Incorrect number of flywheel teeth specified in parameter settings. High Engine Speed Mode Sw Short A Consist: 8C-4773 SENR3559 Consist: 3E-1944 SENR3581 Consist: 106-8558 SENR3559 CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Wire Number Wire Color 101 RD 103 Wire Description Wire Color Bat (+) H415 BR O.L. Warning Relay to O.L. Warning Press. SW RD Dome Lamp H454 PK O.L. Warning Relay to Diode 17.6 ± 0.6 105 BR Key SW H455 OR Diode to O.L. Warning Buzzer 80.0 ± 10 @ 50 ± 0.2°C (122 ± 0.4°F) 56.3 ± 5 @ 60 ± 0.2°C (140 ± 0.4°F) 29.5 ± 2.5 @ 80 ± 0.2°C (176 ± 0.4°F) 16.5 ± 0.9 @ 100 ± 0.3°C (212 ± 0.5°F) 14.3 ± 0.5 @ 106 ± 0.5°C (223 ± 0.9°F) 10 ± 0.3 @ 120 ± 0.3°C (248 ± 0.5°F) 107 RD Engine Shutdown 109 RD Alt Output (+) Term. 500 BR Wiper - Front (Park) 110 RD Washer/Cigar Relay 501 GN Wiper - Front (Low) 112 PU Main Power Relay Output 506 PU Washer - Front 113 OR Opr Mon Panel B (+) Switched 508 PU Radio Speaker - Left 114 RD Warning Horn Relay (Forward) 509 WH Radio Speaker - Left (Common) 115 RD Chassis/Boom Lamp Relay 511 BR Radio Speaker - Right 118 RD Wiper Relay 512 GN Radio Speaker - Right (Common) 121 YL Backup Alarm 513 OR A/C Compressor/Refrigerant Pressure SW 122 BU Refueling Pump 519 PK Thermostat to Refrigerant Press. SW 124 GN A/C A537 PK Seat Heater SW to Seat Heater 127 RD Cab Lamp Relay A588 GN Neutral Start Relay to Neutral Start SW 129 BU Lighter C576 BU Switch #1 to Medium Pressure Sol #1 135 BU 12V SW Out C577 GY Switch #1 to Medium Pressure Sol #2 139 OR +12V Mem Out C588 BR Blade SW to Blade Relay 142 BU Solenoid C589 GY Blade Relay to Blade Sol 150 RD Bat (+) C591 PK Floating Blade Relay to Floating Blade Sol Power Circuits Resistor, Sender and Solenoid Specifications Part No. Component Description 3E-1906 Solenoid: 096-4643 Resistance (Ohms)¹ A/C Clutch Sender: Hydraulic Oil Temperature 121-1491 Solenoid: Hydraulic Lock 32.0 ± 3.2 140-0924 Resistor: Indicator Power 300(3 sets of 2 in Parallel) ¹ At room temperature unless otherwise noted. Part No. 5I-6587 085-5121 106-0179 Function Off Machine Switch Specification Engine Oil Pressure Engine Coolant Temperature Actuate Deactuate Contact Position Description Monitoring Circuits Continued Electrical Schematic Symbols And Definitions Accessory Circuits Normally 151 GN Neutral Start SW C599 OR Floating Blade Sw to Floating Blade Relay #2 7.1 ± 1.4 psi Open 168 GN Air Bleed SW E500 YL Blade Relay to Floating Blade Relay 106 ± 2° C 97° C Normally 180 GN Aux Ckt / Seat Heater SW E501 PU Floating Blade Relay #2 to Blade Relay ( 222.8 ± 3.6°F ) ( 206.6°F MIN ) Closed 190 PK Gov Actr E535 GN Swing Boom SW to Swing Boom Sol PK Flood Lamp - Front Ground Circuits Normally ( 163 psi MIN ) Open 200 BK Main Chassis 607 275 to 1750 kPa¹ -- Normally 210 BK Converter Output (24/12 Volt) 615 YL Cab Flood Lamp/Rops (40 to 255 psi) -- Open² 616 BU Bucket Flood Lamp/Boom Flood Lamp 20103 ± 517 kPa 18517 ± 517 kPa Normally 303 BR Hyd Lock Timer 633 BU Attach Lighting Ckt ( 2915.7 ± 75 psi ) ( 2685.7 ± 75psi ) Closed 135-7748 Over Load Warning Pressure Basic Machine Circuits WH Starter Relay No. 1 Output 306 GN Starter Relay Coil 763 BU Travel Speed SW to Travel Speed Sol 307 OR Key SW to Neutral Start Relay 786 GN Cab Light SW ² Contact position at the contacts of the harness connector. 310 PU Start Aid SW to Start Aid Sol 791 PK Boom Lamp SW 320 RD Horn Relay Coil to Horn SW 792 OR Wiper SW 321 BR Backup Alarm Lamp Travel Alarm 799 WH Travel Alarm Cancel SW 322 GY Warning Horn (Forward) B786 BU Low Idle SW 323 WH Fuel Pump Power H740 OR HEX Governor Motor + 325 PK Fuel Pump Relay Cut-Out H741 WH HEX Governor Motor - 327 PK Shutdown Solenoid H742 PU HEX Governor Accel Input 330 YL Neutral Start Relay Coil H743 YL HEX Governor Decel Input 332 BU Shutdown SW to Shutdown Ctrl H744 BU HEX Governor Low Idle 365 YL Fuel Pump Relay to Fuel Pump SW H745 BR HEX Governor SW Return J703 PK Alt Pulse Sig to Anti-Start Relay Title Form Number Electrical and Electronic Systems RENR2978 Monitoring Circuits This indicates that the component has a wire connected to it that is connected to ground. GN Alternator (R) Term. K776 GN Alternator L terminal 405 GY Opr Mon Oil Press. (Low Setting) K777 GY Governor Pressure SW 406 PU Opr Mon Coolant Temp K778 WH Hydraulic Excavator Pwr Mode SW 441 OR Eng Coolant Temp Gauge 817 WH Travel Alarm Timer to Travel Press SW 442 GY Hyd System Temp Gauge 877 YL Glow Plug Magnetic SW to Glow Plug 447 PK Fuel Level Gauge D813 OR Low Idle SW HEDC G480 GN 12 Volt (Fuel Indicator) 955 BU Hammer Sol A G481 WH 12 Volt (Coolant Temperature Indicator) L976 GN Excavator Fuel Pump SW G482 PK 12 Volt (Hydraulic Temperature Indicator) N933 PU Low Idle Indicator H414 YL O.L. Warning Switch to O.L. Warning Relay Schematic Location The circle indicates that the component has screw terminals and a wire can be disconnected from it. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. © 2001 Caterpillar All Rights Reserved Actuator - Engine Governor E-2 Machine Location C Sender - Hydraulic Oil Temp A-6 Machine Location 19 Alarm - Over Load Warning H-4 D Sensor - Fuel Level A-6 20 Alarm - Travel A-6 1 Socket - 12V C-2 C Alternator B-8 2 Solenoid - Hydraulic Lock G-3 F Antenna B-1 3 Solenoid - Medium Pressure Valve B-6 21 Assembly - Diode F-3 C Solenoid - A/C Compressor Clutch C-8 22 Batteries D-9 4 Solenoid - Blade B-6 23 Block Assembly F-7 E Solenoid - Engine Pump Control A-6 24 Breaker - Alternator F-9 E Solenoid - Engine Shutdown A-8 25 Controller D-2 5 Solenoid - Hammer F-4 F Converter C-2 B Solenoid - Travel Speed A-6 26 Diode J-4 A Solenoid - Swing Boom G-3 B Fuse Block J-7,8,9 E Speakers C-5 F Glow Plug C-8 6 Switch - Air Bleed H-2 C Ground Strap B-8 7 Switch - Blade F-2 C Ground Strap G-5 8 Switch - Blade J-5 C Horn B-3 9 Switch - Blade Floating F-2 C Component Schematic Location CONN 1 E-9 E CONN 2 E-9 E CONN 3 E-8 E Lamp - Boom B-2 10 Switch - Cab Lamp J-2 C CONN 4 E-8 E Lamp - Cab E-1 11 Switch - Coolant Temperature B-8 22 CONN 5 E-8 E Lamp - Chassis A-3 12 Switch - Disconnect D-9 28 Lamp - Dome C-5 A Switch - Engine Oil Pressure B-8 29 Lighter - Cigar C-4 C Switch - Governor Pressure D-7 30 Meter - Service J-2 C Switch - Hammer F-2 C CONN 6 F-7 E CONN 7 C-6 C CONN 8 C-6 C CONN 9 B-6 C CONN 10 E-5 G Monitor C-4 34 Switch - Horn G-1 D CONN 11 G-4 G Motor - Fuel Pump A-5 13 Switch - Key Switch E-2 C CONN 12 G-4 G G Switch - Lamp(Boom/Chassis) J-1 D G-4 A-8 14 CONN 13 Motor - Starter CONN 14 E-4 G Motor - Washer E-9 15 Switch - Low Idle F-2 C CONN 15 E-4 G Motor - Wiper F-1 16 Switch - Medium Pressure G-1 D CONN 16 E-4 G Multiswitch - Joystick (LH) G-1 D Switch - Neutral Start J-1 C CONN 17 E-4 G Multiswitch - Joystick (RH) F-2 C Switch - Over Load Warning J-4 D CONN 18 A-3 17 Radio AM/FM C-2 A Switch - Over Load Warning Pressure B-2 31 CONN 19 A-3 17 Relay - A/C and Heater G-6 E Switch - Power Mode H-2 D CONN 20 A-3 12 CONN 21 B-3 10 Relay - Start Cont. H-5 E Switch - Refrigerant Low Press C-8 29 CONN 22 E-1 11 Relay - Blade 1 H-9 E Switch - Refueling A-6 20 CONN 23 E-1 11 A-6 20 CONN 25 B-3 33 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Relay - Blade 2 H-8 E Switch - Refueling Start A-3 17 Relay - Blade Floating H-7 E Switch - Refueling Stop A-3 17 Relay - Cab Lamp H-8 E Switch - Seat Heater J-4 D Relay - Chassis/Boom Lamp H-9 E Switch - Swing Boom J-5 D Relay - Horn H-7 E Switch - Swing Boom G-1 D Relay - Neutral Start H-7 E Switch - Travel Alarm Cancel H-2 D Relay - Over Load Warning J-4 C Switch - Travel Alarm Timer J-5 E Relay - Refueling A-3 17 Switch - Travel Pressure D-7 30 Relay - Refueling 2 A-2 17 Switch - Travel Speed H-1 D Relay - Refueling Pump A-2 17 Switch - Washer H-1 D Relay - Start G-6 E Switch - Wiper H-1 D Relay - Washer/Cigar H-8 E Timer - Engine Shutdown H-5 E Relay - Wiper J-9 E Timer - Hydraulic Lock H-6 E Resistor C-4 C Unit - Air Conditioner H-4 27 Seat With Heater Seat J-2 A Unit - Heater H-4 32 Sender - Engine Coolant Temp B-8 18 Machine locations are repeated for components located close together. A = Located inside of cab. B = Inside of cab, rear. C = Righthand console. D = Lefthand console. E = Located around relay panel. F = Located under platform. Printed in U.S.A. Harness And Wire Electrical Schematic Symbols Component Location Machine Location CONN 24 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. AFB1-UP Schematic Location Connector Number Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. 403 Component Connector Location 307 Swing Boom Excavator Electrical System Control Circuits 304 ¹ With increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kPa (25psi). Related Electrical Service Manuals Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Lighting Circuits 1127 kPa MIN (220 ± 14psi ) Flow Symbol Level Symbol Normally open switch that will close with an increase of a specific condition (temp,press,etc.). 49.0 ± 9.8 kPa 1520 ± 98kPa Temperature Symbol Pressure Symbol 78.5 ± 9.8 kPa Travel Pressure Refrigerant Pressure (A\C) T (11.4 ± 1.4 psi ) Governor Pressure 114-5333 RENR1174-01 March 2001 Wire Number Description A AA 2 11 D 15 28 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. 4 E 18 29 A F 8 27 22 34 C 5 11 31 7 19 1 23 21 24 10 26 C A A 325-PK-14 12 13 Component Part Number Single Wire Connector 33 9 14 Wire, Cable, or Harness Assembly Identification 10 30 25 Pin or Socket Number 16 32 B 3 2 6 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 17 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 20 2 200-BK-14 Circuit Number Identification 11 3 16 Electrical Schematic Symbols And Definitions A 10 6 28 22 14 7 18 E 15 24 2 1 27 B 21 4 34 20 19 26 23 FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. 29 30 25 13 8 REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 33 32 5 C 31 D 17 Wire Gauge 12 9 T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Machine Harness Connector And Component Locations CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Component Location Schematic Location Machine Location AEC - Aux. Hyd. G-8 D Air Horn E-7 Description Connector Location 67 Schematic Location Machine Location Solenoid - Right Front Stabilizer Lockout H-1 2 62 Solenoid - Right Rear Stabilizer Lockout I-10 4 Description Schematic Location Machine Location I-14 25 Alternator D-13 62 Solenoid - Swing Brake G-15 34 CONN 2 E-13 55 Alternator Fuse D-15 71 Solenoid - Swing Pump PRV. G-14 36 CONN 3 H-13 26 Battery 12v (2) I-13 23 Solenoid - Transmission Speed G-13 41 CONN 4 D-12 72 Cigar Lighter F-2 A Solenoid - Travel Activation G-15 33 CONN 5 C-12 61 Converter 24v - 12v D-3 A Stop Lamp F-7 D CONN 6 C-11, D-11 61 Diode - AEC - Aux. Hyd. F-8 D Supplimental Steering Control H, I-14 26 CONN 7 D-11 61 Diode - Brake E-6 D Switch - AEC B-10 C CONN 8 F-11, E-11 61 Diode - Harness AS B-8 D Switch - AEC Boom Cyl. F-15 59 CONN 9 G-11, F-11 61 Diode - Stop Lamp F-8 D Switch - AEC Impl. Travel F-15 45 CONN 10 I-10 4 Diode - Temp E6 D Switch - AEC Stick Cyl. F-15 59 CONN 11 H-10 4 Engine Pump Control C-11, B-11 A Switch - AEC Swing E-15 43 CONN 12 E-10,9,8 61 Engine Speed Dial C-2 C Switch - Air Filter Clog C-14 70 CONN 13 D-10 C Fuse Block (A Black) G-10 D Switch - Air Horn H-2 A CONN 14 F-5 D Fuse Block (B Yellow) G-9 D Switch - Aux. Hyd. (ccw rotation) E-3 B CONN 15 E-4 B Fuse Block (C Green) F-10 D Switch - Aux. Hyd. (cw rotation) C-5 C CONN 16 D-2 3 Fuse Block (D Red) F-9 D Switch - A/C B-11 C CONN 17 H-1 2 Hour Meter E-5 D Switch - A/C Refrigerent Pressure E1-4 57 CONN 18 H-1 2 Main Fuse G-8 68 Switch - Backup C-11 C CONN 19 E-1 11 Monitor Panel C-2 C Switch - Beacon B-5 C Motor - Air Conditioner Fan E-14 55 Switch - Brake Light H-5 17 Motor - Governor Actuator B-12, 13 72 Switch - Brake Light Cutoff E-3 B B-8 20 Switch - Coolant Temp D-13 64 Connector Number CONN 1 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Motor - Heater Fan Resistor, Sender, and Solenoid Specifications Part No. Part Type 3E-1906 Solenoid: Component Description A/C Clutch Resistance (Ohms)¹ 17.6 ± 0.6 Blade Rear Hammer Heavy Lift Solenoid: Left Front Stabilizer Lockout 19 Left Rear Stabilizer Lockout Parking Brake Right Front Stabilizer Lockout Right Rear Stabilizer Lockout Transmission Speed 112-7178 Sender: Fuel Level Full = 0.4 Empty = 70.6 38.5 @ 100° C (212° F) 116-4710 Sender: Hydraulic Oil Temperature Switch 51.2 @ 90° C (194° F) 134 @ 60° C (140° F) 124-0329 Resistor: Backup Main Pump PRV F-1 7 Switch - Coolant Temp Cold Start C-13 65 Motor - Re-fueling Pump I-13 25 Switch - Creeper Speed C-6 C Motor - Starter D-14 67 Switch - Disconnect I-12 24 Motor - Suppl. Steer I-12 28 Switch - Engine Oil Press D-13 61 Motor - Upper Washer Motor - Upper Wiper Overall 6.0; Tap 1.5 or 4.5 Backup Swing Pump PRV ¹ At room temperature. H-12 32 Switch - Forward/Reverse Travel Alarm (Qty.2) H-6 19 F-2 A Switch - Front Flood Lamp D-5 C 8 15 10 1 C 7 2 5 16 6 17 A Switch - Head Lamp D-5 C Switch - Heater Fan B-10, 9 C Relay - A/C Fan E-13 D Switch - Heavy Lift C1-0 C Relay - Brake G-6 D Switch - Horn/Turn /High Beam H-3 A Relay - Brake / Travel Cutoff E-5 D Switch - Hyd. Oil Filter Clog E-14 54 Relay - Flasher/Warning Light G-7 D Switch - Hyd. Oil Low Temp Relay - Main Power G-7 D Switch - Key (Start) Relay - Power Mode F-6 D Relay - Start C-15 Relay - Start / Stop I-13 27 Switch - Low Trans. Clutch Press. F-13 42 Relay - Temp F-6 D Switch - Lower Windshield E-2 A Relay - Trans Speed G-6 D Switch - Lower Wiper C-7 C Relay - Travel Alarm G-6 D Switch - Overload Warning Device A-5 C Resistor - Backup Main Pump PRV E-10 D Switch - Overload Warning Device C-8 15 Resistor - Backup Swing Pump PRV E-10 D Switch - Parking Brake B-5 C Resistor - Heater Fan B-8 21 Switch - Pilot Control Lock B-5 C Sender - A/C Temp Regulator B-10 22 Switch - Power Mode D-6 C Sender - Coolant Temp D-13 63 Switch - Primary Steering Flow H-4 16 Sender - Fuel Level G-14 46 Switch - Rear Flood Lamp C-5 C Sender - Hyd. Oil High Temp F-14 52 Switch - Refueling Pump F-5 D Sensor - Engine Speed D-15 66 Switch - Reverse Steer Prox. B-5 14 Solenoid - Aux. Hyd. (ccw rotation) H-15 B Switch - Right Front Stabl. Lockout B-8 C Solenoid - Aux. Hyd. (cw) H-14 C Switch - Right Rear Stabl. Lockout B-9 C Solenoid - A/C Clutch E-14 58 Switch - Starting Pilot Press. Enable E-4 B Solenoid - Blade Front H-1 2 Switch - Swing Brake H-2 C Solenoid - Blade Rear I-10 4 Switch - Swing Brake C-5 A Solenoid - Creeper Speed G-14 35 Switch - Trans Speed C-6 C Solenoid - Engine Start / Stop D-13 60 Switch - Travel Alarm Cancel C-5 C Solenoid - Hammer F-13 44 Switch - Travel Cutoff G-5 D Solenoid - Heavy Lift G-14 59 Switch - Travel Lock B-6 C Solenoid - Impl. Activation H-15 32 Switch - Travel Pedal H-2 A Solenoid - Left Front Stabilizer Lockout H-1 1 Switch - Upper Windshield E-2 A Solenoid - Left Rear Stabilizer Lockout H-10 4 Switch - Upper Wiper B-7 A Solenoid - Main Pump PRV. H-14 37 Travel Lock Magnet I-2 A Solenoid - Parking Brake G-14 40 66 d 40 71 33 23 34 35 24 D 31 27 55 28 30 21 22 2 32 26 20 36 37 56 38 39 57 43 3 42 8 72 43 35 39 31 56 Relay - Supplimentary Steering 3 59 G-2 C A 60 E-13 18 14 40 Relay - A/C Clutch H-5 B 41 Radio Switch - Low Brake Press. 67 64 62 D 44 61 30 58 D M312: 6TL540-541 6TL635-950 34 38 45 24 33 37 54 44 23 32 36 46 66 70 29 52 Off Machine Switch Specification Function Primary Flow Low Brake Pressure Form Number Electronic Control System SENR8937 8U-2158 9D-7032 114-5333 Brake Light Pressure Forward/Reverse Travel Alarm Pressure Refrigerant Pressure (AC) 116-4710 Hydraulic Oil High Temperature 116-8514 Hydraulic Oil Filter Clog Pressure 117-0651 118-5501 119-3399 119-3400 71 C B 49 © 2001 Caterpillar All Rights Reserved 9 2 67 4 25 5 16 20 55 26 2 6 17 21 56 27 68 48 7 18 22 57 28 69 50 19 51 67 Harness And Wire Electrical Schematic Symbols Electrical Schematic Symbols And Definitions A 2 T Temperature Symbol Error Message Logged AEC Switch Yes Automatic engine control operation may be disturbed. Symptom Automatic engine control switch contacts are dirty. Main PRV Circuit No Main Pump has minimal power. Main pump solenoid circuit is open. Level Symbol Flow Symbol AEC Implement Travel Pressure Overload Warning Device Pressure Coolant Temperature Hydraulic Oil Low Temperature No Reduced output current is possible. Brake Switch Yes Travel pedal control or Travel Mode may be disturbed. Brake relay contacts are dirty. Swing PRV Circut No Swing pump has minimal power. Swing pump solenoid circuit may be open. Contact Position Low Engine Speed No Reduction of hydraulic power. Engine RPM is too low. 1.5 grams Normally High Engine Speed Yes High engine lugging possible. Engine RPM is too high. (0.14 oz) (0.05 oz) Open Engine Spd. Dial Sig Yes Engine speed goes to current maximum allowed RPM. Engine speed dial potentiometer has short circuit or open. 10000 kPa -- Normally Heavy Lift Circuit Yes Heavy lift function is impossible. Heavy lift solenoid circuit open, not installed, or shorted. (1450 psi) -- Open Heavy Lift Switch Yes Heavy lift function is possibly disturbed. Heavy lift switch contacts are dirty. Spd Chg w/o Press Yes Both pumps are out of regulation. AEC Pressure switch open when the engine is loaded. Replace Control Yes Current Limiting is possible. 500 kPa -- Normally (72.5 psi) -- Open Pin or Socket Number 517 ± 34.5 kPa 414 ± 34.5 kPa Normally Mode SW Short 1&3 Yes Mode 1 is set. Mode 1 and 3 signal lines are simultaneously grounded. (75.0 ± 5.0 psi) (60.1 ± 5.0 psi) Open Mode SW Short 2&3 Yes Mode 2 is set. Mode 2 and 3 signal lines are simultaneously grounded. Mode SW Short Yes Mode 1 is set. Mode 1 and 2 signal lines are simultaneously grounded. Mode SW Open Yes Mode 1 is set. Mode swith is open or shorted. Travel Lock Circuit Yes Travel pedal magnet does not function. Travel Lock magnet is open or shorted. Act Mot Pos Chgd Yes Wrong loads and speeds possible. Injection pump worn or actuator linkage has changed. RPM Setting Low No Low idle too low or Engine lug is too small. Actual feedback voltage of the governor actuator is too low. Caused by an open -- Open 94º C -- Normally 201º F -- Open -- Normally (36.3 psi) -- Open 1500 kPa -- 1 to 2 Normally Closed (218 psi) -- 1 to 3 Normally Open 16000 kPa 250 kPa ² Contact position at the contacts of the harness connector. Wire, Cable, or Harness Assembly Identification C RPM Setting High No High idle too high or Engine lug is too large. Actual feedback voltage of the governor actuator is too high. Caused by the A A 325-PK-14 Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Pin Normally closed switch that will open with an increase of a specific condition. AA 1 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. Wire Gauge Electrical Schematic Symbols And Definitions The circle indicates that the component has screw terminals and a wire can be disconnected from it. FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. or grounded circuit, low idle possition is to low, or the Actuator linkage may be loose. Component Part Number Single Wire Connector Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The engine and pump electronic control was not calibrated correctly when manufactured. No circle indicates that the wire cannot be disconnected from the component. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. This indicates that the component has a wire connected to it that is connected to ground. SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. circuit being shorted to B+ or open, high idle possition is to high, or the actuator linkage may be loose. -- Normally (2320 psi) -- Open 100º C -- Normally 212º F -- Open Defaults Loaded Yes 11º C 17º C Normally Press w/o Spd. Chg No 52º F 63º F Open RPM Setting Diff No Engine speed or engine lug is incorrect. Difference between the engine and pump controllers output to the governor actuator and the feedback signal from the governor actuator motor is too large. There is a defect in the governor actuator motor or the wiring harness. Engine and pump controller is not adjusted. No error if the default values are loaded. Delete the error. Engine speed reduction or automatic speed shifting AEC pressure switch or wiring is defective. does not function. Engine speed sensor or wiring is defective. Presure when the engine is stopped. ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). Battery Voltage is below 17 DCV. Deactuate (40 to 255 psi) Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Possible Causes Actuate Normally ² Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 HARNESS CONNECTOR AND COMPONENT LOCATIONS 4.0 grams -- AA 1 Swing pump solenoid circuit is shorted to frame or the backup switch is on 275 to 1750 kpa¹ Printed in U.S.A. 47 1 D35440 Low Battery Voltage SENR3685 53 1 Main pump solenoid circuit is shorted to the fram, or the backup switch is on. Alternator: 109-2362 M315: 7ML1061-1064 7ML1215-1646 System Faults Detected by the Controller D = Located on or near relay panel. Title 48 Pressure Symbol C = Located in the righthand console. 5W-9972 53 A B = Located in the lefthand console. Related Electrical Service Manuals 52 M312 and M315 Excavators Electrical System A = Located in the cab. 3E-6429 51 25 Machine locations are repeated for components located close together. Part No. 50 Black callouts are for connectors, see the Connector Location chart. C D-13 60 White callouts are for components, see the Component Location chart. C C 62 19 B-4 C-9 41 18 B-8 Switch - Left Rear Stabl. Lockout 68 47 9 Switch - Hazard 69 45 29 Switch - Hammer C 61 46 D C-8 63 RENR1196-02 June 2001 4 32 Switch - Left Front Stabl. Lockout 42 49 F-7 53 11 69 54 H-12 E-14 12 59 1 Pilot Press Enable C, D-7 58 72 70 63 Motor - Washer Lower Blade Front, 8U-6424 Motor - Lower Wiper 13 64 Travel Lock Switch Yes Control of the travel pedal magnet is possibly disturbed. Travel lock contacts are dirty. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. T RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Component Locations - Prime Power Applications 26 16 15 25 15 18 19 16 14 RENR1242-02 July 1997 7 13 20 25 Electrical Schematic Symbols And Definitions 21a 21 21 23 18 19 T AIR CLEANER 24 Schematic Location Component 11 17 3 10 6 5 Left Side View Front View 22 26 8 28 30 29 12 E-4 note 4 Batteries H-6 note 1 Sensor - Engine Coolant Temp E-2 14 Breaker - Alternator G-7 8 Sensor - Engine Oil Press (Filtered) E-1 15 Breaker - CB4 H-10 note 5 Sensor - Engine Oil Press (Unfiltered) E-1 16 Breaker - ECM (Engine Control) G-6 13 Sensor - Engine Speed (EMCP) H-4 9 Control - Engine B-5 3 Sensor - Engine Speed Timing D-4 17 Control - Speed C-11 note 5 Sensor - Fuel Filter Press (Filtered) E-1 18 Control - Genset Status H-12 note 5 Sensor - Fuel Filter Press (Unfiltered) E-1 19 Module - Loadshare E-14 note 5 Sensor - L. Turbo Exhaust Temp D-4 20 Module - Relay G-12 note 5 Sensor - L. Turbo Inlet Press (note 3) E-2 21,21a E-4 4 Sensor - R. Turbo Exhaust Temp D-4 22 Motor - Starter (1/2 Group) G-7 5 Sensor - R. Turbo Inlet Press (note 3) E-2 23,23a Motor - Starter (1/2 Group) H-7 6 Sensor - Turbo Outlet Press E-2 24 Potentiometer - Speed Adjustment C-11 note 1 Solenoid - Air Shut-off (Left Side) F-4 25 Relay - Air Shut-off G-10 note 5 Solenoid - Air Shut-off (Right Side) G-4 26 Relay - Start Aid Hold B-10 note 5 Solenoid - Air Start (if equipped) H-4 27 Relay - Start Aid Start B-10 note 5 Solenoid - Cylinder Head (note 2) B-2,D-2 28 Relay - Mag #1 F-10 note 5 Solenoid - Start Aid F-4 29 Relay - Mag #2 F-10 note 5 Solenoid - Start Aid F-4 30 Relay - Prelube (Master) D-10 note 5 Switch - Disconnect H-7 note 1 Relay - Prelube (Slave) D-10 note 5 Switch - E Stop C-10 note 5 E-4,F-4 7 Switch - E Stop G-10 note 5 E-2 10 Switch - Start Aid Auto/Man C-10 note 1 Sensor - Atmospheric Press E-2 11 Switch - Prelube Press C-5 31 Sensor - Crankcase Press E-1 12 Sensor - Aftercooler Temp CLEANER 23 2 9 Machine Location Sensor - Engine Coolant Level Resistor AIR Schematic Location Component 2 Motor - Prelube 3 Machine Location F-7 Alternator 11 Component Location Flow Symbol Level Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Normally closed switch that will open with an increase of a specific condition. 3500B Engine for Electrical Power Generation (EPG) with Electronic Modular Control Panel (EMPC) Note 1: Customer supplied component. Note 2: One located at each cylinder. Note 3: Location marked with an "a" indicate the sensor location when the engine is NOT aquipped with an air shut-off 4GM171-UP 5XM1-UP 6PM1-UP 7KM1-UP 8RM175-UP 6HN138-UP 6PN249-UP 6WN114-UP 7RN428-UP 3LS1-UP Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. The circle indicates that the component has screw terminals and a wire can be disconnected from it. 4AW1-UP 5AW1-UP 3MS1-UP 3NS1-UP 1NW1-UP 2HW1-UP 2JW1-UP No circle indicates that the wire cannot be disconnected from the component. Note 4: Located at the radiator. 23a Temperature Symbol Pressure Symbol This indicates that the component has a wire connected to it that is connected to ground. Note 5: Located in the insrtumen box mounted on the generator. 17 This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. 31 27 110-6847 Plug As. or DT, DRC, HD, and Deutsch connectors. 7N-7779 Surseal connectors only. 4-6 8N-1548 8N-1547 25-pin CE connectors only. 10 8N-1542 8N-1543 25-pin CE connectors only. Wire Gauge Pin# 12-14 8N-1540 8N-1541 25-pin CE connectors only. 16-18 9X-6856 8N-1538 9X-6857 8N-1539 25-pin CE connectors only. 14 16-18 9W-0852 8T-8729 110-6848 Plug As. 3 1 24 C A A 325-PK-14 3E-3368 Wedge 102-8808 Plug Kit Wire Gauge Pin # 8N-1548 10 8N-1542 8N-1543 14 9W-0852 9W-0844 12-14 8N-1540 8N-1541 16-18 8T-8729 8T-8730 16-18 9X-6856 8N-1538 9X-6857 8N-1539 16-18 8T-8729 8T-8730 9 REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T Wire Gauge Pin # Socket # 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 10 20 30 40 6 16 26 36 SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. 9X-3132 Seal . 8T-9834 Connector As D86819 Wire Gauge Electrical Schematic Symbols And Definitions 35 9W-0844 10 31 9W-0852 11 200-BK-14 6 5 14 3E-4367 Ring 31 Socket # Wire Color Socket 7 8 3T-3043 or 8N-1517 Receptacle As . 35 34 33 32 31 DEUTSCH D IP DRC16-40S Right Side View Pin # 23 21 25 3E-8557 Bolt 3E-3361 Plug As. 102-8807 Plug Kit Wire Gauge 22 4 40 39 38 37 36 3 E-3362 Wedge 3E-3364 Plug As. 24 325-PK-14 Circuit Number Identification 3 40-Pin DRC Connector 102-8812 Seal 1 9X-1123 FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. 4-6 102-8802 Receptacle Kit D86924 12 8 Socket # 3E-3365 Wedge 15 7 Pin # 18 16 9 2 20 5 25 13 Wire Gauge 2-Pin DT Plug 12 10 1 19 15 14 6 Socket# 8N-1547 21a 2 23 11 21 18 15 9 22 24 17 1 19 16 4 3T-3044 or 8N-1518 Plug As . 8N-1521 Endbell As . 104-2921 Plug As. 102-8803 Receptacle Kit CLEANER 3 5 25 14 12 3E-3371 Wedge 20 15 102-8813 Seal 30 AIR 2 1 19 13 3E-3307 Receptacle As. Rear View 18 16 AA 2 21 29 17 3-Pin DT Plug Pin 25-Pin CE Plug 10 8 8T-8730 8T-8730 11 7N-7779 9W-0844 8T-8729 9W-0844 8T-8729 6 28 7N-7780 9W-0852 16-18 9W-0852 16-18 5 22 14-18 14 14 9X-0145 Receptacle As . 40 26 Socket # 5 Left Side View Front View Pin # Socket # 35 3 Wire Gauge Pin # Socket # 36 6 Wire Gauge Pin# 1 7N-9738 Receptacle 7N-9737 Plug 3 Wire Gauge 8T-8736 Receptacle Component Part Number Single Wire Connector 1 11 D86923 Wire, Cable, or Harness Assembly Identification 9X-3265 Seal 7X-6222 Connector As . Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Pin or Socket Number J H 2 17 3 F G 10 3E-4367 Ring B 1 17 C 21 20 19 2-Pin Sure-Seal Plug D A DEUTSCH D IP DRC16-24SA USA E 23 3E-8558 Bolt 9-Pin HD10 Receptacle 22 8T-8730 21 8T-8729 19 16-18 6 9W-0844 24-Pin DRC Connector 18 9W-0852 2 12 14 9W-0844 8T-8730 4 Socket # Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug Socket # 1 2 1 2 3E-3373 Plug As . 102-8809 Plug Kit 16 Pin # 3E-3374Wedge 102-8804 Receptacle Kit 24 23 22 11 Wire Gauge 3E-3377Wedge . 3E-3376 Receptacle As 10 CLEANER 24 8T-8730 7N-7780 9 AIR 8T-8729 14-18 15 23 110-6848 Plug As. or 110-6847 Plug As. (Service Replacement) 16-18 AA 1 7 21a DT, DRC, HD, and Deutsch connectors. 13 21 Notes 9W-0844 6 20 Socket # 9W-0852 4 7 Pin # 14 24 13 21 102-8814 Seal A Wire Gauge 21 25 26 110-6844 Seal 25 Harness And Wire Electrical Schematic Symbols 4-Pin DT Plug 40-Pin Deutsch Connector 22 Component Locations - Standy Power Applications 14 Printed in U.S.A. © 1997 Caterpillar All Rights Reserved 4 Right Side View D86926 19 D86927 Rear View . 9X-1343 Receptacle As D86820 MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Component Locations - Standby Power Applications 21 25 26 19 18 15 9 14 16 Component Alarm 20 7 21 25 15 23 21a Air Cleaner 18 19 16 24 17 11 11 10 8 6 3 1 3 5 Left Side View 29 30 Front View 22 26 28 1 32 Air Cleaner 1 23 2 23a 17 Schematic Location F-14 27 12 Component Location Machine Location 1 Component Sensor - Crankcase Press Schematic Location D-3 Machine Location 12 Alternator D-8 2 Sensor - Engine Coolant Level G-7 note 4 Assembly - Relay Board H-2 note 5 Sensor - Engine Coolant Temp D-5 14 Assembly - Relay Board F-2 note 5 Sensor - Engine Oil Press (Filtered) D-4 15 Batteries E-6 note 1 Sensor - Engine Oil Press (Unfiltered) D-3 16 Breaker - Alternator F-11 1 Sensor - Engine Speed Timing C-4 17 Breaker - Battery F-11 1 Sensor - Fuel Filter Press (Filtered) D-3 18 Breaker - Control Switch C-13 1 Sensor - Fuel Filter Press (Unfiltered) D-4 19 Breaker - Denox C-11 1 Sensor - L. Turbo Exhaust Temp C-4 20 Breaker - EMS II D-14 1 Sensor - L. Turbo Inlet Press (note 3) D-4 21 ,21a Breaker - Engine Control C-14 1 Sensor - R. Turbo Exhaust Temp C-4 22 Breaker - Mag Relay G-12 1 Sensor - R. Turbo Inlet Press (note 3) D-4 23,23a Breaker - Main Crank E-Stop G-11 1 Sensor - Turbo Outlet Press D-4 24 Breaker - PRCM H-12 1 Solenoid - Air Shut-off (Left Side) E-5 25 Breaker - Relay F-12 1 Solenoid - Air Shut-off (Right Side) E-5 26 Control - Engine A-6 3 Solenoid - Air Start (if equipped) E-7 27 Control - Speed E-13 1 Solenoid - Cylinder Head (note 2) A-2,B-2 28 Gauge - Cluster #1 I-14 1 Solenoid - Start Aid E-5 29 Gauge - Cluster #2 I-13 1 Solenoid - Start Aid E-5 30 Gauge - Cluster#3 I-13 1 Switch - Alarm Silence G-14 1 Module - Customer Communication H-9 note 5 Switch - Charger Fault G-7 note 1 Module - Loadshare I-8 1 Switch - Control D-13 1 Module - Prog Relay Control H-4 note 5 Switch - Customer Shut-down G-7 note 1 Module - Relay Driver G-1 note 5 Switch - Disconnect Module - Relay Driver I-1 note 5 Switch - E-Stop Monitor - EMS II G-15 1 Motor - Prelube D-5 4 Motor - Starter (1/2 Group) E-8 F-6 note 1 E-13 1 Switch - Fuel Level G-7 note 1 Switch - LH/RH F-14 1 5 Switch - Low Idle F-12 1 Switch - Manual Crank F-13 1 Switch - Mode/Clear F-14 1 Motor - Starter (1/2 Group) E-8 6 Potentiometer - Speed Adjustment G-9 note 1 Pyrometer E-2 1 Switch - Overspeed Verify C-13 1 Relay - Air Shut-off LH F-13 1 Switch - Prelube Press B-4 31 Relay - Air Shut-off RH F-13 1 Switch - Remote Start/Stop G-7 note 1 Relay - Denox C-11 1 Switch - Service G-14 1 Relay - EMS II D-14 1 Switch - Start Aid C-13 1 Relay - Engine Control C-14 1 Terminal Block (TB-1) G-11 1 Relay - Mag #1 F-13 1 Terminal Block (TB-2) D-11 1 Relay - Mag #2 F-13 1 Terminal Block (TB-3) C-14 1 Relay - PRCM H-12 1 Terminal Block (TB-4) F-12 1 Relay - Prelube (Master) F-13 1 Terminal Block (TB-5) H-14 1 Relay - Prelube (Slave) G-13 1 Terminal Block (TB-6) H-14 1 Relay - Shut-down Notify H-11 1 Terminal Block (TB-7) H-14 1 Relay - Start Aid Hold G-l3 1 Terminal Block (TB-8) H-14 1 Relay - Start Aid Start G-13 1 Terminal Block (TB-10) D-10 1 Resistor D-5 7 Terminal Block (TB-11) D-10 1 Sender - Air Inlet Temp F-7 9 Terminal Block (TB-12) H-11 1 Sender - Engine Oil Temp F-7 8 Thermocouple (note 2) C-1 ,E-1 32 Sensor - Aftercooler Temp D-4 10 Timer - Air Shut-off E-14 1 Sensor - Atmospheric Press D-4 11 RENR1243-02 July 1997 Electrical Schematic Symbols And Definitions T Temperature Symbol Pressure Symbol Flow Symbol Level Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. 3500B Engine For Electrical Power Generation (EPG) With Switchgear Conversion 4GM171-UP 5XM1-UP 6PM1-UP 7KM1-UP 8RM175-UP 6HN138-UP 6PN249-UP 6WN114-UP 7RN428-UP 3LS1-UP 3MS1-UP 3NS1-UP Normally closed switch that will open with an increase of a specific condition. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 1NW1-UP 2HW1-UP 2JW1-UP 4AW1-UP 5AW1-UP The circle indicates that the component has screw terminals and a wire can be disconnected from it. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Note 1: Customer supplied component. Note 2: One located at each cylinder. Note 3: Locations marked with an "a" indicate the sensor location when the engine is equipped with an air shut-off. Note 4: Located at the radiator. Note 5: Remote mounted. 31 Right Side View 4 Harness And Wire Electrical Schematic Symbols 4-Pin DT Plug 40-Pin Deutsch Connector Notes 9W-0844 DT, DRC, HD, and Deutsch connectors. 16-18 8T-8729 8T-8730 DT, DRC, HD, and Deutsch connectors. 14-18 7N-7780 7N-7779 Surseal connectors only. 4-6 8N-1548 8N-1547 25-pin CE connectors only. 10 8N-1542 8N-1543 25-pin CE connectors only. 12-14 8N-1540 8N-1541 25-pin CE connectors only. 16-18 9X-6856 8N-1538 9X-6857 8N-1539 25-pin CE connectors only. 2-Pin Sure-Seal Plug H 2 6 8 5 3 8T-8736 Receptacle 7N-9738 Receptacle 7N-9737 Plug Wire Gauge Pin # Socket # 14-18 7N-7780 7N-7779 Wire Gauge Pin # Socket # 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 Pin # Socket # 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 18 19 20 3 25 12 22 24 23 11 10 9 21 24 2 14 Wire Color Socket 6 12 8 Circuit Number Identification 5 13 7 22 24 23 11 10 9 200-BK-14 4 20 19 25 21 6 7 8 3E-3368 Wedge 104-2921 Plug As. 102-8808 Plug Kit Wire Gauge 9X-6856 8N-1538 9X-6857 8N-1539 40-Pin DRC Connector 3E-3361 Plug As. 3E-3362 Wedge jrhaxis 1 40 30 10 6 5 Wire Gauge Pin # Socket # Wire Gauge Pin # Socket # 14 9W-0852 9W-0844 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 16-18 8T-8729 8T-8730 D86819 15 CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. 9X-3132 Seals 8T-9834 Connector As. SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. 102-8807 Plug Kit 102-8802 Receptacle Kit 12 1 3E-4367 Ring 31 3E-3364 Plug As. T 35 34 33 32 31 2 DEUTSCH IPD DRC16-40S 18 36 3E-8557 Bolt 102-8812 Seal 35 40 39 38 37 36 2-Pin DT Plug 3E-3365 Wedge REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 20 8T-8730 16-18 FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. 36 9W-0844 8T-8729 8N-1541 35 9W-0852 16-18 8N-1540 31 14 8N-1543 12-14 6 Socket # 8N-1547 8N-1542 26 Pin # 8N-1548 10 40 23a Wire Gauge 4-6 3T-3043 or 8N-1517 Receptacle As. 16 19 Socket # 5 102-8803 Receptacle Kit Pin # 25 3E-3371 Wedge Wire Gauge 15 1 17 325-PK-14 Electrical Schematic Symbols And Definitions 3E-3307 Receptacle As. 23 1 9X-1123 3 3T-3044 or 8N-1518 Plug As. 8N-1521 Endbell As. 16 1 32 1 Rear View 18 15 5 13 102-8813 Seal 16 4 17 11 28 22 2 1 21 22 Pin 10 26 3-Pin DT Plug 325-PK-14 9X-0145 Receptacle As. AA 2 17 14 30 A A 25-Pin CE Plug 16 29 C Wire Gauge 15 Front View 21 9X-3265 Seals 7X-6222 Connector As. Component Part Number Single Wire Connector J 1 11 3 A Wire, Cable, or Harness Assembly Identification 1 1 C B F G 10 D 19 E 17 21 20 19 3E-4367 Ring 11 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number 19 9-Pin HD10 Receptacle 6 8T-8730 24-Pin DRC Connector 3E-8558 Bolt 18 9W-0844 8T-8729 2 12 9W-0852 16-18 9W-0844 8T-8730 4 14 9W-0852 8T-8729 16 Socket # 14 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug Socket # 10 Pin # Pin # 16-18 DEUTSCH IPD DRC16-24SA USA Wire Gauge Wire Gauge 1 2 1 2 3E-3373 Plug As. 102-8809 Plug Kit 24 23 22 24 3E-3374 Wedge 102-8804 Receptacle Kit 9 110-6848 Plug As. 3E-3377 Wedge 3E-3376 Receptacle As. 3 110-6848 Plug As. or 110-6847 Plug As. (Service Replacement) Socket # 9W-0852 15 23 Pin # 14 7 110-6847 Plug As. or 21a Wire Gauge 1 21 25 13 20 7 6 9 4 14 21 AA 3 25 1 26 A 1 24 110-6844 Seal 102-8814 Seal 22 Component Locations - Prime Power Applications 21 Rear View Printed in U.S.A. © 1997 Caterpillar All Rights Reserved 9X-1343 Receptacle As. D86820 SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Schematic Location F-14 Component Component Locations Alarm 19 19 18 15 16 14 9 25 21a 20 21 24 AIR CLEANER 11 11 17 3 1 10 6 3 5 8 Front View Left Side View 23 22 26 23a 28 32 1 23 21 AIR CLEANER 2 1 7 17 12 27 Component Location Machine Location 1 Component Sensor - Engine Coolant Temp Schematic Location E-4 Machine Location 14 Alternator D-8 2 Sensor - Engine Oil Press (Filtered) E-4 15 Assembly - Relay Board F-2 note 4 Sensor - Engine Oil Press (Unfiltered) E-3 16 Assembly - Relay Board H-2 note 4 Sensor - Engine Speed C-4 7 Batteries F-6 note 1 Sensor - Engine Speed Timing C-3 17 Breaker - Alternator F-11 1 Sensor - Fuel Filter Press (Filtered) E-3 18 Breaker - Battery F-11 1 Sensor - Fuel Filter Press (Unfiltered) E-3 19 Breaker - Control Switch C-12 1 Sensor - L. Turbo Exhaust Temp C-3 20 Breaker - EMS II D-14 1 Sensor - L. Turbo Inlet Press (note 3) E-4 21,21a Breaker - Engine Control C-14 1 Sensor - R. Turbo Exhaust Temp C-3 22 Breaker - Mag Relay G-12 1 Sensor - R. Turbo Inlet Press (note 3) E-4 23,23a Breaker - Main Crank E-Stop G-11 1 Sensor - Turbo Outlet Press E-4 24 Breaker - PRCM I-12 1 Solenoid - Air Shut-off (Left Side) D-6 25 Breaker - Relay F-12 1 Solenoid - Air Shut-off (Right Side) E-6 26 Control - Engine A-6 3 Solenoid - Air Start (if equipped) E-7 27 Control - Speed E-13 1 Solenoid - Cylinder Head (note 2) A-2,C-2 28 Gauge - Cluster #1 I-14 1 Switch - Alarm Silence G-14 1 Gauge - Cluster #2 I-13 1 Switch - Charger Fault H-7 note 1 Gauge - Cluster #3 I-13 1 Switch - Control D-13 1 Module - Customer Communication H-9 note 4 Switch - Customer Shut-down G-7 note 1 Module - Loadshare I-8 1 F-6 note 1 Module - Prog Relay Control H-4 note 4 Switch - Disconnect Switch - E-Stop D-13 1 Module - Relay Driver G-1 note 4 Switch - Electronic Speed E-14 1 Module - Relay Driver I-1 note 4 Switch - Fuel Level H-7 note 1 Monitor - EMS II G-15 1 Switch - LH/RH F-14 1 Motor - Prelube D-5 4 Switch - Low Idle F-12 1 Motor - Starter (1/2 Group) E-8 5 Switch - Manual Crank F-13 1 Motor - Starter (1/2 Group) E-8 6 Switch - Mode/Clear G-14 1 Potentiometer - Speed Adjustment G-9 note 1 Switch - Overspeed Verify C-13 1 Pyrometer F-2 1 Switch - Prelube Press B-4 31 Relay - Air Shut-off LH F-13 1 Switch - Remote Start/Stop G-7 note 1 Relay - Air Shut-off RH F-13 1 Switch - Service G-14 1 Relay - EMS II D-14 1 Terminal Block (TB-1) G-11 1 Relay - Engine Control C-14 1 Terminal Block (TB-2) D-11 1 Relay - Mag #1 F-13 1 Terminal Block (TB-3) C-14 1 Relay - Mag #2 F-13 1 Terminal Block (TB-4) F-12 1 Relay - PRCM I-12 1 Terminal Block (TB-5) H-14 1 Relay - Prelube (Master) G-13 1 Terminal Block (TB-6) H-14 1 Relay - Prelube (Slave) G-13 1 Terminal Block (TB-7) H-14 1 Relay - Shut-down Notify H-11 1 Terminal Block (TB-8) H-14 1 Sender - Air Inlet Temp F-6 9 Terminal Block (TB-10) D-10 1 Sender - Engine Oil Temp F-7 8 Terminal Block (TB-11) D-10 1 Sensor - Aftercooler Temp E-4 10 Terminal Block (TB-12) H-11 1 Sensor - Atmospheric Press E-4 11 Thermocouple (note 2) D-1,F-1 32 Timer - Air Shut-off E-14 1 Sensor - Crankcase Press E-3 12 Sensor - Engine Coolant Level G-7 note 1 RENR1245-02 July 1997 3500B Engine For Marine Auxiliary Power Electrical System Serial #: 3DM86-UP 8EM249-UP 9AN111-UP Serial #: 3TS1-UP 3WS1-UP 3XS1-UP Serial #: 1PW1-UP 2FW1-UP 3DW1-UP Note 1: Customer supplied component. Note 2: One located at each cylinder. Note 3: Locations marked with an “a” indicate the sensor location when the engine is equipped with an air shut-off. Note 4: Remote mounted. 31 Right Side View D86935 Printed in U.S.A. ©1997 Caterpillar All Rights Reserved Harness And Wire Electrical Schematic Symbols 40-Pin Deutsch Connector 4-Pin DT Plug 110-6844 Seal 110-6847 Plug As. or 110-6848 Plug As. or 110-6847 Plug As. (Service Replacement) Wire Gauge Pin # Socket # Notes 14 9W-0852 9W-0844 DT, DRC, HD, and Deutsch connectors. 16-18 8T-8729 8T-8730 DT, DRC, HD, and Deutsch connectors. 14-18 7N-7780 7N-7779 Surseal connectors only. 4-6 8N-1548 8N-1547 25-pin CE connectors only. 10 8N-1542 8N-1543 25-pin CE connectors only. 12-14 8N-1540 8N-1541 25-pin CE connectors only. 16-18 9X-6856 8N-1538 9X-6857 8N-1539 25-pin CE connectors only. 110-6848 Plug As. 8T-8730 2 8T-8736 Receptacle 7N-9738 Receptacle 8T-8730 9W-0852 9W-0844 16-18 8T-8729 8T-8730 18 16 14 3E-3368 Wedge 102-8808 Plug Kit Pin # Socket # 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 22 24 23 11 10 9 21 17 24 18 22 21 19 18 1 2 19 20 24 22 12 Pin # Socket # 4-6 8N-1548 8N-1547 10 8N-1542 8N-1543 12-14 8N-1540 8N-1541 16-18 9X-6856 8N-1538 9X-6857 8N-1539 23 11 10 9 21 6 7 8 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. Wire Gauge Pin # Socket # 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 30 20 36 35 40 This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. 31 26 25 10 6 16 5 15 1 31 This indicates that the component has a wire connected to it that is connected to ground. 9X-3132 Seals 8T-9834 Connector As. D86819 11 3E-4367 Ring Wire Gauge Pin # Socket # 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 Wire Gauge FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. T 21 40 102-8807 Plug Kit 102-8802 Receptacle Kit 200-BK-14 No circle indicates that the wire cannot be disconnected from the component. 35 34 33 32 31 3E-3364 Plug As. DEUTSCH IPD DRC16-40S 3E-3361 Plug As. 3E-3362 Wedge Wire Color Socket REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 40 39 38 37 36 3E-8557 Bolt 325-PK-14 Electrical Schematic Symbols And Definitions The circle indicates that the component has screw terminals and a wire can be disconnected from it. 3T-3043 or 8N-1517 Receptacle As. 40-Pin DRC Connector 102-8812 Seal 1 9X-1123 Circuit Number Identification 4 5 25 13 7 8 Normally closed switch that will open with an increase of a specific condition. 3 15 14 6 Wire Gauge 2-Pin DT Plug 3E-3365 Wedge 16 4 3T-3044 or 8N-1518 Plug As. 8N-1521 Endbell As. 104-2921 Plug As. Wire Gauge 3 Component Part Number AA 2 5 25 12 102-8803 Receptacle Kit 20 15 102-8813 Seal 3E-3371 Wedge Pin Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. 2 1 19 A A 325-PK-14 25-Pin CE Plug 13 3E-3307 Receptacle As. 12 6 14 17 3-Pin DT Plug C 9X-0145 Receptacle As. 10 7N-7779 9W-0844 8T-8729 Socket # 6 7N-7780 9W-0852 16-18 Pin # 5 14-18 14 Pin or Socket Number Flow Symbol Single Wire Connector 1 Socket # Socket # Wire Gauge 36 Pin # Pin # Level Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). 35 Wire Gauge Wire Gauge 16 4 2 Temperature Symbol Wire, Cable, or Harness Assembly Identification 9X-3265 Seals 7X-6222 Connector As. 1 1 3 H 3 J G 1 3E-4367 Ring 21 B 21 20 19 C A F DEUTSCH IPD DRC16-24SA USA D 10 3E-8558 Bolt 9-Pin HD10 Receptacle 2-Pin Sure-Seal Plug 7N-9737 Plug Pressure Symbol 24-Pin DRC Connector E Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. T 9 8T-8730 8T-8729 15 8T-8729 9W-0844 16-18 Receptacle Plug Socket # 7 16-18 9W-0852 13 9W-0844 Pin # 14 6 9W-0852 Wire Gauge Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 3E-3373 Plug As. 102-8809 Plug Kit 1 2 1 2 4 14 102-8804 Receptacle Kit 24 Socket # 3E-3374 Wedge 22 Pin # 3E-3377 Wedge 3E-3376 Receptacle As. AA 1 Electrical Schematic Symbols And Definitions 24 23 22 Wire Gauge A 102-8814 Seal 19 Rear View 4 9X-1343 Receptacle As. D86820 SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Schematic Location F-14 Component Alarm Component Locations 19 15 18 24 14 16 Alternator 21 20 19 11 11 10 3 29 17 3 6 5 Left Side View 7 Front View 23 26 23a 22 28 32 23 2 1 29 33 12 17 31 27 Right Side View D86932 Sensor - Engine Speed Timing (Secondary) D-5 29 9 Sensor - Fuel Filter Press (Filtered) C-3 18 Assembly - Relay Board G-3 note 4 Sensor - Fuel Filter Press (Unfiltered) C-3 19 Assembly - Relay Board H-2 note 4 Sensor - L. Turbo Exhaust Temp A-7 20 Batteries F-7 note 1 Sensor - L. Turbo Inlet Press (note 3) C-4 21,21a Breaker - Alternator F-12 1 Sensor - R. Turbo Exhaust Temp A-7 22 Breaker - Battery F-12 1 Sensor - R. Turbo Inlet Press (note 3) C-4 23,23a Breaker - Control Switch D-12 1 Sensor - Throttle Position (Port) I-9 note 4 Breaker - Customer Power H-12 1 Sensor - Throttle Position (Starboard) I-9 note 4 Breaker - EMS II E-14 1 Sensor - Turbo Outlet Press C-3 24 Breaker - Engine Control (Primary) D-14 1 Solenoid - Air Shut-off (Left Side) D-7 25 Breaker - Engine Control (Secondary) E-14 1 Solenoid - Air Shut-off (Right Side) E-7 26 Breaker - Mag Relay F-12 1 Solenoid - Air Start (if equipped) E-7 27 Breaker - Main Crank E-Stop G-12 1 Solenoid - Cylinder Head (note 2) C-2,E-2 28 Breaker - PRCM H-12 1 Switch - Alarm Silence G-14 1 Breaker - Relay F-12 1 Switch - Charger Fault H-8 note 1 Control - Engine (Primary) A-6 3 Switch - Control D-13 1 Control - Engine (Secondary) F-6 7 Switch - Customer Shut-down H-6 note 4 Gauge - Cluster #1 I-7 note 4 Switch - E-Stop E-13 1 Gauge - Cluster #1 I-15 1 Switch - Engine Protection Override C-12 1 Gauge - Cluster #2 I-7 note 4 Switch - Fuel Level H-8 note 1 Gauge - Cluster #2 I-14 1 Switch - LH/RH F-14 1 Gauge - Cluster #3 I-13 1 Switch - Manual Crank F-13 1 Module - Customer Communication I-8 note 4 Switch - Mode/Clear G-14 1 Module - Prog Relay Control I-3 note 4 Switch - Overspeed Verify C-13 1 Module - Relay Driver G-2 note 4 Switch - Prelube Override D-13 1 Switch - Prelube Press B-7 31 Switch - Remote Start/Stop H-6 note 4 note 4 H-1 note 4 G-15 1 Monitor - Electronic (EMS) I-5 note 4 Switch - Scroll G-6 Motor - Prelube D-7 4 Switch - Service G-14 1 Motor - Starter (1/2 Group) E-8 5 Switch - Throttle Synchronization I-9 note 1 Motor - Starter (1/2 Group) E-8 6 Tachometer I-6 note 4 Potentiometer G-5 note 4 Terminal Block (TB-1) F-12 1 Pyrometer C-2 1 Terminal Block (TB-2) E-12 1 Relay - Air Shut-off LH F-13 1 Terminal Block (TB-3) C-14 1 Relay - Air Shut-off RH F-13 1 Terminal Block (TB-4) F-13 1 Relay - Customer Power H-12 1 Terminal Block (TB-5) H-14 1 Relay - EMS II E-14 1 Terminal Block (TB-6) H-14 1 Relay - Engine Control (Primary) D-14 1 Terminal Block (TB-7) H-14 1 Relay - Engine Control (Secondary) D-14 1 Terminal Block (TB-8) H-14 1 Relay - General Alarm G-12 1 Terminal Block (TB-9) H-14 1 Relay - Mag #1 F-13 1 Terminal Block (TB10) D-11 1 Relay - Mag #2 F-13 1 Terminal Block (TB-11) D-11 1 Relay - PRCM I-12 1 Terminal Block (TB-12) G-12 1 Relay - Prelube (Master) F-13 1 Terminal Block (TB-13) H-11 1 Relay - Prelube (Slave) G-13 1 Terminal Block (TB-14) H-11 1 Relay - Shut-down Notify H-12 1 Terminal Block (TB-15) H-11 1 Sensor - Aftercooler Temp C-4 10 Terminal Block (TB-16) I-11 1 Sensor - Atmospheric Press C-4 11 Terminal Block (TB-17) H-11 1 Sensor - Crankcase Press C-3 12 Terminal Block (TB-18) H-11 1 Sensor - Engine Coolant Level G-8 note 1 Terminal Block (TB-19) H-11 1 Sensor - Engine Coolant Temp C-4 14 Terminal Block (TB-20) G-11 1 Sensor - Engine Oil Press (Filtered) C-3 15 Thermocouple (note 2) A-1,C-1 32 4 Sensor - Engine Oil Press (Unfiltered) C-3 16 Timer - Air Shut-off E-14 1 RENR1297-01 July 1997 3500B Engine For Marine Propulsion Electrical System 2BM123-UP 7HM173-UP 7SM77-UP 4TN96-UP 8CN144-UP 8KN143-UP 3PS1-UP 3RS1-UP 3SS1-UP 1TW1-UP 2GW1-UP 3CW1-UP Note 1: Customer supplied component. Note 2: One located at each cylinder. Note 3: Locations marked with an “a” indicate the sensor location when the engine is equipped with an air shut-off. Note 4: Remote mounted. D86933 Rear View © 1997 Caterpillar All Rights Reserved 4-Pin DT Plug 40-Pin Deutsch Connector Socket # Notes 9W-0852 9W-0844 DT, DRC, HD, and Deutsch connectors. 16-18 8T-8729 8T-8730 DT, DRC, HD, and Deutsch connectors. 14-18 7N-7780 7N-7779 Surseal connectors only. 4-6 8N-1548 8N-1547 25-pin CE connectors only. 10 8N-1542 8N-1543 25-pin CE connectors only. 12-14 8N-1540 8N-1541 25-pin CE connectors only. 16-18 9X-6856 8N-1538 9X-6857 8N-1539 25-pin CE connectors only. J G H 2 8T-8736 Receptacle 7N-9738 Receptacle Wire Gauge Pin # Socket # 14-18 7N-7780 7N-7779 Wire Gauge Pin # Socket # 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 Wire Gauge Pin # Socket # 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 17 14 20 3 104-2921 Plug As. 102-8808 Plug Kit Pin # Socket # 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 18 24 22 21 6 12 4 16 9 10 16 4 25 22 24 23 11 10 9 21 17 18 1 3 5 15 14 6 25 13 7 12 8 22 24 23 11 10 9 21 Pin # Socket # 4-6 8N-1548 8N-1547 10 8N-1542 8N-1543 12-14 8N-1540 8N-1541 16-18 9X-6856 8N-1538 9X-6857 8N-1539 The circle indicates that the component has screw terminals and a wire can be disconnected from it. 40 30 36 35 31 20 26 25 21 10 6 16 5 15 1 11 6 5 This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. 1 31 This indicates that the component has a wire connected to it that is connected to ground. jrhaxis 1 9X-3132 Seals 8T-9834 Connector As. Wire Gauge Pin # Socket # 14 9W-0852 9W-0844 Wire Gauge Pin # Socket # 8T-8730 14 9W-0852 9W-0844 16-18 8T-8729 8T-8730 8T-8729 D86819 1 jrhaxis Wire Gauge REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T 10 40 3E-4367 Ring 102-8807 Plug Kit 200-BK-14 FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. 102-8802 Receptacle Kit 16-18 Wire Color Socket Electrical Schematic Symbols And Definitions No circle indicates that the wire cannot be disconnected from the component. 35 34 33 32 31 DEUTSCH IPD DRC16-40S 3E-3361 Plug As. 35 36 3E-8557 Bolt 9X-1123 325-PK-14 8 3T-3043 or 8N-1517 Receptacle As. 40 39 38 37 36 102-8812 Seal 3E-3364 Plug As. AA 1 Circuit Number Identification 7 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. Wire Gauge 2-Pin DT Plug 3E-3362 Wedge Pin 6 40-Pin DRC Connector 3E-3365 Wedge A A 325-PK-14 Normally closed switch that will open with an increase of a specific condition. 4 20 19 Component Part Number 2 3T-3044 or 8N-1518 Plug As. 8N-1521 Endbell As. Wire Gauge C Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. 5 12 3E-3368 Wedge 102-8803 Receptacle Kit Pin or Socket Number Single Wire Connector 9X-0145 Receptacle As. 2 1 19 13 102-8813 Seal 3E-3371 Wedge Flow Symbol 2 18 16 3E-3307 Receptacle As. Level Symbol Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Wire, Cable, or Harness Assembly Identification 25-Pin CE Plug 15 3-Pin DT Plug 2 9X-3265 Seals 7X-6222 Connector As. 1 7N-9737 Plug 3 B A F Temperature Symbol Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle 19 3E-4367 Ring C 21 20 19 2-Pin Sure-Seal Plug D DEUTSCH IPD DRC16-24SA USA E Pressure Symbol 1 2 1 2 1 T 24-Pin DRC Connector 9-Pin HD10 Receptacle AA Plug 15 8T-8730 9W-0844 8T-8730 7 8T-8729 9W-0852 8T-8729 1 16-18 14 16-18 3E-8558 Bolt A Socket # 13 9W-0844 Pin # 6 Socket # 9W-0852 Wire Gauge Electrical Schematic Symbols And Definitions 3E-3373 Plug As. 102-8809 Plug Kit 19 Pin # 14 102-8804 Receptacle Kit 24 23 22 Wire Gauge 3E-3374 Wedge 4 110-6848 Plug As. 3E-3377 Wedge 3E-3376 Receptacle As. 3 110-6848 Plug As. or 110-6847 Plug As. (Service Replacement) Pin # 14 1 110-6847 Plug As. or Wire Gauge 24 110-6844 Seal Printed in U.S.A. Harness And Wire Electrical Schematic Symbols 102-8814 Seal 22 21 Machine Location 17 C-2,E-2 Monitor- EMS II 1 Sensor - Engine Speed Timing (Primary) Schematic Location A-7 2 Module - Relay Driver 9 Component 21 1 Machine Location 1 E-8 Assembly - Diode (Note 2) 25 21a Component Location 9X-1343 Receptacle As. D86820 SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
ECM Connectors 6 HEUI Injectors Engine Control Module RENR1368-04 May 2001 Cab Diagnostic Connector 0-00 1-11 2-11 3-11 4-11 5-11 6-11 22-13 30-08 30-13 41-03 41-04 42-11 - 12 V + Batteries Cruise Control On/Off & Set/Resume Switches ECM Side ECM Connector P1 Harness Side Accelerator Pedal Position Sensor Top Camshaft Speed/Timing Sensor Caterpillar Installed Bottom Camshaft Speed/Timing Sensor ECM Side ECM Connector P2 Harness Side Injection Actuation Pressure Sensor DT Connector Receptacle OEM Installed Coolant Level Sensor Check Engine Lamp Warning Lamp 3126B and 3126E Truck Engine Electrical System Speedometer & Tachometer DT Connector Plug 45 35 25 Boost Pressure Sensor 15 55 20 65 10 75 15 25 5 5 0 Receptacle Wedge Atmospheric Pressure Sensor Plug Wedge A/C High Pressure Switch MPH 85 RPM X 1000 30 Cooling Fan (Specific Ratings Only) Vehicle Speed Sensor Receptacle Wedge Plug Wedge Oil Pressure Sensor Receptacle Wedge PTO Accelerator Position Sensor (Optional) Fast Idle Enabled Lamp Or Wait To Start Lamp Plug Wedge HD Connector Receptacle HD Connector Plug Oil Level Switch (Optional) Fast Idle Enable Switch Coolant Temperature Sensor Pin Contact Socket Contact PTO Switch On Lamp PTO On/Off & PTO Set/Resume Switches Transmission Neutral Switch AT/MT/HT Transmission Relay Sealing Plug Intake Manifold Air Temperature Sensor Speed/Timing Sensor Connectors IAPCV Connector Intake Air Heater Relay Exhaust Brake Exhaust Brake On/Off Switch Intake Air Heater Lamp Intake Air Heater A 150 Series Receptacle 150 Series Plug © 2001 Caterpillar All Rights Reserved Printed in U.S.A. BKD1-UP 1AJ1-UP 8YL1-UP CKM1-UP CRP1-UP 7AS1-UP 8SZ1-UP 9SZ1-UP Diagnostic Code Listing Flash PID-FMI Description Codes 55 102-04 Boost Press Sensor Short Circuit 72 102-07 Excessive Boost Pressure 72 105-03 Inlet Manifold Air Temp Sensor Open Circuit 73 105-04 Inlet Manifold Air Temp Sensor Short Circuit 73 108-03 Atmospheric Press Sensor Open Circuit 74 108-04 Atmospheric Press Sensor Short Circuit 74 110-00 High Coolant Temp Warning 42 110-03 Coolant Temp Sensor Open Circuit 29 110-04 Coolant Temp Sensor Short Circuit 29 110-11 Very High Coolant Temp 21 111-01 Low Coolant Level Warning 21 111-02 Coolant Level Sensor Fault 18 111-11 Very Low Coolant Level 70-05 70-06 71-00 71-01 71-14 84-00 Vehicle Overspeed Warning 41 190-11 84-01 84-02 84-08 84-10 91-08 91-13 100-03 100-04 100-11 102-03 Loss of Vehicle Speed Signal Invalid Vehicle Speed Signal Vehicle Speed Out of Range Vehicle Speed Rate of Change Invalid Throttle Signal Throttle Sensor Calibration Oil Press Sensor Open Circuit Oil Press Sensor Short Circuit Very Low Oil Press Boost Press Sensor Open Circuit 31 36 36 36 32 28 24 24 46 25 224-11 224-14 231-11 232-03 232-04 246-11 247-11 252-11 253-02 253-14 64-11 Clutch and Service Brake Switches Description No Detected Faults Cylinder 1 Fault Cylinder 2 Fault Cylinder 3 Fault Cylinder 4 Fault Cylinder 5 Fault Cylinder 6 Fault Check Timing Sensor Calibration Invalid PTO Throttle Signal PTO Throttle Sensor Calibration 8 Volt Supply Above Normal 8 Volt Supply Below Normal Injection Actuation Press Control Valve Driver Fault Ignition Key Switch Fault Loss of Engine RPM Signal on Engine Speed and Timing Sensor Number 2 No Pattern on Engine Speed and Timing Sensor Number 2 Inlet Air Heater Open Circuit Inlet Air Heater Short Circuit Idle Shutdown Override Idle Shutdown Occurrence PTO Shutdown Occurrence 43-02 64-02 Ignition Key Switch Injection Actuation Pressure Control Valve (IAPCV) PID-FMI Flash Codes 25 25 38 38 26 26 61 27 27 61 62 12 62 71 34 164-00 164-02 Injection Actuation Press Out of Range Injection Actuation Press Sensor Erratic 17 15 34 164-03 Injection Actuation Press Open Circuit 15 49 49 01 47 47 164-04 164-11 168-02 190-00 190-02 Injection Actuation Press Short Circuit Injection Actuation Press System Intermittent Battery Power to the ECM Engine Overspeed Warning Loss of RPM Signal on Engine Speed and Timing Sensor Number 1 No Pattern on Engine Speed and Timing Sensor Number 1 Theft Deterrent Enabled Engine Cranking / Theft Deterrent Enabled J1939 Data Link Fault 5 Volt Supply Above Normal 5 Volt Supply Below Normal Service Brake Switch Number 1 Fault Service Brake Switch Number 2 Fault Incorrect Engine Software Check Customer or System Parameters Truck Manuf. Parameter Not Programmed 15 39 51 35 34 34 00 00 58 21 21 00 00 59 56 56
Connector Location¹ Connector Number CONN1 CONN2 CONN3 CONN4 CONN5 CONN6 CONN7 CONN8 CONN9 CONN10 CONN11 CONN12 CONN13 CONN14 CONN15 CONN16 CONN17 CONN18 CONN19 CONN20 CONN21 CONN22a CONN22b CONN22c CONN23 CONN24 CONN25 CONN26 CONN27 CONN28 CONN29 CONN30 CONN31a CONN31b CONN32 CONN33a CONN33b CONN34 CONN35 CONN36 CONN37 CONN38 CONN39 CONN40 CONN41 CONN42 Service Tool CONN43 CONN44 CONN45 CONN46 CONN47 CONN48 CONN49 CONN50a CONN50b CONN51 CONN52 CONN53 CONN54 CONN55 CONN56 CONN57 CONN58 CONN59 CONN60 CONN61 CONN62 CONN63 CONN64 CONN65 CONN66 CONN67 Schematic Location C-15 C-15 D-15 D-15 E-15 F-14 F-14 A-14 A-14 A-14 A-14 B-13 B-13 B-13 D-13 D-13 D-13 E-13 F-12 E-12 B-12 A-10 B-11 A-11 F-11 F-11 D-10 D-10 D-10 D-10 D-10 C-10 C-10 C-10 B-10 B-10 A-9 B-9 B-9 E-9 E-9 D-8 D-8 D-8 B-8 A-8 A-7 A-7 B-7 B-7 B-7 D-7 F-7 F-7 F-7 E-6 E-6 E-6 D-6 C-6 C-6 C-6 C-6 A-6 C-5 C-5 C-5 B-3 E-3 E-3 F-3 F-3 Machine Location 3 3 27 27 27 36 7 8 44 45 45 37 37 37 37 37 37 37 37 37 10 C C C 46 46 B B 39 39 39 21 33 33 21 C C C 38 B 39 39 39 39 38 C 30 31 10 38 38 17 17 20 20 17 17 17 17 17 17 17 17 40 40 40 40 43 17 42 17 17 ¹ The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Transmission Electronic Control Diagnostic Codes Code Flashed 11 12 CID - FMI Description N/A No diagnostics active N/A No logged diagnostic codes 21 641 F05 Transmission Solenoid A open circuit 22 642 F05 Transmission Solenoid B open circuit 23 643 F05 Transmission Solenoid C open circuit 24 644 F05 Transmission Solenoid D open circuit 25 645 F05 Transmission Solenoid E open circuit 26 646 F05 Transmission Solenoid F open circuit 27 647 F05 Transmission Solenoid G open circuit 28 648 F05 Transmission Solenoid H open circuit 31 641 F06 Transmission Solenoid A short to ground 32 642 F06 Transmission Solenoid B short to ground 33 643 F06 Transmission Solenoid C short to ground 34 644 F06 Transmission Solenoid D short to ground 35 645 F06 Transmission Solenoid E short to ground 36 646 F06 Transmission Solenoid F short to ground 37 647 F06 Transmission Solenoid G short to ground 38 648 F06 Transmission Solenoid H short to ground 41 641 F03 Transmission Solenoid A short to battery 42 642 F03 Transmission Solenoid B short to battery 43 643 F03 Transmission Solenoid C short to battery 44 644 F03 Transmission Solenoid 0 short to_battery 45 645 F03 Transmission Solenoid E short to battery 46 646 F03 Transmission Solenoid F short to battery 47 647 F03 Transmission Solenoid G short to battery 48 648 F03 Transmission Solenoid H short to battery 52 637 F06 Backup alarm short to ground 58 688 F06 VHP 1 solenoid short to ground 59 688 F03 VHP 1 solenoid short to battery 61 668 F02 Shift lever input invalid 62 668 F03 Shift lever open/short to ÷battery 63 269 F00 Sensor supply voltage above normal 64 269 F01 Sensor supply voltage below normal 65 701 F02 Transmission output speed signal incorrect 68 168 520 F01 System voltage below normal F02 Invalid transmission configuration code F02 Check programmable parameters 71 72 73 74 75 268 764 764 764 76 177 77 177 81 868 82 868 83 868 F05 Transmission indicator lamp open circuit F06 Transmission indicator lamp short to ground F03 Transmission indicator lamp short to battery oil temperature sender short to F03 Transmission battery or open circuit oil temperature switch short to F04 Transmission ground F05 Auto/Manual open circuit F06 Auto/Manual lamp short to ground F03 Auto/Manual lamp short to +battery ¹ VHP (Dual Horsepower) Wire Number Wire Color 101 RD 102 Wire Description Wire Number Wire Color Bat (+) 508 PU Radio Speaker - Left RD HdLmp 509 WH Radio Speaker - Left (Commom) 103 RD AuxCkt 511 BR Radio Speaker - Right 105 RD KeySw 512 GN Radio Speaker - Right (Common) 107 RD Eng Shutdown 513 OR A/C Compressor/Refrigerant Pressure SW 108 RD AuxCkt 515 GY Blower Motor (HI) 109 RD Alt Output (+) Term. 516 GN Blower Motor (Medium) 112 PU Main Power Rly Output 517 BU Blower Motor (Low) 113 OR Opr Mon Panel B+ Switched 521 YL A/C SW To Refrigerant SW 114 RD Warning Horn (Forward) 522 WH A/C Clutch To Thermostat SW 115 RD AuxCkt 537 GN Turn Signal SW To Flasher 116 BR AuxCkt 556 WH Differential Lock 118 GY AuxCkt 570 BU Blade Cushion Sol 119 PK AuxCkt 575 YL Wiper - Aux (Park) 122 BU Aux Ckt 576 PK Wiper - Aux (Low) 124 GN A/C 577 PU Wiper - Aux (HI) 126 PK Xmsn Ctrl 578 BU Washer - Aux 129 BU Aux Ckt 584 YL Wiper SW Jumper 130 RD AuxCkt 592 BU DC/DC Converter Power Output 134 RD AuxCkt 593 GN Condensor Fan Relay To Motors 135 BU Aux Ckt 597 PU A/C Ref rigerent Press SW 136 GN Suppl Ster A503 PK Front Defroster Fan (Low) 141 PK AuxCkt A504 GN Rear Defroster Fan (Low) 144 RD AuxCkt A506 OR Front Defroster Fan (HI) 147 RD AuxCkt A507 YL Rear Defroster Fan (HI) 149 PU Aux Ckt A513 PK 151 GN AuxCkt DC/DC Converter Memory Output Lighting Circuits 152 BU Aux Ckt 600 BR Dash Lamp Basic 158 BR AuxCkt 601 GY Dash Lamp Hi 160 PU AuxCkt 603 PK Rotary Beacon 165 YL Aux Ckt 604 OR Stop Lamp 169 PK Aux Ckt 605 YL Turn Lamp - Left 173 RD AuxCkt 606 GY Turn Lamp - Right 176 OR Aux Ckt Ground Circuits 608 GN Flood Lamp - Rear 609 YL Flood Lamp - Side Description Power Circuits 200 BK Main Chassis 611 PU Head Lamp Hi 201 BK Operator Monitor Return 614 PU Park/Tail/Dash/Lamp 202 BK XMSN Ctrl 619 GN Head Lamp Lo 276 BK XMSN Ctrl Ident Code 0 629 PK 277 BK XMSN Ctrl Ident Code 1 Aux Head Lamp Control Circuits 278 BK XMSN CtrI Ident Code 2 Basic Machine Circuits 710 GN XMSN Speed Pickup Signal 718 BU AWD Normal Mode 304 WH Starter Relay No. 1 Output 719 GY AWD Aggressive Mode 306 GN Starter Relay Coil 727 GN Secondary Ster Motor Relay 307 OR Key Switch 728 BU Secondary Ster Cont SW 308 YL Main Power Relay Coil 751 GN XMSN Shift Sol No. 1 Or 3 310 PU Engine Test SW To Start Aid Sol 752 YL XMSN Shift Sol No. 2 311 WH Start Aid Sol To Temp SW 754 BU XMSN Shift Sol No. 3 Or 1 321 BR Bckp Alarm 755 OR XMSN Shift Sol No. 4 Or 5 322 GY Warning Horn (Forward) 759 OR AWD Pump Press. 326 RD Key SW “C’ Term. 760 PK AWD Freewheel Sol 327 PK Shutdown Sol 795 YL Dual Hp Sol 334 BU Start Aid Sol #2 796 BR AWD Pump Displacement Forward 373 GN Start Aid Switch To Timer Monitoring Circuits 797 PU AWD Pump Displacement Reverse F769 BU AWD To Inch Pedal SW 403 GN Alternator (R) Term. F775 BU Centershift Solenoid 404 YL Opr Mon Hyd Oil Temp 823 GN AWD “Off” Mode 405 GY Opr Mon Oil Press. (Low Setting) 824 YL AWD Press. Sensor Sol 406 PU Opr Mon Coolant Temp 826 OR AWD Test SW 408 WH Opr Mon System Air Press. 878 OR Displacement Sol 409 OR Opr Mon Neut 892 BR CAT Data Link (-) 410 WH Opr Mon Fault Alarm 893 GN CAT Data Link (+) 411 PK Opr Mon Master F843 YL Inching Pedal 413 BR Opr Mon Fuel Press. 858 OR AWD Agressiveness Cont Lever 415 GN Opr Mon Test SW 900 PU XMSN Shift Sol No. 4 417 GY Primary Ster SW 901 WH XMSN Shift Sol No. 6 419 YL Opr Mon Parking Brake 902 BR XMSN Shift Sol No. 7 439 YL Lamp Indicator 903 GY XMSN Shift Sol No. 8 441 OR Eng Coolant Temp Gage 909 BU AWD Service Mode SW 447 PK Fuel Level Gage 911 YL AWD Mode SW Jumper 449 BU Trans Spd Sender 912 GY AWD Sol Return 450 YL Tach Sender (+) 921 WH XMSN Sol No 1 Or 3 Return 462 YL Secondary Ster Motor Indicator 977 YL CST Autoshift- Auto/Manual SW 1 467 WH System Fault (Xmsn) 989 YL AWD Charge Flow Dump Valve 482 WH AWd Hyd Oil Temp SW C913 BU AWD Ground Speed (Radar) 485 YL Opr Mon Panel AWD Fault E937 PU MG MESH CNTL - Redundant Neutral 486 PK AWD On/Off Lamp E938 OR MG MESH CNTL - First Gear 488 WH Brake Air Switches E939 WH MG MESH CNTL - Second Gear 498 WH Diff. Lock Indicator E940 BU MG MESH CNTL - Third Gear A429 YL Articulation Indicator E941 YL MG MESH CNTL - Fourth Gear G434 BU AWD Hydraulic Temp Sensor E942 GN MG MESH CNTL - Fifth Gear G460 GN Transmission Temperature SW Accessory Circuits E943 BR MG MESH CNTL - Sixth Gear E944 GY MG MESH CNTL - Seventh Gear 500 BR Wiper - Front (Park) E945 PU MG MESH CNTL - Eighth Gear 501 GN Wiper - Front (Low) E946 OR MG MESH CNTL - Forward Direct 502 OR Wiper - Front (HI) E947 WH MG MESH CNTL - Reverse Direct 503 BR Wiper - Rear (Park) E948 BU MG MESH CNTL - Park 504 YL Wiper - Rear (Low) E949 YL MG MESH CNTL - Neutral 505 BU Wiper - Rear (HI) E975 PU MESH Lamp 506 PU Washer - Front M917 PK TOS Sensor 507 WH Washer - Rear M918 GN TOS Sensor M998 OR Transmission Autoshift Mode CID No. Component Identifiers (CID¹) Module Identifier (MID²) Component All Wheel Drive ECM (MID No. 75) 084 Ground Speed Sensor (Radar) 168 Electrical System Voltage 190 Engine Speed Sensor 248 CAT Data Link 296 Transmission ECM 380 AWD Modulation Pressure Switch 390 Forward Pump Displacement Solenoid 391 Reverse Pump Displacement Solenoid 392 Charge Solenoid 393 Drive Solenoid 394 Motor Displacement Solenoid 395 Pump Pressure Solenoid 396 AWD Mode Lamp 397 Charge Pump Pressure 398 Pump Pressure Sensor 517 AWD Mode Switch 520 Transmission Configuration Code 600 Hydraulic Temperature Switch ¹ The CID is a diagnostic code that indicates which component is faulty. ² The MID is a diagnostic code that indicates which electronic control module diagnosed the fault. FMI No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 Component Description Accessory Circuits (Continued) Component Location Machine Location Component Schematic Location Machine Location Alarm - Action B-8 Alarm - Backup F-15 1 Alternator D-14 2 Batteries - 12 Volt C-14 5,6 Sender - Fuel Level A-13 25 Breaker - Alternator (60A) D-13 8 Senders - Trans. SPD (Speedometer) D-15 28 Breaker - Converter (25A) F-11 13 Sensor - AWD Control Lever D-7 B Breaker - Headlamp (15A) D-10 B Sensor - AWD Pump Pressure D-2 44 Breaker - Lightbar Low Beam (15A) D-10 B Sensor - Engine Speed B-14 26 Control - All Wheel Drive C-2 17 Sensor - Ground Speed (Radar) F-7 45 Control - Engine Shutdown E-13 9 Sensor - Trans. Oil Temp. E-15 27 Control - Neutral Start A-6 10 Solenoid - Air Conditioning Clutch A-13 22 Control - Secondary Steering E-13 9 Solenoid - AWD Displacement (Forward) C-15 3 Control - Transmission A-6 11 Solenoid - AWD Displacement (Reverse) B-15 3 Converter - 24V to 1 2V F-8 12 Solenoid - Centershift B-3 29 Converter - 24V to 12V F-10 12 Solenoid - Differential Unlock E-1 4 4 Converter - 24V to 1 2V F-12 13 Solenoid - Drive Pressure Flasher E-9 B Solenoid - Dual Horsepower/Shutdown A-13 22 Fuses B-5 C Solenoid - Forward Horn F-3 10 Fuses D-9 B Solenoid - Park Brake B-11 10 Fuses E-10 B Solenoid - Start Aid A-13 25 Gauge - L/S System Air Press. E-5 A Solenoids - Trans. Control Gauge - R/S System Air Press. E-5 A Suppressor - Arc (A/C Clutch) A-13 Gauge - Speedometer E-5 A Suppressor - Arc (Diff. Unlock) E-14 3 Gauge - Tachometer E-5 A Switch - A/C Refrigerant A-13 22 Gauge Cluster F-5 A Switch - Air Dryer F-14 31 Ground-Cab D-5 17 Switch - Autoshift A-9 C Ground - Engine C-13 22 Switch - AWD Mode B-8 C Ground - Frame (Front) D-6 39 Switch - Beacon B-5 C Ground - Frame (Rear) C-13 8 Switch - Beacon B-10 C Ground - Frame To Cab (Front) D-6 17 Switch - Blade Cushion B-8 C Ground - Localized Stud F-12 D Switch - Blower (A/C) B-10 C Ground - Strap C-12 23 Switch - Blower (Heater) A-10 C Lamp - AIH Indicator D-5 A Switch - Centershift Indicator B-3 29 Lamp - Centershift Pin E-5 A Switch - Centershift Pin B-9 C Lamp - Cold Temp. E-5 A Switch - Coolant A-14 24 Lamp - Diff. Unlock E-5 A Switch - Coolant Temp. B-14 24 Lamp - Hi Beam Indicator D-6 A Switch - Defrost (Front) A-5 C Lamp - Master Action E-5 A Switch - Defrost (Rear) B-5 C Lamp - Trans. A/M D-6 A Switch - Differential Unlock D-9 B Lamp - Turn Indicator (Left) E-5 A Switch - Disconnect Lamp - Turn Indicator (Right) E-4 A Switch - EMS Test (Start Aid) Meter - Service E-10 B Monitor - Electronic Monitoring System C E-9 Resistor - Panel Lamp Dimmer Sender - Articulation C-12 23 Sender - Coolant Temp. B-14 24 RENR1423-01 September 1997 B D-2 D-15, E-15 27 22 C-14 6 E-10, E-8 B Switch - Engine Oil C-13 32 143H & 163H Motor Grader (NA Version) Electrical System 143H: 1AL408-UP Related Electrical Service Manuals Title 163H: 5AK156-UP E-6 A Switch - Flood Lamp D-8 B A-12 15 Switch - Fuel B-13 34 Motor - Blower (A/C) B-10 14 Switch - Headlamp/Tail E-8 B Motor - Blower (Defrost) E-4 15 Switch - Headlight Dimmer D-9 B Motor - Blower (Heater) A10 E Switch - Horn E-9 B Motor - Secondary Steering F-13 20 Switch - Inching Pedal (AWD) C-15 3 Motor - Starter C-13 19 Switch - Inching Pedal (Transmission) C-1 5 3 Motor - Washer (Front Lower) F-6 16 Switch - Key Start B-9 C Motor - Washer (Front Upper) F-6 16 Switch - Light Bar Low Beam E-8 B Motor - Washer (Rear) F-6 16 Switch - Panel Lamp Dimmer E-9 B Motor - Wiper (Front Lower) C-4 17 Switch - Parking Brake Press. B-11 34 Motor - Wiper (Front Upper) D-4 17 Switch - Primary Steering F-10 35 Motor - Wiper (Rear) A-11 18 Switch - Secondary Steering Test B-8 C Motor - Condenser B-10 21 Switch Service Clear (Front Loc) B-2 44 Power Port - (12V) F-1 2 41 Switch Service Clear (Rear Loc) B-2 44 Relay-Condenser C-10 21 Switch - Stop Lamp A-2 11 Relay-Main D-14 8 Switch-Tail Lamp D-8 B Relay - Secondary Steering F-13 22 Switch-Thermostat B-11 E Relay - Start D-13 8 Switch - Turn Signal E-9 B Resistor - Blower Motor A-12 E Switch - Wiper (Front Upper) B-4 C Resistor - Blower Switch (A/C) B-1 E Switch - Wiper (Rear) A-4 C Resistor - Blower Switch (Heater) A-11 E Switch - Wipper (Front Lower) A-4 C Part No. Resistor - Defrost Motor E-4 E Switches - Brake Air A-2 11 3E-1906 Solenoid - A/C Clutch 3E-5383 Sender - Articulation Position 3E-6424 Solenoid - Dual Horsepower/Shutdown 3T-3123 Resistor - Dimmer Switch 25.0 ± .3 6T-5859 Solenoid - Freewheel Motor Displacement System Charge 33.7 ± 1.0 7N-8532 Sender - Coolant Temperature 7T-4003 Resistor - Defroster Blower Motor Defroster Blower Motor 10.0 ± 0.5 7T-6517 Solenoids - Blade Cushion 20.1 ± 1.0 7T-9074 Solenoid - Forward HornPark Brake 55.2 ± 5.8 8T-8808 Solenoid - Centershift 34.3 ± 1.7 9G-1950 Resistor - A/C Blower Motor Heater Blower Motor 9G-4365 Solenoid - Start Aid 9W-2739 Solenoids - Transmission 104-6387 Sender - Transmission Speed 134-2845 Sender - AWD Hydraulic Temperature 136-1678 Solenoid - Injector (Trans) 140-7722 Sender - Fuel Level 144-6295 Solenoid - Differential Unlock 36 27 1 28 31 4 3 26 32 45 7 25 44 2 8 19 16 1213 41 2046 D 42 1435 6 9 21 14 D 18 13 E 45 1 36 7 44 25 1926 2 27 31 28 8 3 4 9 24 32 22 37 5 6 33 40 46 39 41 B C 42 16 38 39 11 12 35 10 23 20 34 43 A 17 Resistor, Sender and Solenoid Specifications Component Description Part No. 43 30 29 E08087 Machine Harness Connector and Component Locations SENR4130 SENR2082 Electronic Monitoring System Starting Motor: 106-8555 Consist No. 6V-5023 Consist No. 6V-5207 Consist No. 6V-5226 SENR2945 SENR3536 SENR3581 SENR4975 Transmission Electronic Control SENR9167 Printed in U.S.A. Electrical Schematic Symbols And Definitions Resistance (Ohms)¹ 17.6 ± 0.6 6.0 ± 3 MIN 92 ± 5 MAX 4.2 ± 0.4 16.1 ± 1.6 T Pressure Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. 560- 716 @ 54°C (1 30°F) 72-82@ 110°C(230°F) This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Overall 2.0 ± .1; Tap 1.0 ± .05 6 Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. 31 ± 3.0 1000 - 1200 Function T 158-202 @ 54°C (129.2 °F) 63-79 @82°C (179.6 °F) Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. 31 ± 3 92 - 98 @ Empty7 - 12 @ Full Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. 33.6 ± 1.0 Off Machine Switch Specification 3E-2028 Coolant Temp (EMS Warning) 3E-2033 Brake Air Pressure Park Brake Air Pressure 3E-6425 Start Aid Coolant Temperature 3E-7811 Inching Pedal Pressure (AWO) 3T-0190 AWD - Hydraulic Oil Temperature (EMS) 8T-8640 Primary Steering Pressure 9X-0378 Engine Oil Pressure 107-0616 Fuel Pressure 111-7088 Inching Pedal Pressure (Transmission) 114-5334 A/C Refrigerant Pressure 125-9352 Stop Lamp Pressure Actuate 107 ± 3°C (225 ± 5°F) 640 kPa (92.0 psi) 37.8 ± 2.8°C (100 ± 5°F) 160 ± 20 kPa (23.2 ± 2.9 psi) 87.78 ± 2.8°C (190 ± 5°F) 1206 kPa MAX (175 psi MAX) 62.0 kPa MAX (9.0 psi MAX) 93 ± 21 kPa (13.5 ± 3.0 psi) 75 kPa (10.9 psi) 275 to 1750 kPa ¹ (40 to 255 psi) 83 kPa MAX (12 psi MAX) Deactuate 93.0°C MIN (200°F MIN) 530 ± 40 kPa (77.0 ± 6.0 psi) 26.7°C MIN (80°F MIN) 120 kPa (17.4 psi) 79.44°C MIN (1 75°F MIN) 700 ± 103 kPa (100 ± 15 psi) 38.0 ± 20.0 kPa (5.5 ± 3.0 psi) 69 ± 21 kPa (10.0 ± 3.0 psi) 50 kPa (7.3 psi) — — 48 ± 20 kPa MIN (7 ± 3 psi MIN) Harness And Wire Symbols Contact Position Normally Closed Normally Open Pin Socket Wire Color A A-B, Normally Open A-C, Normally Closed Single Wire Connector Circuit Number Identification Normally Open Plug Normally Open ² Normally Open ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure pressure the closed condition can be maintained down to 170 kPa (25 psi). ² Contact position at the contacts of the harness connector. 105-9344 Receptacle 2 200-BK-14 Pin or Socket Number Normally Closed Normally Open AA Wire Gauge Ground Connection Fuse 1 325-PK-14 Normally Open Component Part Number Wire, Cable, or Harness Assembly Identification Normally Closed Normally Closed Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol ¹ At room temperature unless otherwise noted. 15 SENR6983 © 1997 Caterpillar All Rights Reserved 15 E B A 17 30 29 24 21 18 22 37 3323 34 11 5 10 C 38 40 Form Number All Wheel Drive Electronic Control Alternator: 100-5047 Consist No. 100-5045 Consist No. 100-5046 (EMS) Motor - Blower Failure Mode Identifiers (FMI) Failure Description Data valid but above normal operational range. Data valid but below normal operational range. Data erratic, intermittent, or incorrect. Voltage above normal or shorted high. Voltage below normal or shorted low. Current below normal or open circuit. Current above normal or grounded circuit. Mechanical system not responding properly. Abnormal frequency, pulse width, or period. Abnormal update. Abnormal rate of change. Failure mode not identifiable. Bad device or component. Out of calibration. Schematic Location 1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.
Wire Number Wire Description Wire Color Wire Number Description Wire Color Description Power Distribution Circuits 101 Diagnostic Code Conversion Code Flashed CID - FMI 11 N/A No diagnostics active 12 N/A No logged diagnostic codes 1 21-28 641-648F05 Transmission Solenoid open circuit 31-38 641-648F06 Transmission Solenoid1 short to ground 1 41-48 1 Description 641-648F03 Transmission Solenoid short to battery RD Bat (+) 500 BR Schematic Location Component Accessory Circuits Component Location Machine Location Component Wiper - Front (Park) Alarm - Action B-B C Resistor - Panel Lamp Dimmer F-15 1 Sender - Articulation Schematic Location Machine Location E-9 B C-12 23 102 BU Hd Lmp 501 GN Wiper - Front (Low) Alarm - Backup 103 YL Aux Ckt 502 OR Wiper - Front (HI) Alternator (35A STD) D-14 2 Sender- Engine Coolant Temp A-14 24 105 BR Key Sw 503 BR Wiper - Rear (Park) Arc - Suppressor E-14 3 Sender - Fuel Level A-13 25 107 WH Eng Shut 504 YL Wiper - Rear (Low) Battery C-14 5,6 Sensor-Engine Speed B-14 26 108 BU Aux Ckt 505 BU Wiper - Rear (HI) Beacon C-10 7 Sensor - Transmission Oil Temp E-15 27 109 OR Alt Output (+) Term. 506 PU Washer - Front Beacon A-12 7 Sensor - Transmission Speed D-15 28 112 PU Main Power Rly Output 507 WH Washer - Rear Breaker - Alternator (35A) D-13 8 Solenoid - A/C Clutch A-13 22 113 OR Opr Mon Panel B+ Switched 508 PU Radio Speaker - Left Breaker - Convertor (15A) F-11 13 Solenoid - Centershift B-3 29 114 GN Warning Horn (Forward) 509 WH Radio Speaker - Left (Commom) Breaker - Headlamp (15A) D-10 B Solenoid - Differential Unlock E-14 4 115 PK Aux Ckt 511 BR Radio Speaker - Right 116 BR Aux Ckt 512 GN Radio Speaker - Right (Common) Breaker - Lightbar (15A) D-10 B Solenoid - Dual Horsepower A-13 22 118 GY Aux Ckt 513 OR A/C Compressor/Refrigerant Pressure SW 119 PK Aux Ckt 515 GY Blower Motor (HI) Control - AIH Timer D-8 B Solenoid - Dual HP/Shutdown A-12 22 E-13 9 Solenoid - Engine Shutdown D-13 22 Control - Neutral Start A-6 10 Solenoid - Forward Horn F-3 10 Control - Supplement Steer E-13 9 Solenoid - Park Brake B-11 10 Control - Transmission A-7 11 Solenoid - Start Aid A-13 25 Converter - Voltage F-8, F-10 12 Solenoids - Blade Cushion E-2 30 Converter - Voltage F-12 13 Solenoids - Transmission Valve (8) D-15, E-15 27 Flasher E-10 B Switch - A/C Refrigeration A-13 22 Fuses D-9 B Switch - Air Dryer F-14 31 Fuses E-10 B Switch - Autoshift A-9 C Fuses (10A) B-5 C Switch - Beacon B-5 C Control - Engine Shutdown 52 637 F06 Backup alarm short to ground 122 BU Aux Ckt 516 GN Blower Motor (Medium) 58 688 F06 VHP solenoid short to ground 124 GN A/C 517 BU Blower Motor (Low) 59 688 F03 VHP solenoid short to battery 126 PK Xmsn Ctrl 521 YL A/C SW To Refrigerant SW 61 688 F02 Shift lever input invalid 129 BU Aux Ckt 522 WH A/C Clutch To Thermostat SW 62 688 F03 Shift lever open circuit/short to +battery 130 GN Aux Ckt 537 GN Turn Signal SW To Flasher 63 269 F00 Sensor supply voltage above normal 134 YL Aux Ckt 556 WH Differential Lock 64 269 F01 Sensor supply voltage below normal 135 BU Aux Ckt 570 BU Blade Cushion Sol 65 701F02 Transmission Output Speed Signal (TOS) incorrect 136 GN Suppl Ster 575 YL Wiper - Aux (Park) 68 168 F01 System voltage below normal 141 PK Aux Ckt 576 PK Wiper - Aux (Low) 577 PU Wiper - Aux (HI) A Switch - Beacon B-10 C Invalid transmission configuration code Aux Ckt F-5 520 F02 GN Gauge - Articulation 71 144 578 BU Washer - Aux A Switch - Blower (A/C) B-10 C Check programmable parameters Aux Ckt F-5 268 F02 PU Gauge - Engine Coolant Temperature 72 147 149 PU Aux Ckt 584 YL Wiper SW Jumper Gauge - Fuel Level E-5 A Switch - Blower (Heater) A-10 C 73 764 F05 Transmission indicator lamp open circuit 151 GN Aux Ckt 592 BU DC/DC Converter Power Output Gauge - Speedometer F-5 A Switch - Brake Air Pressure A-2 11 74 764 F06 Transmission indicator lamp short to ground 152 BU Aux Ckt 593 GN Condensor Fan Relay To Motors Gauge - System Air Pressure (Left) E-5 A Switch - Brake Air Pressure A-2 11 75 764 F03 158 BR Aux Ckt 597 PU A/C HI Press. Coutout SW To Low Press. SW Gauge - System Air Pressure (Right) E-5 A Switch - Centershift Indicator B-3 29 160 PU Aux Ckt A503 PK Front Defroster Fan (Low) Gauge - Tachometer E-5 A Switch - Centershift Pin B-9 C 165 YL Aux Ckt A504 GN Rear Defroster Fan (Low) Lamp - AIH Indicator D-5 A Switch - Cushion Blade B-9 C 169 PK Aux Ckt A506 OR Front Defroster Fan (HI) Lamp - C Shift Pin E-5 A Switch - Defroster (Front) A-5 C 76 177 F03 Transmission indicator lamp short to +battery Transmission oil temperature sender short to +battery or open circuit 77 177 F04 Transmission oil temperature sender short to ground 81 868 F05 Auto/Manual lamp open circuit 173 YL Aux Ckt A507 YL Rear Defroster Fan (HI) 82 868 F06 Auto/Manual lamp short to ground Lamp - Cold Temperature E-5 A Switch - Defroster (Rear) B-5 C 176 OR Aux Ckt A513 PK DC/DC Converter Memory Output Lamp - Diff Unlock E-5 A Switch - Differential Unlock D-9 B Lamp - High Beam Indicator D-6 A Switch - Disconnect C-14 6 200 BK Main Chassis 600 BR Dash Lamp Basic 201 BK Operator Monitor Return 601 GY Dash Lamp Hi Lamp - Master Action E-5 A Switch - Engine Coolant Temp (Monitor) B-14 24 202 BK XMSN Ctrl 603 PK Rotary Beacon Lamp - Transmission A/M D-6 A Switch - Engine Coolant Temp (Start Aid) A-14 24 276 BK XMSN Ctrl Ident Code 0 604 OR Stop Lamp Lamp - Turn Indicator (Left) E-5 A Switch - Engine Oil Pressure C-13 32 277 BK XMSN CtrI Ident Code 1 605 YL Turn Lamp - Left Lamp - Turn Indicator (Right) E-4 A Switch - Flood Lamps D-8 B 278 BK XMSN Ctrl Ident Code 2 606 GY Turn Lamp - Right E-10 B Switch - Forward Horn E-9 B 608 GN Flood Lamp - Rear E-6 A Switch - Fuel Pressure B-13 24 301 BU Starter No. 1 Sol 609 YL Flood Lamp - Side Motor - Blower A-12 15 Switch - Head/Tail Lamp E-8 B 304 WH Starter Relay No. 1 Output 611 PU Head Lamp Hi Motor - Blower (A/C group) B-10 14 Switch - Headlamp Dimmer D-9 B 306 GN Starter Relay Coil To Neut Start SW Or Key SW 614 PU Park/Tail/Dash/Lamp Motor - Blower (Heater group) A-10 E Switch - Hydraulic Oil Temperature B-11 33 307 OR Key SW To Neut Start SW 619 GN Head Lamp Lo Motor - Blower/Defroster E-4 15 Switch - Inching Pedal Pressure C-15 27 308 YL Main Power Relay Coil 629 PK Aux Head Lamp Motor - Starter C-13 19 Switch - Key Start B-9 C 310 PU Start Aid SW To Start Aid Sol Motor - Supplemental Steer F-13 20 Switch - Light Bar Low Beam E-8 B 311 WH Start Aid Sol To Temp SW Suppl Ster Motor Relay Motor - Washer (Front Lower) F-6 16 Switch - Monitor (EMS) Test E-8 B Suppl Ster Cont SW Motor - Washer (Front Upper) F-6 16 Switch - Panel Lamp Dimmer E-9 B F-6 i6 Switch - Park Brake Pressure B-11 34 35 83 868 F03 Auto/Manual lamp short to +battery The last digit in the CID number identifies the solenoid. Solenoid 1 is Solenoid A, Solenoid 2 is Solenoid B, ect. Ground Circuits Lighting Circuits Basic Machine Circuits 321 BR 727 Bckp Alarm Lamp Travel Alarm GN 728 BU 322 GY Warning Horn (Forward) 751 GN XMSN Shift Sot No. 1 Or 3 Motor - Washer (Rear) 326 PU Key SW “C” Term. 752 YL XMSN Shift Sot No. 2 Motor - Wiper (Front Lower) C-4 17 Switch - Primary Steer F-10 327 PK Shutdown Sol 754 BU XMSN Shift Sol No. 3 Or 1 Motor - Wiper (Front Upper) D-4 17 Switch - Start Aid/Monitor Test E-10 B 334 BU Start Aid Sot #2 755 OR XMSN Shift Sol No. 4 Or 5 Motor - Wiper (Rear) B-11 18 Switch - Stoplamp Pressure A-2 11 373 GN Start Aid Switch To Timer C 403 1 795 YL Dual Hp Sol Motors - Condenser B-11 21 Switch - Supplemental Steer Test B-B F769 BU AWD To Inch Pedal SW Relay-Condenser C-10 21 Switch-Tail Lamp D-B B F775 BU Centershift Solenoid Relay - Main D-14 8 Switch - Transmission Direction & Speed A-B C GN Alternator (R) Term. 404 YL Opr Mon Hyd Oil Temp 892 BR Start Mod Right (-) Port/CAT Data Link (-) Relay - Start D-13 8 Switch - Turn Signal D-9 B 405 GY Opr Mon Oil Press. (Low Setting) 893 GN Start Mod Right (+) Port/CAT Data Link (+) Relay - Supplemental Steer F-13 22 Switch - Wiper (Front Lower) A-4 C 406 PU Opr Mon Coolant Temp F843 YL Inching Pedal Resistor - Blower Speed A-11 E Switch - Wiper (Front Upper) B-4 C 408 WH Opr Mon System Air Press. G858 OR AWD Agressiveness Cont Lever 409 OR Opr Mon Neut 900 PU XMSN Shift Sol No. 4 Resistor - Blower Speed E-4 E Switch - Wiper (Rear) A-4 C 410 WH Opr Mon Fault Alarm 901 WH XMSN Shift Sol No. 6 Resistor - Blower Speed (A/C) B-11 15 Thermostat (A/C) B-11 E Resistor - Blower Speed (Heater) A-11 E 411 PK Opr Mon Master 902 BR XMSN Shift Sol No. 7 413 BR Opr Mon Fuel Press. 903 GY XMSN Shift Sol No. 8 415 GN Opr Mon Test SW 921 WH XMSN Sol No 1 Or 3 Return 417 GY Primary Ster SW 977 YL CST Autoshift- Auto/Manual SW 1 419 YL Opr Mon Parking Brake E937 PU MG MESH CNTL - Redundant Neutral 439 YL Lamp Indicator E938 OR MG MESH CNTL - First Gear OR Eng Coolant Temp Gage E939 WH MG MESH CNTL - Second Gear Schematic Location Machine Location 441 447 PK Fuel Level Gage E940 BU MG MESH CNTL - Third Gear CONN 1 B-15 27 2 449 BU Spdom Sender (Signal No. 1) E941 YL MG MESH CNTL - Fourth Gear CONN 2 C-15 27 3 450 YL Tach Sender (+) E942 GN MG MESH CNTL - Fifth Gear CONN 3 D-15 27 462 YL Suppl Ster Motor Indicator E943 BR MG MESH CNTL - Sixth Gear CONN 4 D-15 27 467 WH System Fault (Xmsn) E944 GY MG MESH CNTL - Seventh Gear CONN 5 E-15 27 485 YL Opr Mon Panel AWD Fault E945 PU MG MESH CNTL - Eighth Gear CONN 6 F-14 36 488 WH Afr SW To Air SW Jumper E946 OR MG MESH CNTL - Forward Direct CONN 7 A-13 37 498 WH Diff. Lock Indicator E947 WH MG MESH CNTL - Reverse Direct CONN 8 B-13 37 A429 YL Articulation Indicator E948 BU MG MESH CNTL - Park CONN 9 B-13 37 CONN 10 D-13 37 G434 BU AWD Hydraulic Temp Sensor (was B426) E949 YL MG MESH CNTL - Neutral CONN 11 D-13 37 G460 GN Transmission Temperature SW E975 PU MESH Lamp CONN 12 B-12 10 M917 PK TOS Sensor + M918 GN TOS Sensor - CONN 13 E-12 37 M998 OR Transmission Autoshift Mode CONN 14 E-12 37 CONN 15 A-10 38 CONN 16 C-10 33 CONN 17 D-10 39 CONN 18 D-10 39 CONN 19 D-10 39 CONN 2O A-9 C CONN 21 B-9 38 CONN 22 B-9 38 CONN 23 E-9 39 CONN 24 Service Tool A-8 C CONN 25 B-8 38 CONN 26 D-6 39 CONN 27 D-6 39 CONN 28 D-6 39 CONN 29 D-6 39 CONN 30 A-7 Connector Number SENR2082 Electronic Monitoring System SENR2945 30 Electronic Transmission Shift Control SENR9167 Starting And Charging Systems Starting Motor: (106-8555) Consist No. 6V-5207 Consist No. 6V-5023 Consist No. 6V-5226 SENR2947 CONN 32 B-7 10 CONN 33 B-7 38 CONN 34 B-7 38 CONN 35 F-7 20 CONN 36 F-7 20 CONN 37 A-6 40 CONN 38 C-6 17 CONN 39 C-6 17 CONN 40 C-6 17 CONN 41 D-6 17 CONN 42 E-6 17 CONN 43 E-6 17 CONN 44 E-6 17 CONN 45 C-5 40 CONN 46 C-5 40 CONN 47 C-5 40 CONN 48 F-3 17 CONN 49 F-3 17 CONN 50 C-6 17 1 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component 2 Location Chart. 120 ES machine ONLY. 3 143 and 163 series machines ONLY. E = Operator’s compartment (Under seat). 27 4 3 26 32 1 28 8 24 22 19 37 39 E 21 B 18 7 33 23 15 D 14 35 9 25 20 13 12 6 31 10 Data erratic, intermittent, or incorrect. 3 Voltage above normal or shorted high. 4 Voltage below normal or shorted low. 5 Current below normal or open circuit. 6 Current above normal or grounded circuit. 7 Mechanical system not responding properly. 8 Abnormal frequency, pulse width, or period. 9 Abnormal update. 10 Abnormal rate of change. 11 Failure mode not identifiable. 12 Bad device or component. 13 Out of calibration. ¹The FMI is a diagnostic code that indicates what type of failure has occurred. 3E-2033 Brake/Park Brake Air Pressure 8C-3569 Coolant Temperature (Start Aid) 8T-8640 Steering Press 9X-0378 Engine Oil Pressure A 111-7088 Inching Pedal Pressure 114-5334 Refrigerant Pressure (A/C) 125-9352 Stop Lamp Pressure 93.00 °C (199.4 °F) 530 ± 40 kPa (77.0 ± 6.0 psi) 27°C MIN (80.6°F MIN) 700 ± 103 kPa (101.5 ± 15 psi) 38 ±20 kPa (5.5 ± 3.0 psi) 69 ± 21 kPa (10.0 ± 3.0 psi) 50.0 kPa MIN (7.3 psi MIN) 48 ± 20 kPa MIN (7 ± 3 psi MIN) Contact Position Normally Closed T Normally Open Pressure Symbol Normally Closed 1-2 NO 1-3 NC C Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally Open Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. Normally Closed Normally Open Normally Open ² This indicates that the component has a wire connected to it that is connected to ground. Normally Open This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 11 38 Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. 40 14 13 B 15 9G-1950 A 7N-8532 3E-1906 7T-6517 8T-8808 111-0570 7T-9073 Resistor - Blower Speed Senders: Engine Coolant Temp Converter Temp Solenoid - A/C Clutch Solenoid - Blade Cushion Solenoid - Centershift Solenoid - Dual HP Solenoid - Differential Unlock 3E-6424 Solenoid - Dual HP Push Coil- Pull Coil 3E7985 7T-9074 9G-4365 9W-2739 Solenoid - Engine Shutdown Start (Latch) CoilStop (Unlatch) Coil Solenoid - Forward Horn/ParkBrake Solenoid - Start Aid Solenoid - Transmission 9 24 2 1 36 19 26 32 22 8 3 27 31 28 5 6 C 37 12 16 38 35 30 29 11 39 10 23 4 17 33 34 Component Description Resistor - Panel Dimmer Resistor - Power 40 D Resistor, Sender and Solenoid Specifications 3T-3123 7T-4003 7 E 25 Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol 17 30 29 Part No. Failure Description 2 Engine Coolant Temperature Deactuate T Failure Mode Identifiers (FMI)¹ Data valid but below normal operational range. 8T-9793 Actuate 107.0 ± 3.0°C (224.6 ± 5.4 °F) 640 kPa MAX (92.0 psi MAX) 38±3°C (100.4° ± 5.4°F) 1206 kPa MAX (175 psi MAX) 62.0 kPa MAX (9.0 psi MAX) 93 ± 21 kPa (13.5 ± 3.0 psi) 75.0 kPa MAX (10.9 psi MAX) 275to1750kPa ¹ (40 to 255 psi) 83kPa MAX (12 psi MAX) 102±3°C (215.6 ± 5°F) Electrical Schematic Symbols And Definitions 34 5 18 1 Function Off Machine Switch Specification 131-41 35 Hydrualic Oil Temperature 90°C(194.0 °F) Normally Closed ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25psi). ² Contact postion at the contacts of the harness connector. SENR3581 SENR3536 SENR4975 Data valid but above normal operational range. Printed in U.S.A. © 1997 Caterpillar All Rights Reserved 115-71 03 Fuel Pressure (EMS) 2 0 135H: 3YK267-UP Part No. 21 FMI No. 120H: 4MK404-UP 2AN104-UP C = Operator’s compartment (Right side console). Form Number Alternator (100-5047 50A): ATT 31 D = Operator’s compartment (Headliner). B = Operator’s compartment (Steering console). Related Electrical Service Manuals SENR4978 SENR2082 SENR4130 A-7 A = Operator’s compartment (Dash). 36 Title 120H, 135H, Motor Grader (NA Version) 120H Motor Grader (Australian Version) Electrical System Machine locations are repeated for components located close together. 16 Alternator (6N-9294 35A): STD Consist No. 3T-6352 Consist No. 7N-9720 Consist No. 9G-4574 CONN 31 Monitor - Electronic Monitoring System (EMS) Control Circuits Monitoring Circuits Connector Location Meter - Service RENR1424 June 1997 20 Machine Harness Connector And Component Locations Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Resistance (Ohms)¹ 25.0 ± .3 10.0± 0.5 Overall 2.00 ± .10 Tap 1.00 ± .05 54°C (130°F) - 560 to 716 110°C (230°F) - 72 to 82 17.6 ± 0.6 20.1 ± 1.0 34.3 ± 1.7 31.1 ± 2.4 33.6 ± 1.0 4.2 ± 0.42 16.1 ± 1.61 1.55 ± 0.15 10.3 ± 1.03 55.17 ± 5.77 6.0 31 ± 3 Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols Pin Socket Wire Color A Circuit Number Identification 105-9344 Receptacle Wire Gauge Ground Connection Fuse AA 1 325-PK-14 Single Wire Connector Component Part Number Wire, Cable, or Harness Assembly Identification Plug 2 200-BK-14 Pin or Socket Number ¹ At room temperature 1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.
Component Location Connector Location¹ Schematic Location E-15 D-15 C-15 A-14 A-14 A-14 A-14 B-3 F-14 F-14 B-13 B-13 B-13 D-13 D-13 D-13 E-13 B-12 F-12 A-9 E-12 A-7 A-7 E-6 B-3 F-12 A-1 B-11 A-11 F-11 F-3 C-10 E-3 D-11 D-11 D-11 D-11 D-10 B-9 B-9 E-9 E-9 B-7 B-8 E-3 D-8 D-8 D-8 B-7 B-7 A-8 E-2 A-6 C-5 C-6 C-6 D-6 D-6 D-6 D-6 D-6 C-5 C-5 Connector Number CONN 1 CONN 2 CONN 3 CONN 4 CONN 5 CONN 6a CONN 6b CONN 7 CONN 8 CONN 9 CONN 10 CONN 11 CONN 12 CONN 13 CONN 14 CONN 15 CONN 16 CONN 17 CONN 18 CONN 19 CONN 20 CONN 21 CONN 22 CONN 23 CONN 24 CONN 25 CONN 26a CONN 26b CONN 26c CONN 27 CONN 28 CONN 29 CONN 30 CONN 31 CONN 32 CONN 33 CONN 34 CONN 35 CONN 36 CONN 37 CONN 38 CONN 39 CONN 40 CONN 41 CONN 42 CONN 43 CONN 44 CONN 45 CONN 46 CONN 47 CONN 48 Service Tool CONN 49 CONN 50 CONN 51 CONN 52 CONN 53 CONN 54 CONN 55 CONN 56 CONN 57 CONN 58 CONN 59 CONN 60 Machine Location 31 31 31 41 27 8 8 46 36 42 37 37 37 22 37 37 3 10 43 C 43 30 31 17 21 37 38 38 38 44 17 33 47 39 39 39 B B 38 38 39 39 10 38 47 39 39 39 38 38 C 30 40 40 17 17 17 17 17 17 17 40 40 Air Dryer Alarm - Action Alarm - Backup Alternator Battery Breaker - Alternator Breaker - Cab Flood Lamp Breaker - Converter Breaker - Headlamp and Right Tail/Pos Breaker - Left Tail Lamp Buss Bar Control - Neutral Start Control - Secondary Steer Control - Transmission Converter - Voltage Converter - Voltage Converter - Voltage Electronic Monitoring System(EMS) Flasher Fuses Fuses Fuses Gauge - Articulation Gauge - Coolant Temperature Gauge - Fuel Level Ground - Cab Frame to Front Frame Ground - Front Frame 18 36 6 31 27 42 4 3 26 32 1 25 41 2 8 19 28 22 20 15 47 D 44 14 35 43 39 E B A 17 30 29 16 1213 9 24 37 5 33 34 23 11 10 C 38 40 21 46 Ground Strap - Rear Frame to Front Frame 14 16 13 D 44 E 27 42 41 25 2 1 36 31 9 19 2632 8 3 4 28 24 22 37 5 6 33 40 15 B C A 17 47 18 38 39 46 12 35 11 43 10 23 20 34 21 30 29 E38888 Machine Harness Connector and Component Locations Wire Description Title Form No. Alternator: 6N-9294 (35A) Consist: Alternator: 9G-4547 SENR4130 100-5047 (50A) Consist: 100-5046 SENR2082 Consist: 100-5045 SENR4130 Electronic Monitoring System SENR2945 Transmission Electronic Control SENR9167 Starting Motor: 106-8558 Consist: 106-8557 SENR3559 Consist: 106-8559 SENR3581 Wire Number Wire Color 101 102 105 107 108 109 112 113 114 115 116 118 119 122 124 126 129 130 134 135 136 141 144 147 149 151 152 160 165 169 173 176 RD RD RD RD RD RD PU OR RD RD BR GY PK BU GN PK BU RD RD RD GN PK RD RD PU ON BU PU YL PK RD OR 200 201 202 276 277 278 BK BK BK BK BK BK 301 304 306 307 308 310 311 321 322 326 327 334 373 BU WH GN OR YL PU WH BR GY RD PK BU ON 403 404 405 406 408 409 410 P411 413 415 417 419 439 441 447 449 450 462 467 488 498 A429 G460 GN YL GY PU WH OR WH PK BR ON GY YL YL OR PK BU YL YL WH WH WH YL GN 500 501 502 503 504 505 BR GN OR BR YL BU Description Power Circuits Bat (+) Hd Lmp Key SW Eng Shut Aux Ckt Alt Output (+) Term. Main Power Rly Output Opt Mon Panel B+ Switched Warning Horn (Forward) Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt A/C Xmsn Ctrl Aux Ckt Aux Ckt Aux Ckt Aux Ckt Sec Ster Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Ground Circuits Main Chassis Operator Monitor Return XMSN Ctrl XMSN Ctrl ldent Code 0 XMSN Ctrl Ident Code 1 XMSN Ctrl Ident Code 2 Basic Machine Circuits Starter Sol Starter Relay No. 1 Output Starter Relay Coil To Neut Start SW Or Key SW Key SW To Neut Start SW Main Power Relay Coil Start Aid SW To Start Aid Sol Start Aid Sol To Temp SW Bckp Alarm Lamp Travel Alarm Warning Horn (Forward) Key SW “C” Term. Shutdown Solenoid Start Aid Sol #2 Start Aid Switch To Timer Monitoring Circuits Alternator (A) Term. Opr Mon Hyd Oil Temp Opr Mon Oil Press. (Low Setting) Opr Mon Coolant Temp Opr Mon System Air Press. Opr Mon Neut Opr Mon Fault Alarm Opr Mon Master Opr Mon Fuel Press. Opr Mon Test SW Primary Ster SW Opr Mon Parking Brake Lamp Indicator Eng Coolant Temp Gage Fuel Level Gage Spdom Sender (Signal No. 1) Tach Sender (+) Sec Ster Motor Indicator System Fault (Xmsn) Air SW To Air SW Jumper Diff Lock Indicator Articulation Indicator Transmission Temperature SW Accessory Circuits Wiper - Front (Park) Wiper - Front (Low) Wiper - Front (HI) Wiper - Rear (Park) Wiper - Rear (Low) Wiper - Rear (HI) Heater - Air Intake Meter - Service Motor - Blower (A/C group) Motor - Blower (Heater group) Motor - Defroster Motor - Secondary Steer Motor - Starter Motor - Washer (Front Lower) Motor - Washer (Front Upper) Motor - Washer (Rear) Motor - Wiper (Front Lower) Motor - Wiper (Front Upper) Motor - Wiper (Rear) Relay-AIH Relay - Cab Flood Lamp Relay - Flood/Tail Lamp Relay - Left Tail Lamp Relay - Main Relay - Right Tail Lamp Relay - Secondary Steer Relay - Start Resistor - Blower Speed Resistor - Blower Speed (A/C) Resistor - Blower Speed (Heater) Resistor - Panel Lamp Dimmer Sender - Articulation Sender-Coolant Temp Machine Location F-14 B-8 F-15 D-14 C-14 D-13 D-10 F-11 D-11 D-10 C-13 A-6 E-13 A-6 F-8 F-10 F-12 E-6 E-10 B-5 D-10 E-10 F-5 F-5 E-5 D-6 D-6 C-12 A-15 D-10 B-10 A-10 A-12,E-4 F-13 C-13 F-6 F-6 F-5 C-4 D-4 A-11 A-15 E-10 E-10 E-10 D-14 E-10 F-13 D-13 A-11,E-4 B-11 A-11 E-9 C-12 A-14 Schematic Location Component 31 C 1 2 5,6 8 B 13 B B 5 10 9 11 12 12 13 A B C B B A A A 17 39 23 31 B 14 E 15 20 19 16 16 16 17 17 18 31 B B B 8 B 22 8 E 15 E B 23 24 Sender - Fuel Level Sender - Transmission Speed Sensor - Engine Speed Sensor - Transmission Oil Temp Solenoid - A/C Clutch Solenoid - Centershift Solenoid - Differential Unlock Solenoid - Dual Horsepower Solenoid - Engine Shutdown Solenoid - Forward Horn Solenoid - Park Brake Solenoid - Start Aid Solenoids - Blade Cushion Solenoids - Transmission Valve (8) Speedometer Switch - A/C Refrigeration Switch - Air Inlet Heater Switch - Beacon Switch - Blower (A/C) Switch - Blower (Heater) Switch - Brake Air Pressure Switch - Centershift Indicator Switch - Centershift Pin Switch - Coolant Temp (Monitor) Switch - Coolant Temp (Start Aid) Switch - Cushion Blade Switch - Defroster (Front) Switch - Defroster (Rear) Switch - Differential Unlock Switch - Disconnect Switch - EMS Test Switch - Engine Oil Pressure Switch - Flood Lamps Switch - Forward Horn Switch - Fuel Pressure Switch - Head/Tail Lamp Switch - Headlamp Dimmer Switch - Hydraulic Oil Temperature Switch - Inching Pedal Pressure Switch - Key Start Switch - Panel Lamp Dimmer Switch - Park Brake Pressure Switch - Primary Steer Switch - Rear Flood Lamp Switch - Secondary Steer Test Switch - Start Aid/Monitor Test Switch - Stoplamp Pressure Switch - Transmission Direction & Speed Switch - Turn Signal Switch - Wiper (Front Lower) Switch - Wiper (Front Upper) Switch - Wiper (Rear) Tachometer Thermostat (A/C) Timer-AIH Machine Location A-13 C-15 B-14 C-15 A-13 B-3 E-14 A-13 D-13 F-3 B-11 A-13 E-2 D-15 F-5 A-13 B-8 B-5 B-10 A-10 A-2 C-3 B-9 B-14 A-14 B-9 A-5 B-5 D-9 C-14 E-8 C-13 D-8 E-9 B-13 E-8 E-9 B-11 C-15 B-9 E-9 B-11 F-10 D-8 B-8 E-11 A-2 A-8 E-9 A-4 B-4 A-4 E-5 B-11 D-8 25 28 26 31 22 29 4 22 22 10 10 25 30 31 A 22 C C C C 11 29 C 24 24 C C C B 6 B 32 B B 24 B B 33 31 C B 34 35 B C B 11 C B C C C A E B RENR1425-01 April 1998 Diagnostic Code Conversion Flash Codes 11 120H Motor Grader (ES Version) Electrical System 120H: 9YR330-UP Machine locations are repeated for components located close together. A = Operator’s compartment (Dash). B = Operator’s compartment (Steering console). C = Operator’s compartment (Right side console). D = Operator’s compartment (Headliner). E = Operator’s compartment (Under seat). ¹ The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Related Electrical Service Manuals Schematic Location Component Wire Number Wire Color 506 507 508 509 511 512 513 515 516 517 521 522 537 538 539 556 570 575 576 577 578 584 592 597 A503 A504 A506 A507 A513 PU WH PU WH BR GN OR GY GN BU YL WH ON OR BU WH BU YL PK PU BU YL BU PU PK ON OR YL PK 600 601 603 604 605 606 608 609 610 611 614 615 617 618 619 646 668 BR GY PK OR YL GY ON YL OR PU PU YL BR YL GN OR BU 727 728 751 752 754 755 795 F769 F775 892 893 F843 900 901 902 903 921 977 E937 E938 E939 E940 E941 E942 E943 E944 E945 E946 E947 E948 E949 E975 M917 M918 M998 GN BU GN YL BU OR YL BU BU BR GN YL PU WH BR GY WH YL PU OR WH BU YL ON BR GY PU OR WH BU YL PU PK GN OR CID - FMI Description N/A No diagnostics active 12 N/A No logged diagnostic codes 21 641 F05 Transmission Solenoid A open circuit 22 642 F05 Transmission Solenoid B open circuit 23 643 F05 Transmission Solenoid C open circuit 24 644 F05 Transmission Solenoid D open circuit 25 645 F05 Transmission Solenoid E open circuit 26 646 F05 Transmission Solenoid F open circuit 27 647 F05 Transmission Solenoid G open circuit 28 648 F05 Transmission Solenoid H open circuit 31 641 F06 Transmission Solenoid A short to ground 32 642 F06 Transmission Solenoid B short to ground 33 643 F06 Transmission Solenoid C short to ground 34 644 F06 Transmission Solenoid D short to ground 35 645 F06 Transmission Solenoid E short to ground 36 646 F06 Transmission Solenoid F short to ground 37 647 F06 Transmission Solenoid G short to ground 38 648 F06 Transmission Solenoid H short to ground 41 641 F03 Transmission Solenoid A short to battery 42 642 F03 Transmission Solenoid B short to battery 43 643 F03 Transmission Solenoid C short to battery 44 644 F03 Transmission Solenoid D short to battery 45 645 F03 Transmission Solenoid E short to, battery 46 646 F03 Transmission Solenoid F short to battery 47 647 F03 Transmission Solenoid G short to battery 48 648 F03 Transmission Solenoid H short to battery 52 637 F06 Backup alarm short to ground 58 688 F06 VHP solenoid short to. ground 59 688 F03 VHP solenoid short to battery 61 668 F02 Shift lever input invalid 62 668 F03 Shift lever open/short to + battery 63 269 F00 Sensor supply voltage above normal 64 269 F01 Sensor supply voltage below normal 65 701 F02 Transmission output speed signal incorrect 68 168 F01 System voltage below normal 71 520 F02 Invalid transmission configuration code 72 268 F02 Check programmable parameters 73 764 F05 Transmission indicator lamp open circuit 74 764 F06 Transmission indicator lamp short to ground 75 764 F03 Transmission indicator lamp short to battery 76 177 F03 Transmission oil temperature sender short to battery or open circuit 77 762 F04 Transmission oil temperature switch short to ground 81 868 F05 Auto/Manual lamp open circuit 82 868 F06 Auto/Manual lamp short to ground 83 868 F03 Auto/Manual lamp short to battery Printed in U.S.A. © 1998 Caterpillar All Rights Reserved Description Accessory Circuits (Continued) Washer - Front Washer - Rear Radio Speaker - Left Radio Speaker - Left (Common) Radio Speaker - Right Radio Speaker - Right (Common) A/C Compressor/Refrigerant Pressure SW Blower Motor (HI) Blower Motor (Medium) Blower Motor (Low) A/C SW To Refrigerant SW A/C Clutch To Thermostat SW Turn Signal SW To Flasher Hazard Indicator Turn Signal Differential Lock Blade Cushion Sol Wiper - Aux (Park) Wiper - Aux (Low) Wiper - Aux (HI) Washer - Aux Wiper SW Jumper DC/DC Converter Power Output A/C HI Press. Cutout SW To Low Press. SW Front Defroster Fan (Low) Rear Defroster Fan (Low) Front Defroster Fan (HI) Rear Defroster Fan (HI) DC/DC Converter Memory Output Lighting Circuits Dash Lamp Basic Dash Lamp Hi Rotary Beacon Stop Lamp Turn Lamp - Left Turn Lamp - Right Flood Lamp - Rear Flood Lamp - Side Head Lamp Head Lamp Hi Park/Tail/Dash/Lamp Cab Flood Lamp Tail/Position Lamp Tail/Position Lamp Head Lamp Lo Sw to Front Flood Relay Head Lamp/Tail Lamp Sw Control Circuits Sec Ster Motor Relay Sec Ster Cont SW XMSN Shift Sol No. 1 Or 3 XMSN Shift Sol No. 2 XMSN Shift Sol No. 3 Or 1 XMSN Shift Sol No. 4 Or 5 Dual Hp Sol AWD To Inch Pedal SW Centershift Sol Start Mod Right (-) Port/CAT Data Unk (-) Start Mod Right (+) Port/CAT Data Link (+) Inching Pedal XMSN Shift Sol No. 4 XMSN Shift Sol No. 6 XMSN Shift Sol No. 7 XMSN Shift Sol No. 8 XMSN Sol No 1 Or 3 Return CST Autoshift- Auto/Manual SW 1 MG MESH CNTL - Redundant Neutral MG MESH CNTL - First Gear MG MESH CNTL - Second Gear MG MESH CNTL - Third Gear MG MESH CNTL - Fourth Gear MG MESH CNTL - Fifth Gear MG MESH CNTL - Sixth Gear MG MESH CNTL - Seventh Gear MG MESH CNTL - Eighth Gear MO MESH CNTL - Forward Direct MG MESH CNTL - Reverse Direct MG MESH CNTL - Park MG MESH CNTL - Neutral MESH Lamp TOS Sensor + TOS Sensor XMSN Autoshift Mode Harness And Wire Electrical Schematic Symbols A AA Part No. 3E-2033 Function Off Machine Switch Specifications Brake/Park Brake Air Pressure Electrical Schematic Symbols And Definitions Actuate Deactuate 640 kPa MAX (92.0 psi MAX) Normal Condition 530 ± 40 kPa (77.0 ± 6.0 psi) Normally Open 38.00 ± 3.0 °C 27.0 °C MIN Normally Closed (1 00.4° ± 5.4 °F) (80.6 °F MIN) 1206 kPa MAX 700.0 ± 103 kPa 1-2 Normally Open 81-8640 Steering Pressure (175.0 psi MAX) (101.5 ± 15.0 psi) 1-3 Normally Closed 107.0 ± 3.0 °C 93.00 °C 8T-9793 Coolant Temperature Normally Closed (224.6 ± 5.4 °F) (199.4 °F) 62.0 kPa MAX 38 ± 20 kPa 9X-0378 Engine Oil Pressure Normally Open (9.00 psi MAX) (5.5 ± 3.0 psi) 75.0 kPa MAX 50.0 kPa MIN 111-7088 Inching Pedal Pressure Normally Open (10.9 psi MAX) (7.30 psi MIN) — 275 to 1750 kPa¹ 114-5334 Refrigerant Pressure (A/C) Normally Open² (40 to 255 psi) — 93.0 ± 21 kPa 69 ± 21 kPa 115-7103 Fuel Pressure Normally Closed (13.5 ± 3.0 psi) (10 ± 3.0 psi) 83 kPa MAX 48 ± 20 kPa MIN 125-9352 Stop Lamp Pressure Normally Open (12 psi MAX) (7 ± 3 psi MIN) 102 ± 3 °C 90°C MIN 131-4135 Hydraulic Oil Temperature Normally Closed (215.6 ± 5.4 °F) (194.0°F MIN) ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25psi). 8C-3569 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Coolant Temperature ² Contact position at the contacts of the harness connector. Pin or Socket Number T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Wire, Cable, or Harness Assembly Identification Single Wire Connector C Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Pin Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Component Description 3E-1906 Solenoid - A/C Clutch 3T-3123 Resistor - Panel Dimmer Resistance (Ohms)¹ Wire Color Socket 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. The circle indicates that the component has screw terminals and a wire can be disconnected from it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. No circle indicates that the wire cannot be disconnected from the component. SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. 25.0 ± .3 560 to 716 @ 54°C (130°F) 72 to 82 @ 110°C (230°F) Sender - Coolant Temperature 7T-4003 Resistor - Power 10.0 ± 0.5 7T-6517 Solenoid - Blade Cushion 20.1 ± 1.0 7T-9074 8T-8808 Solenoid - Forward Horn/Park Brake Solenoid - Engine Shutdown Start (Latch) Coil Stop (Unlatch) Coil Solenoid - Centershift 9G-1 950 Resistor - Blower Speed 9G-4365 Solenoid Start Aid 104-6387 Sender - Transmission Speed 136-1678 Solenoids - Transmission 31.0 ± 3.0 129-7707 Solenoid-Dual HP 31.1 ±2.4 144-6295 Solenoid - Differential Unlock 33.6 ± 1.0 149-1116 Sender - Articulation ¹ At room temperature unless otherwise noted. 9X-1123 325-PK-14 17.6 ± 0.6 4W-9972 8C-3663 AA 1 2 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. Part No. A A 325-PK-14 Normally closed switch that will open with an increase of a specific condition. Resistor, Sender and Solenoid Specifications Component Part Number 55.17 ± 5.77 1.55 ± 0.15 10.3 ± 1.03 This indicates that the component has a wire connected to it that is connected to ground. 34.3 ± 1.7 Overall 2.00 ± .10 Tap 1.00 ± .05 6.0 1000 to 1200 7 to 192 This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. T RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Connector Location¹ Connector Number CONN 1 CONN 2 CONN 3 CONN 4 CONN 5 CONN 6 CONN 7 CONN 8 CONN 9 CONN 10 CONN 11 CONN 12 CONN 13 CONN 14 CONN 15 CONN 16 CONN 17 Service Tool CONN 18 CONN 19 CONN 20 CONN 21 CONN 22 CONN 23 CONN 24 CONN 25 CONN 26 CONN 27 CONN 28 CONN 29 CONN 30 CONN 31 CONN 32 CONN 33 CONN 34 Schematic Location C-15 E-15 E-15 F-14 A-14 B-13 B-13 D-13 D-13 B-12 A-11 D-10 D-10 D-10 A-9 A-9 A-9 B-9 E-9 E-9 B-8 B-8 E-6 E-6 C-6 C-6 C-6 A-6 C-5 C-5 B-3 E-3 F-3 F-3 Machine Location 26 26 26 6 5 29 29 30 29 25 C B 23 23 10 10 C 25 B B 10 10 24 24 24 27 27 27 27 27 15 23 23 23 ¹ The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Schematic Location Component Component Location Machine Location Schematic Location Sender - Transmission Speed D-15 Machine Location Sensor - Transmission Oil Temp E-15 26 16 Component Alarm - Action B-8 Alarm - Backup F-15 1 Alternator (35A STD) D-14 2 Solenoid - Centershift B-3 Batteries C-14 3,4 Solenoid - Differential Unlock E-4 17 Breaker - Alternator (35A) D-1 3 5 Solenoid - Dual Horsepower A-13 5 Breaker - Headlamp (15A) D-10 B Solenoid - Engine Shutdown D-13 5 Control - Neutral Start B-9 10 Solenoid - Forward Horn A-3 16 Control - Transmission A-7 E Solenoid - Park Brake B-12 16 Fuses B-6 C Solenoid - Start Aid A-13 18 Fuses D-9 B Solenoids - Transmission Valve (8) D-15,E-15 14 Gauge Cluster F-5 A Switch - Beacon B-6 C Ground-Engine C-13 12 Switch - Blower (Heater) A-10 C Ground - Front Frame D-6 21 Switchs - Brake Air Pressure A-2 16 Ground - Rear Frame C-13 28 Switch - Centershift Indicator B-3 19 Ground Strap - Cab to Front Frame D-6 24 Switch - Centershift Pin B-9 C C-12 20 Switch - Defroster (Front) A-6 C Horn - Forward F-3 16 Switch - Defroster (Rear) B-6 C Meter - Service E-10 B Switch - Differential Unlock D-8 B Motor - Blower (Heater group) A-10 E Switch - Disconnect C-14 13 Motor - Blower/Defroster A-11 E Switch - Engine Coolant Temp (Start Aid) A-14 11 Motor - Blower/Defroster E-4 E Switch - Flood Lamp D-8 B Motor - Starter C-13 5 Switch - Forward Horn E-9 B Motor - Washer (Front Lower) F-6 8 Switch - Fuel Pressure B13 13 Motor - Washer (Front Upper) F-6 8 Switch - Head/Tail Lamp E-8 B Motor - Washer (Rear) F-6 8 Switch - Headlamp Dimmer E-9 B Motor - Wiper (Front Lower) C-4 9 Switch - Inching Pedal Pressure C-15 14 Motor - Wiper (Front Upper) D-4 0 Switch - Key Start B-9 C Motor - Wiper (Rear) B-11 0 Switch - Park Brake Pressure B-11 16 Relay - Start D-13 5 Switch - Start Aid E-8 B Relay - Transmission Action Lamp C-10 8 Switch - Stoplamp Pressure A-2 16 Resistor - Blower Speed A-12 E Switch - Tail Lamp D-8 B Resistor - Blower Speed E-4 E Switch - Transmission Direction & Speed A-8 C Resistor - Blower Speed (Heater) A-10 E Switch - Wiper (Front Lower) A-5 C Sender - Articulation C-12 7 Switch - Wiper (Front Upper) B-5 C Sender - Engine Coolant Temp A-14 11 Switch - Wiper (Rear) A-5 C Sender - Engine Oil Pressure B-14 13 Ground Strap - Front Frame to Rear Frame C RENR1426-01 June 1998 14 1 B = Operator’s compartment (Steering console). 12 2 5 11 17 7 29 30 21 D E 20 23 B C 10 25 27 9 A 19 24 1615 120H and 135H Motor Grader Standard Version Electrical System 27 D 120H: 5FM800-UP 6TM366-UP A 22 C 12 13 5 4 3 29 2 B 11 18 6 14 26 A = Operator’s compartment (Dash). 22 13 8 4 1 Machine locations are repeated for components located close together. 3 6 26 18 14 30 20 28 8 25 10 21 24 15 23 16 19 7 17 C = Operator’s compartment (Right side console). E 9 135H: 7MM249-UP 8WN350-UP D= Operator’s compartment (Headliner). E = Operator’s compartment (Under seat). E20367 Machine Harness Connector And Component Locations Related Electrical Service Manuals Title Alternator (6N-9294 35A): STD Consist No. 3T-6352 Consist No. 7N-9720 Consist No. 9G-4574 Form Number SENR4978 SENR2082 SENR4130 Alternator (100-5047 50A): ATT SENR2082 Transmission Electronic Shift Control Starting Motor: (106-8558) Consist No. 106-8557 Consist No. 106-8559 SENR91 67 SENR3559 5ENR3581 Wire Number Wire Color 101 RD 102 BU 103 Wire Description Wire Number Wire Color Bat(+) 504 YL Wiper - Rear (Low) HdLmp 505 BU Wiper - Rear (Hi) RD AuxCkt 506 PU Washer - Front 105 RD Key Start Sw 507 WH Washer - Rear 108 BU AuxCkt 515 GY Blower Motor (Hi) 109 OR Alt Output (+) Term. 516 GN Blower Motor (Medium) 113 RD Opr Mon Panel 517 BU Blower Motor (Low) 114 RD Warning Horn (Forward) 521 YL A/C SW To Refrigerant SW 116 RD AuxCkt 522 WH A/C Clutch To Thermostat SW 118 GY AuxCkt 556 WH Differential Lock Description Power Circuits Code Flashed 11 Transmission Diagnostic Code Conversion 12 CID - FMI Description N/A No diagnostics active N/A No logged diagnostic codes 21 641 22 642 23 643 24 644 25 645 26 646 27 647 28 648 31 641 32 642 33 643 34 644 35 645 36 646 37 647 38 648 41 641 42 642 43 643 44 644 Resistor, Sender and Solenoid Specifications Part No. 3E-5383 Component Description Sender - Articulation Position Resistance (Ohms)¹ Accessory Circuits (Continued) Range - 3 to 97 Ohms 119 PK AuxCkt 575 YL Wiper - Aux (Park) 560 to 716 @ 54°C (1 30°F) 72 tO 82 @ 110°C(230°F) 124 RD A/C 576 PK Wiper - Aux (Low) 7N-8532 Sender - Engine Coolant Temp 126 PK XMSNCTRL 577 PU Wiper - Aux (Hi) F05 Transmission Solenoid A open circuit F05 Transmission Solenoid B open circuit 7T-4003 Resistors - Defroster Blower 10.0 ± 0.5 129 BU 578 BU 7T-9073 Solenoid - Differential Unlock 33.6 ± 1.0 Aux Ckt Washer - Aux 130 RD AuxCkt 584 YL Wiper SW Jumper F05 Transmission Solenoid C open circuit F05 Transmission Solenoid D open circuit 7T-9074 Solenoids - Forward Horn Park Brake 55.17 ± 5.77 135 BU AuxCkt A503 PK Front Defroster Fan (Low) F05 Transmission Solenoid E open circuit F05 Transmission Solenoid F open circuit 8C-3663 8T-8808 9G-1 950 9G-4365 104-6387 111-0570 F05 Transmission Solenoid G open circuit F05 Transmission Solenoid H open circuit F06 Transmission Solenoid A short to ground F06 Transmission Solenoid B short to ground F06 Transmission Solenoid C short to ground F06 Transmission Solenoid D short to ground F06 Transmission Solenoid E short to ground F06 Transmission Solenoid F short to ground 116-9937 Solenoid - Engine Shutdown Start (Latch) Coil Stop (Unlatch) Coil Solenoid - Centershift Resistor - Blower Speed Solenoid - Start Aid Sender - Transmission Speed Solenoid - Dual Horsepower Sender - Engine Oil Pressure 127-0574 Solenoids - Transmission ¹ At room temperature unless otherwise noted. 141 PK Aux Ckt A504 GN Rear Defroster Fan (Low) 1.55 ± 0.15 10.3 ± 1.03 144 GN Aux Ckt A506 OR Front Defroster Fan (Hi) 149 RD AuxCkt A507 YL 34.3 ± 1.7 Overall 2.00 ± .10 Tap 1.00 ± .05 6 1000 to 1200 31.1 ± 2.4 21.5-49.5 @552 kPa (80.1 psi) 227 - 257 @ 21 kPa (3.0 psi) 31 ± 3 151 GN AuxCkt Rear Defroster Fan (Hi) Lighting Circuits 152 BU AuxCkt 603 PK Rotary Beacon 165 RD Aux Ckt Ground Circuits 604 OR Stop Lamp 608 GN Flood Lamp - Rear 201 BK Main Chassis 609 YL Flood Lamp - Side 202 BK XMSN CTRL 611 PU Head Lamp Hi 276 BK XMSN CTRL Ident Code 0 614 PU Park/Tail/Dash/Lamp 277 BK XMSN CTRL Ident Code 1 619 GN 278 BK XMSN CTRL Ident Code 2 Basic Machine Circuits Head Lamp LowControl Circuits Control Circuits 710 GN XMSN Speed Pickup Signal 301 BU Starter No. 1 Sol 751 GN XMSN Shift Sol No. 1 Or 3 304 WH Starter Relay No. 1 Output 752 YL XMSN Shift Sol No. 2 306 GN Starter Relay Coil To Neut Start SW Or Key Start SW 754 BU XMSN Shift Sol No. 3 Or 1 307 OR Key Start SW To Neutral Start SW 755 OR XMSN Shift Sol No. 4 Or 5 308 YL YL Dual Hp Sol F06 Transmission Solenoid G short to ground F06 Transmission Solenoid H short to ground F03 Transmission Solenoid A short to battery F03 Transmission Solenoid B short to battery F03 Transmission Solenoid C short to battery F03 Transmission Solenoid D short to battery 45 645 F03 Transmission Solenoid E short to battery Main Power Relay Coil 795 46 646 F03 Transmission Solenoid F short to battery 310 PU Start Aid SW To Start Aid Sol F775 BU Centershift Solenoid 47 647 F03 Transmission Solenoid G short to battery 311 WH Start Aid Sol To Temp SW 892 BR Start Mod Right (-) Port/CAT Data Link (-) 48 648 F03 Transmission Solenoid H short to battery 321 BR Backup Alarm Lamp Travel Alarm 893 GN Start Mod Right (+) Port/CAT Data Link (+) 52 637 F06 Backup alarm short to ground 322 GY Warning Horn (Forward) F843 YL Inching Pedal 58 688 F06 VHP solenoid short to ground 326 PU PU XMSN Shift Sol No. 5 or 4 688 F03 VHP solenoid short to battery Key Start SW C Term. Monitoring Circuits 900 59 901 WH XMSN Shift Sol No. 6 61 668 F02 Shift lever input invalid GN Alternator (R) Term. 902 BR XMSN Shift Sol No. 7 62 668 F03 Shift lever open/short to +battery 439 YL Lamp Indicator 903 GY XMSN Shift Sol No. 8 441 OR Eng Coolant Temp Gauge 921 WH XMSN Sol No 1 Or 3 Return 460 WH Opr Mon Panel Program Pin E937 PU MG MESH CNTL - Redundant Neutral 63 269 F00 Sensor supply voltage above normal 64 269 F01 Sensor supply voltage below normal 65 701 F02 Transmission output speed signal incorrect 68 168 F01 System voltage below normal 71 520 F02 Invalid transmission configuration code 72 268 F02 Check programmable parameters 73 764 74 764 75 Part No. Function 2W-9346 Stop Lamp Pressure 8C-3569 Coolant Temperature (Start Aid) 111-7088 Inching Pedal Pressure 112-2024 Brake Air Park Brake Pressure 115-7103 Fuel Pressure (EMS) Off Machine Switch Specification Actuate 45 kPa MAX (6.5 psi MAX) 38 ± 3°C (100.4° ± 5.4°F) 75.0 kPa MAX (10.9 psi MAX) 640 kPa MAX (92.0 psi MAX) 93 ± 21 kPa (13.5 ± 3.0 psi) Deactuate 5 kPa MIN (0.5 psi MIN) 27 °C MIN (80.6°F MIN) 50.0 kPa MIN (7.3 psi MIN) 530 ± 40 kPa (77.0 ± 6.0 psi) 69 ± 21 kPa (10.0 ± 3.0 psi) Contact Position Normally Open Normally Closed Normally Open 403 498 WH Diff. Lock Indicator E938 OR MG MESH CNTL - First Gear A429 YL Articulation Indicator E939 WH MG MESH CNTL - Second Gear A476 PU Eng Oil Press Gauge To Sender - Eng #1 E940 BU MG MESH CNTL - Third Gear B476 BU (NFND) Transmission Indicator Lamp E941 YL MG MESH CNTL - Fourth Gear F05 Transmission indicator lamp open circuit C491 PU Park Brake Pressure E942 GN MG MESH CNTL - Filth Gear F06 Transmission indicator lamp short to ground E458 YL Low Air Pressure Lamp E943 BR MG MESH CNTL - Sixth Gear 764 F03 Transmission indicator lamp short to battery E459 WH Low Air Pressure Alarm E944 GY MG MESH CNTL - Seventh Gear 76 177 E460 BR Trans Cntl To Relay Coil E945 PU MG MESH CNTL - Eighth Gear 77 762 F03 to +battery Transmission oil temperture switch short F04 to ground F473 YL Transmission Warning E946 OR MG MESH CNTL - Forward Direct 81 868 GN WH MG MESH CNTL - Reverse Direct 868 Transmission Temperature Accessory Circuits E947 82 F05 Auto/Manual lamp open F06 Auto/Manual lamp short to ground G460 E948 BU MG MESH CNTL - Park 83 868 F03 Auto/Manual lamp short to +battery Transmission oil temperature signal Open/Short Normally Open Normally Closed 500 BR Wiper - Front (Park) E949 YL MG MESH CNTL - Neutral 501 GN Wiper - Front (Low) E975 PU MESH Lamp 502 OR Wiper - Front (Hi) M917 PK TOS Sensor + 503 BR Wiper - Rear (Park) M91 8 PK TOS Sensor M998 OR Xmsn Autoshift Mode Printed in U.S.A. © 1998 Caterpillar All Rights Reserved Description Harness And Wire Electrical Schematic Symbols A Electrical Schematic Symbols And Definitions AA Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Pin or Socket Number Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector Normally open switch that will close with an increase of a specific condition (temp-press-etc.). C A A 325-PK-14 Pin Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. AA 1 Wire Color Socket 2 Normally closed switch that will open with an increase of a specific condition. Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. The circle indicates that the component has screw terminals and a wire can be disconnected from it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. No circle indicates that the wire cannot be disconnected from the component. T This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. 200-BK-14 Circuit Number Identification Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. This indicates that the component has a wire connected to it that is connected to ground. 9X-1123 325-PK-14 SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Wire Number Connector Location Connector Number CONN 1 CONN 2 CONN 3 CONN 4 CONN 5 CONN 6 CONN 7 CONN 8 CONN 9 CONN 10 CONN 11 CONN 12 CONN 13 CONN 14 CONN 15 CONN 16 CONN 17a CONN 17b CONN 17c CONN 18 CONN 19 CONN 20 CONN 21 CONN 22 CONN 23 CONN 24 CONN 25 CONN 26a CONN 26b CONN 27a CONN 27b CONN 28 CONN 29 CONN 30 CONN 31 CONN 32 CONN 33 CONN 34 CONN 35a Secondary Steering CONN 35b CONN 36 CONN 37 CONN 38 CONN 39 CONN 40 CONN 41 CONN 42 CONN 43 CONN 44 CONN 45 CONN 46 CONN 47 CONN 48 CONN 49 CONN 50 CONN 51 Wire Description Wire Color Wire Number Description Wire Color Schematic Location C-15 F-14 F-14 B-14 B-14 A-14 A-14 A-14 B-13 B-13 B-13 D-13 D-13 D-13 F-12 B-12 A-10 B-11 A-11 F-11 F-11 D-10 D-10 D-10 D-10 D-10 C-10 C-10 C-10 B-10 A-9 B-9 B-9 E-9 A-9 D-8 D-8 B-8 F-7 F-7 A-6 C-6 C-6 C-6 C-6 E-6 E-6 E-6 C-5 C-5 C-5 F-3 F-3 E-3 E-3 B-3 Machine Location 4 36 7 8 11 27 26 8 37 37 37 22 37 37 37 10 C C C 28 28 B B 39 39 39 21 33 33 C C 38 38 39 39 39 39 38 20 20 40 17 17 17 17 17 17 17 40 40 40 17 17 42 42 43 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Component Description Accessory Circuits Power Circuits Schematic Location 101 RD Bat (+) 500 BR Wiper - Front (Park) 102 RD Hd Lmp 501 GN Wiper - Front (Low) 103 RD Aux Ckt 502 OR Wiper - Front (HI) 105 RD Key Sw 503 BR Wiper.- Rear (Park) 108 RD Aux Ckt 504 YL Wiper-Rear(Low) 109 RD Alt Output (+) Term. 505 BU Wiper - Rear (HI) 112 PU Main Power Rly Output 506 PU Washer - Front 113 OR Opr Mon Panel B+ Switched 507 WH Washer - Rear 114 RD Warning Horn (Forward) 508 PU Radio Speaker - Left 115 RD Aux Ckt 509 WH Radio Speaker - Left (Commom) 116 BR Aux Ckt 511 BR Radio Speaker-Right 118 GY Aux Ckt 512 GN Radio Speaker - Right (Common) 119 PK Aux Ckt 513 OR A/C Compressor/Refrigerant Pressure SW 121 RD Back Alarm To Lamp 515 GY Blower Motor (HI) 122 BU Aux Ckt 516 GN Blower Motor (Medium) 123 WH Aux Ckt 517 BU Blower Motor (Low) 124 GN A/C 521 YL A/C SW To Refrigerant SW 129 BU Aux Ckt 522 WH A/C Clutch To Thermostat SW 130 RD Aux Ckt 537 GN Turn Signal SW To Flasfler 134 RD Aux Ckt 556 WH Differential Lock 135 BU Aux Ckt 570 BU Blade Cushion Sol 136 GN Secondary Ster 575 YL Wiper-Aux (Park) 141 PK Aux Ckt 576 PK Wiper-Aux (Low) 144 RD Aux Ckt 577 PU Wiper-Aux (HI) 147 RD Aux Ckt 578 BU Washer-Aux 149 PU Aux Ckt 584 YL Wiper SW Jumper 151 GN Aux Ckt 592 BU DC/DC Converter Power Output 152 BU Aux Ckt 593 GN Condensor Fan Relay To Motors 158 BR Aux Ckt 597 PU A/C HI Press. Coutout SW To Low Press. SW 165 YL Aux Ckt A503 PK Front Defroster Fan (Low) 169 PK Aux Ckt A504 GN Rear Defroster Fan (Low) 173 RD Aux Ckt A506 OR Front Defroster Fan (HI) 176 OR Aux Ckt Ground Circuits A507 YL Rear Defroster Fan (HI) Component Location Machine Location Component Schematic Location Machine Location E Alarm - Action B-8 C Resistor - Defrost Motor A-11 Alarm - Backup F-15 1 Resistor - Defrost Motor E-4 Alternator D-14 2 Resistor - Panel Lamp Dimmer E-9 B Batteries - 12 Volt C-14 5,6 Sender - Articulation C-12 23 Breaker - Alternator (60A) D-13 8 Sender - Engine Coolant Temp. A-14 24 Breaker - Converter (25A) F-11 13 Sender - Fuel Level A-13 25 Breaker - Headlamp D-10 B Solenoid - A/C Clutch A-13 22 Breaker - Lightbar Low Beam D-10 B Solenoid - Blade Cushion E-2 30 Buss Bar C-14 5 Solenoid - Centershift B-3 29 Control - Secondary Steering E-13 9 Solenoid - Centershift C-3 11 Converter - 24V to 1 2V F-8 12 Solenoid - Differential Unlock E-14 4 Converter - 24V to 1 2V F-10 12 Solenoid - Engine Shutdown D-13 22 Converter - 24V to 1 2V E F-12 13 Solenoid - Forward Horn F-3 10 Flasher E-9 B Solenoid - Park Brake B-11 10 Fuses B-5 C Solenoid - Start Aid A-13 25 Fuses D-9 B Suppressor - Arc (A/C Clutch) A-13 22 Fuses E-10 B Suppressor - Arc (Diff. Unlock) E-14 3 Gauge - System Air Press. L/S E-5 A Switch - A/C Refrigerant A-13 22 Gauge - System Air Press. A/S E-5 A Switch - Air Dryer F-14 31 Gauge Cluster F-5 A Switch - Back-Up Alarm F-14 4 Ground - Cab D-5 17 Switch - Beacon B-5 C B-10 C B-8 C C C-13 22 Switch - Beacon Ground - Frame (Front) D-6 39 Switch - Blade Cushion Ground - Frame (Rear) C-13 8 Switch - Blower (A/C) B-10 Ground - Frame To Cab (Front) D-6 17 Switch - Blower (Heater) A-10 C Ground - Localized Stud F-12 D Switch - Brake Air A-2 11 Ground - Strap C-12 23 Switch - Centershift Pin B-9 C Lamp - Diff. Unlock E-5 A Switch - Defroster (Front) A-5 C Lamp - High Beam Indicator D-6 A Switch - Defroster (Rear) B-5 C Lamp - Master Action E-5 A Switch - Differential Unlock D-9 B Lamp - Turn Indicator (Left) E-5 A Switch - Disconnect C-14 6 Lamp - Turn Indicator (Right) E-4 A Switch - Engine Coolant Temp. (Monitor) B-14 24 Meter - Service Monitor - Electronic Monitoring System (EMS) E-10 B Switch - Engine Coolant Temp. (Start Aid) A-14 24 E-6 A Switch - Engine Oil Press. C-13 32 15 Ground - Engine A513 PK DC/DC Converter Memory Output Lighting Circuits Motor-Blower A-12 Motor - Blower (A/C) B-10 14 Switch - Fuel Press. Motor - Blower (Defrost) E-4 15 Switch - Head/Tail Lamp E-8 B Motor - Blower (Heater) A-10 E Switch - Headlight Dimmer D-9 B Motor - Secondary Steering F-13 20 Switch - Horn E-9 B Motor - Starter C-13 19 Switch - Hyd. Oil Temp. B-11 33 Motor - Washer (Front Lower) F-6 16 Switch - Key Start B-9 C Motor - Washer (Front Upper) F-6 16 Switch - Light Bar Low Beam E-8 B Motor - Washer (Rear) F-6 16 Switch - Neutral/Start Motor - Wiper (Front Lower) C-4 17 Motor - Wiper (Front Upper) D-4 17 Motor - Wiper (Rear) A-11 18 B-11 21 200 BK Main Chassis 201 BK Operator Monitor Return Basic Machine Circuits 600 BR Dash Lamp Basic 601 GY Dash Lamp Hi Starter No. 1 Sol 603 PK Rotary Beacon OR Stop Lamp YL Turn Lamp - Left 301 BU 304 WH Starter Relay No. 1 Output 604 306 GN Starter Relay Coil To Neut Start SW Or Key SW 605 307 OR Key Start SW To Neut Start SW Or Sensor Module 606 GY Turn Lamp - Right 308 YL Main Power Relay Coil 608 GN Flood Lamp - Rear 310 PU Start Aid SW To Start Aid Sol 609 YL Flood Lamp - Side 311 WH Start Aid Sol To Temp SW 611 PU I-lead Lamp Hi 321 BR Bckp Alarm Lamp Travel Alarm 614 PU Park/Tail/Dash/Lamp 322 GY Warning Horn (Forward) 619 GN Head Lamp Lo Motors - Condenser 326 RD Key Start SW C” Term. Monitoring Circuits 629 PK Aux Head LampControl Circuits Control Circuits Power Port - (i2V) F-12 Receptical - Aux. Start C-14 403 GN Alternator (R) Term. 727 GN Secondary Ster Motor Relay Relay - Condenser 404 YL Opr Mon Hyd Oil Temp 728 BU Secondary Ster Cont SW Relay - Main 405 GY Opr Mon Oil Press. (Low Setting) E773 YL Center Shift Sol - Push 406 Pu Opt Mon Coolant Temp F775 BU Centershift Solenoid 408 WH Opr Mon System Air Press. 409 OR Opr Mon Neut 410 WH Opr Mon Action Alarm 411 PK Opr Mon Master 413 BR Opr Mon Fuel Press. 415 GN Opr Mon Test SW 417 GY Primary Ster SW 419 YL Opr Mon Parking Brake 441 OR Eng Coolant Temp Gauge 447 PK Fuel Level Gauge 450 YL Tach Sender (+) 462 YL Secondary Ster Motor Indicator 488 WH Air SW To Air SW Jumper 498 WH Diff. Lock Indicator A429 YL Articulation Indicator Switch - Flood Lamps RENR1427-01 August 1997 D-8 B B-13 24 E-14 4 Switch - Panel Lamp Dimmer E-9 B Switch - Parking Brake Press. B-11 34 Switch - Primary Steering F-10 35 Switch - Secondary Steering Test B-8 C 41 Switch - Start Aid EMS Test E-8 B 3 Switch - Stop Lamp A-2 11 C-10 21 Switch - Tail Lamp D-8 B D-14 8 Switch - Thermostat(A/C) B-11 E Relay - Secondary Steering F-13 22 Switch - Turn Signal E-9 B Relay - Start D-13 8 Switch - Wiper (Front Lower) A-4 C Resistor - Blower Switch (A/C) B-11 15 Switch - Wiper (Front Upper) B-4 C Resistor - Blower Switch (Heater) A-11 E Switch - Wiper (Rear) A-4 C 14H Motor Grader Electrical System 7WJ664-UP Printed in U.S.A. © 1997 Caterpillar All Rights Reserved Machine Locations are repeated for components located close together. A = Operator’s compartment (Dash). B = Operator’s compartment (Steering console). C=Operator's compartment (Right side console) D = Operator’s compartment (Headliner). E = Operator’s compartment (Under seat). Harness And Wire Electrical Schematic Symbols A Electrical Schematic Symbols And Definitions AA Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 2 Resistor, Sender and Solenoid Specifications Part No. Component Description 3E-1906 Alternator: 6N-9294 Consist No. 9G-4574 Alternator (100-5047)(Atch): Consist No. 100-5045 Consist No. 100-5046 Electronic Monitoring System Starter Motor: 106-8555 Consist No. 6V-5023 Consist No. 6V-5207 Consist No. 6V-5226 Form Number SENR4130 SENR4130 SENR2082 SENR2945 5ENR3536 SENR3581 SENR4975 6.0 ± 3 (MIN) 92±5 (MAX) Sender - Articulation Position Solenoid - Engine Shutdown Start (Latch) Coil Stop (Unlatch) Coil 3E-7985 Title 17.6 ± 0.6 Solenoid - A/C Clutch 3E-5383 Related Electrical Service Manuals Resistance (Ohms)¹ 1.55 ± 0.15 10.3 ± 1.03 3T-3123 Resistor - Panel Lamp Dimmer Switch 7N-8532 Sender - Coolant Temperature 7T-4003 Resistor - Defroster/Blower Motor 10.0± 0.5 7T-6517 Solenoids - Blade Cushion 20.1 ± 1.0 7T-9074 Solenoid - Forward Horn Park Brake 55.2 ± 5.8 9G-1950 Resistor - A/C Blower Motor Heater Blower Motor 9G-4365 Solenoid - Start Aid 6 9X-9482 Solenoid - Centershift 68 140-7724 Sender - Fuel Level 144-6295 Solenoid - Differential Unlock 36 31 7 4 3 27 9 32 26 2 8 19 22 5 25.0 ± .3 3E-2028 Engine Coolant Temperature Park Brake Air Pressure 3E-2033 Brake Air Pressure 3E-6425 Coolant Temperature (Start Aid) 8T-8640 Primary Steering Pressure 9X-0378 Engine Oil (Pressure) 107-0616 Fuel (Pressure - EMS) 114-5334 A/C Refrigerant (Pressure) 125-9352 Stop Lamp (Pressure) 131-4135 Hydraulic Oil Temperature Normally open switch that will close with an increase of a specific condition (temp-press-etc.). NormallyClosed NormallyOpen 21 28 14 D 40 18 13 1 36 31 9 7 26 25 19 2 8 3 4 41 24 32 22 37 5 6 C 33 16 38 12 35 11 23 34 15 B 30 1 T 10 20 E07077 Machine Harness Connector And Component Locations 9X-1123 325-PK-14 Wire Color Socket 200-BK-14 Wire Gauge REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. No circle indicates that the wire cannot be disconnected from the component. 29 NormallyClosed ¹ Contact position at the contacts of the harness connector. ² A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kPa (25 psi). AA FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. The circle indicates that the component has screw terminals and a wire can be disconnected from it. NormallyOpen NormallyClosed A A Electrical Schematic Symbols And Definitions A 17 42 39 43 Component Part Number Circuit Number Identification Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. This indicates that the component has a wire connected to it that is connected to ground. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. A-B, Normally Open A-C, Normally Closed NormallyOpen Pin Normally closed switch that will open with an increase of a specific condition. NormallyCksed NormallyOpen ² C 2 E Contact Position Pin or Socket Number Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. 33.6 ± 1.0 Deactuate 93 °C (199 °F) 530 ± 40 kPa (77 ± 6 psi) 27 °C MIN (81 °F MIN) 700 ± 103 kPa (100 ± 15 psi) 38 ± 20 kPa (5.5 ± 3.0 psi) 69 ± 21 kPa (10 ± 3 psi) — — 48 ± 20 kPa (MIN) (7 ± 3 psi MIN) 90°C MIN (194 °F MIN) Flow Symbol 325-PK-14 92 to 98 (EMPTY) 7 to 12 (FULL) Actuate 107 ±3 °C (225 ± 5 °F) 640 kPa (92 psi) 38 ± 3 °C (100 ± 5 °F) 1206 kPa (MAX) (175 psi MAX) 62 kPa (MAX) (9 psi MAX) 93 ± 21 kPa (13.5 ± 3.0 psi) 275 to 1750 kPa ¹ (40 to 255 psi) 83 kPa (MAX) (12 psi MAX) 102 ± 3°C (216 ± 5 °F) Level Symbol Single Wire Connector Overall 2.0 ± .1; Tap 1.0 ± .05 Off Machine Switch Specification Temperature Symbol Wire, Cable, or Harness Assembly Identification 560 to 716 @ 54 °C (130 °F) 72 to 82 @ 110°C (230°F) 27 Function 39 B A 17 30 29 24 21 18 33 34 37 23 11 10 C 38 43 40 ¹ At room temperature unless otherwise noted. Part No. Pressure Symbol 15 42 E 25 1 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. T 16 41 12 13 20 D 28 1435 6 1 2 1 2 1 SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
RENR1428-01 January 1998 Connector Location Schematic Location Machine Location CONN 1 F-14 36 CONN 2 F-14 28 CONN 3 B-14 8 CONN 4 A-14 25 CONN 5 A-14 XX CONN 6 B-13 37 CONN 7 B-13 37 CONN 8 B-13 37 CONN 9 D-13 37 CONN 10 D-13 37 16 CONN 11 E-13 3 13 CONN 12 F-12 37 CONN 13 F-12 39 CONN 14 E-12 39 Connector Number Part No. 3E-2028 6 31 36 12 28 4 3 32 CONN 15 D-12 39 CONN 16 D-12 39 CONN 17 B-12 10 CONN 18a A-10 38 CONN 18b B-11 38 CONN 18c A-11 38 CONN 19 F-11 D CONN 20 F-11 D CONN 21 D-10 B CONN 22 D-10 B CONN 23 D-10 39 CONN 24 D-10 39 CONN 25 D-10 39 CONN 26 C-10 33 CONN 27 C-10 C 21 CONN 28 B-9 38 CONN 29 B-9 38 18 CONN 30 E-9 B CONN 31 E-9 39 CONN 32 D-8 39 CONN 33 D-8 39 CONN 34 B-8 38 CONN 35a F-7 39 CONN 35b F-7 39 CONN 36 E-6 17 CONN 37 E-6 17 CONN 38 E-6 17 CONN 39 C-6 17 CONN 40 C-6 17 CONN 41 C-6 17 CONN 42 C-6 17 CONN 43 A-6 40 CONN 44 C-5 40 CONN 45 C-5 40 CONN 46 C-5 40 CONN 47 B-3 27 CONN 48 E-3 26 CONN 49 E-3 26 CONN 50 F-3 26 CONN 51 F-3 26 24 1 2 22 19 8 33 37 39 E 21 B 18 7 15 D 14 35 9 25 20 5 17 30 A 11 C 10 38 29 Alternator: 6N-9294 (35A) Consist No.9G-4574 Alternator: 100-5047 (50A) Consist No. 100-5046 Consist No. 100-5045 Electronic Monitoring System (EMS) Form Number SENR4130 SENR2082 SENR4130 SENR2945 Contact Position 93.00 °C (199.4 °F) Normally Closed 640 kPa (92.0 psi) 530 ± 40 kPa (77.0 ± 6.0 psi) Normally Open 3E-2033 Secondary Brake Air Pressure (Trans) 3E-6425 Coolant Temperature (Start Aid) 38 ± 3°C (100.4° ± 5.4°F) 27 °C MIN (80.6°F MIN) Normally Closed 8T-8640 Steering Press 1206 kPa MAX (175 psi MAX) 700.0 ± 103.0 kPa (101.5 ± 14.9 psi) 1-2 Normally Open 1-3 Normally Closed 9X-0378 Engine Oil Pressure 62.0 kPa MAX (9.0 psi MAX) 38.0 ± 20.0 kPa (5.5 ± 3.0 psi) Normally Open 107-0616 Fuel Pressure (EMS) 93 ± 21 kPa (13.5 ± 3.0 psi) 69 ± 21 kPa (10.0 ± 3.0 psi) Normally Closed 114-5334 Refrigerant Pressure (AC) 275 to 1750 kPa ¹ (40 to 255 psi) — — Normally Open ² 125-9352 Stop Lamp Pressure 83 kPa MAX (12 psi MAX) 48 ± 20 kPa MIN (7 ± 3 psi MIN) Normally Open 131-4135 Hydraulic Oil Temperature 102 ± 3°C (215.6 ± 5.4 °F) 90 °C MIN (194.0 °F MIN) Normally Closed ² Contact position at the contacts of the harness connector. 40 D 15 13 E 28 2 Resistor, Sender and Solenoid Specifications Part No. A B 9 24 25 1 16H Motor Grader Electrical System 7 14 19 8 3 31 32 22 5 C 17 33 26 37 6 12 16 38 35 4 11 34 Component Description Resistance (Ohms)¹ 3E-1906 Solenoid - A/C Clutch 17.6 ± 0.6 3E-5383 Sender - Articulation Position 3 to 97 3E-7985 Solenoid - Engine Shutdown Start (Latch) 1.55 ± 0.15 Stop (Unlatch) 10.30 ± 1.03 7N-8532 Sender - Engine Coolant 7T-4003 Resistor 10.0 ± 0.5 7T-6517 Solenoid - Blade Cushion 20.1 ± 1.0 7T-9074 Solenoid - Forward Horn Park Brake 55.17 ± 5.77 9G-1950 Resistor - Blower Speed Overall 2.00 ± .10 Tap 1.00 ± .05 9G-4365 Solenoid - Start Aid 6.0 9X-9482 Solenoid - Centershift 68 144-6295 Solenoid - Differential Unlock 16H: 6ZJ331-UP 30 29 39 27 10 23 36 20 54°C (130°F)- 560 to 716 110°C (230°F) - 72 to 82 33.6 ± 1.0 ¹ At room temperature unless otherwise noted. Alarm — Action Schematic Location B-8 Alarm — Backup F-15 Component Title Deactuate pressure the closed condition can be maintained down to 170 kPa (25 psi). The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Related Electrical Service Manuals Engine Coolant Temperature Actuate 107.0 ± 3.0 °C (224.6 ± 5.4 °F) ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing 27 40 Off Machine Switch Specification 26 34 23 Function Component Location Machine Location C 1 Component Resistor — Blower Speed Resistor— Blower Speed (A/C) Schematic Location E-4 Machine Location E B-11 15 Wire Number Wire Color RD Wire Description Description © 1998 Caterpillar All Rights Reserved Wire Number Wire Color OR Eng Coolant Temp Gauge Power Circuits Description Monitoring Circuits (cont'd) Alternator (35A STD) D-14 2 Resistor — Blower Speed (Heater) A-11 E 101 Bat (+) 441 Arc — Suppressor E-14 3 Resistor - Panel Lamp Dimmer E-9 B 102 RD Hd Lmp 447 PK Fuel Level Gauge Battery C-14 5,6 Sender — Articulation C-12 23 103 RD Aux Ckt 450 YL Tach Sender (+) Beacon C-1 7 Sender — Engine Coolant Temp A-14 24 105 RD Key Start Sw 462 YL Secondary Ster Motor Indicator Beacon A-12 7 Sender — Fuel Level A-13 25 108 RD Aux Ckt 488 WH Brake Air Switches Breaker — Alternator (60A) D-13 8 Solenoid — A/C Clutch A-13 22 109 RD Alt Output (+) Term. A429 YL Articulation Indicator Breaker — Convertor (15A) F-11 13 Solenoid — Centershift B-3 29 112 PU Main Power Rly Output Breaker — Headlamp (1 5A) D-10 B Solenoid — Differential Unlock E-14 4 113 OR Opr Mon Panel B+ Switched 500 BR Wiper — Front (Park) Breaker — Lightbar (1 5A) D-10 B Solenoid — Engine Shutdown D-13 22 114 RD Warning Horn (Forward) 501 GN Wiper — Front (Low) Control — Secondary Steer E-13 9 F-3 10 115 RD Aux Ckt 502 OR Wiper — Front (Hi) Convertor — Voltage F-8 12 Solenoid — Park Brake B-11 10 116 BR Aux Ckt 503 BR Wiper — Rear (Park) Converter — Voltage F-10 12 Solenoid — Start Aid A-13 25 118 GY Aux Ckt 504 YL Wiper — Rear (Low) Converter — Voltage F-12 13 Solenoids — Blade Cushion E-2 30 119 PK Aux Ckt 505 BU Wiper — Rear (Hi) Flasher E-10 B Switch — A/C Refrigeration A-13 22 121 RD Centershift Solenoid 506 PU Washer — Front Fuses D-9 B Switch — Air Dryer F-14 31 122 BU Aux Ckt 507 WH Washer — Rear Fuses E-10 B Switch — Back-Up Alarm F-14 4 124 GN A/C 508 PU Radio Speaker — Left Fuses (10A) B-6 C Switch - Beacon B-5 C 129 BU Aux Ckt 509 WH Radio Speaker — Left (Commom) Gauge — Articulation F-5 A Switch — Beacon B-10 C 130 RD Aux Ckt 511 BR Radio Speaker — Right Gauge — Engine Coolant Temperature F-5 A Switch — Blower (A/C) B-10 C 134 RD Aux Ckt 512 GN Radio Speaker — Right (Common) Gauge — Fuel Level E-5 A Switch — Blower (Heater) A-10 C 135 BU Aux Ckt 513 OR A/C Compressor/Refrigerant Pressure Sw Gauge — System Air Pressure (Left) E-5 A Switch — Brake Air Pressure A-2 11 136 GN Secondary Ster 515 GY Blower Motor (Hi) Gauge — System Air Pressure (Right) E-5 A Switch — Brake Air Pressure A-2 11 141 PK Aux Ckt 516 GN Blower Motor (Medium) Ground — Cab D-5 17 Switch — Centershift Pin B-9 C 144 RD 517 BU C-13 19 C Blower Motor (Low) Switch — Blade Cushion B-9 Aux Ckt Ground — Engine 147 RD 521 YL 39 Switch — Defroster (Front) A-5 C A/C Sw To Refrigerant Sw Ground — Front Frame (A) D-6 Aux Ckt 149 PU WH 17 Switch — Defroster (Rear) B-5 C A/C Clutch To Thermostat Sw Ground — Front Frame D-6 Aux Ckt 522 151 GN 537 GN D Switch — Differential Unlock D-9 B Turn Signal Sw To Flasher Ground — Localized Stud F-12 Aux Ckt 152 BU 556 WH C-13 8 6 Differential Lock Switch — Disconnect C-14 Aux Ckt Ground — Rear Frame 165 YL 570 BU 23 Switch — Engine Coolant Temp (Monitor) B-14 24 Blade Cushion Sol Ground — Strap C-12 Aux Ckt E-5 A 24 PK Aux Ckt 575 YL Wiper — Aux (Park) Switch — Engine Coolant Temp (Start Aid) A-14 169 Lamp — Diff Unlock A 32 Aux Ckt 576 PK Switch — Engine Oil Pressure C-13 RD Lamp — Master Action E-5 173 Wiper — Aux (Low) C B OR Aux Ckt 577 PU Switch — Flood Lamps D-8 176 Lamp — Shift Lever B-9 Wiper — Aux (Hi) A Switch — Forward Horn E-9 B BU Lamp — Turn Indicator (Left) E-5 578 Washer — Aux Lamp — Turn Indicator (Right) E-4 A Switch — Fuel Pressure B-13 24 Meter — Service E-10 B Switch — Head/Tail Lamp E-8 B Monitor — Electronic Monitoring System (EMS) E-6 A D-9 B 301 BU Starter No.1 Sol Motor—Blower A-12 15 Switch — Hydraulic Oil Temperature B-11 33 304 WH Starter Relay No. 1 Output Motor — Blower (A/C group) B-10 14 Switch — Key Start B-9 C 306 GN Motor — Blower (Heater group) A-10 E Switch — Light Bar Low Beam E-8 B 307 B 308 Motor — Blower/Defroster E-4 15 Solenoid — Forward Horn Switch — Headlamp Dimmer Switch — Monitor (EMS) Test E-8 Ground Circuits BK Main Chassis 584 YL Wiper Sw Jumper 201 BK Operator Monitor Return 592 BU DC/DC Converter Power Output 597 PU A/C Refrigerent Press Sw A503 PK Front Defroster Fan (Low) A504 GN Rear Defroster Fan (Low) Starter Relay Coil A506 OR Front Defroster Fan (Hi) OR Key Start Switch A507 YL Rear Defroster Fan (Hi) YL Main Power Relay Coil A513 PK DC/DC Converter Memory Output PU Engine Test Sw To Start Aid Sol Harness And Wire Electrical Schematic Symbols WH Start Aid Sol To Temp Sw 600 BR Dash Lamp Basic A F-13 20 Switch — Neutral/Start E-14 4 Motor — Starter C-13 19 Switch — Panel Lamp Dimmer E-9 B 311 Motor — Washer (Front Lower) F-6 16 Switch — Park Brake Pressure B-11 34 321 BR Bckp Alarm 601 GY Dash Lamp Hi Motor — Washer (Front Upper) F-6 16 Switch — Primary Steer F-10 35 322 GY Warning Horn (Forward) 603 PK Rotary Beacon Motor — Washer (Rear) F-6 16 Switch — Stop Lamp Pressure A-2 11 326 RD Key Start Sw “C” Term. 604 OR Stop Lamp Motor — Wiper (Front Lower) C-4 17 Switch — Secondary Steer Test B-8 C 605 YL Turn Lamp — Left Motor — Wiper (Front Upper) D-4 17 Switch — Tail Lamp D-8 B 403 GN Alternator (R) Term. 606 GY Turn Lamp — Right Motor — Wiper (Rear) A-11 18 Switch — Turn Signal D-9 B 404 YL Opr Mon Hyd Oil Temp 608 GN Flood Lamp — Rear Motors — Condenser B-11 21 Switch — Wiper (Front Lower) A-4 C 405 GY Opr Mon Oil Press. (Low Setting) 609 YL Flood Lamp — Side Relay — Main D-14 8 Switch — Wiper (Front Upper) B-4 C 406 PU Opr Mon Coolant Temp 611 PU Head Lamp Hi Relay — Secondary Steer F-1 3 22 Switch — Wiper (Rear) A-4 C 408 WH Opr Mon System Air Press. 614 PU Park/Tail/Dash/Lamp Relay — Start D-13 8 Thermostat (A/C) B-11 E 409 OR Opr Mon Neut 619 GN Head Lamp Lo Resistor — Blower Speed A-11 E 410 WH Opr Mon Action Alarm 629 PK Aux Head Lamp Machine locations are repeated for components located close together. 411 PK Opr Mon Master A = Operator’s compartment (Dash). 413 BR Opr Mon Fuel Press. 727 GN Secondary Ster Motor Relay B = Operator’s compartment (Steering console). 415 GN Opr Mon Test Sw 728 BU Secondary Ster Cont Sw C = Operator’s compartment (Right side console). 417 GY Primary Ster Sw E773 YL Centershift Solenoid D = Operator’s compartment (Headliner). 419 YL Opr Mon Parking Brake F775 BU Centershift Solenoid Control Circuits AA T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Wire, Cable, or Harness Assembly Identification Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Component Part Number Single Wire Connector Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. C A A 325-PK-14 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket Normally closed switch that will open with an increase of a specific condition. 2 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. Wire Gauge Electrical Schematic Symbols And Definitions The circle indicates that the component has screw terminals and a wire can be disconnected from it. FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. 200-BK-14 Circuit Number Identification Lighting Circuits Motor — Secondary Steer 310 Monitoring Circuits Electrical Schematic Symbols And Definitions Accessory Circuits 200 Basic Machine Circuits Printed in U.S.A. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Wire Number Wire Color 101 RD 102 103 Wire Description Wire Number Wire Color Bat (+) 500 BR Wiper - Front (Park) BU HdLmp 501 GN Wiper - Front (Low) YL AuxCkt 502 OR Wiper - Front (HI) 105 BR Key SW 503 BR Wiper - Rear (Park) 107 WH Eng Shut 504 YL Wiper - Rear (Low) 108 BU AuxCkt 505 BU Wiper - Rear (HI) 109 OR Alt Output (+) Term. 506 PU Washer - Front 112 PU Main Power Rly Output 507 WH Washer - Rear 113 OR Opr Mon Panel B+ Switched 508 PU Radio Speaker - Left 114 GN Warning Horn (Forward) 509 WH Radio Speaker - Left (Commom) PK Aux Ckt 511 BR Radio Speaker - Right 116 BR Aux Ckt 512 GN Radio Speaker - Right (Common) 118 GY Aux Ckt 513 OR A/C Compressor/Refrigerant Pressure SW Description Title Form Number Alternator (6N-9294 35A): STD Consist No. 3T-6352 Consist No. 7N-9720 Consist No. 9G-4574 SENR4978 SENR2082 SENR4130 115 Alternator (100-5047 50A): ATT SENR2082 119 PK Aux Ckt 515 GY Blower Motor (HI) Electronic Monitoring System SENR2945 122 BU Aux Ckt 516 GN Blower Motor (Medium) Electronic Transmission Shift Control SENR6982 124 GN A/C 517 BU Blower Motor (Law) Starting And Charging Systems SENR2947 126 PK Xmsn Ctrl 521 YL A/C SW To Refrigerant SW Starting Motor: (106-8555) Consist No. 6V-5207 Consist No. 6V-5023 Consist No. 6V-5226 130 GN Aux Ckt 522 WH A/C Clutch Ta Thermostat SW SENR3581 SENR3536 SENR4975 134 YL Aux Ckt 537 GN Turn Signal SW To Flasher 136 GN Suppl Ster 556 WH Differential Lock 141 PK Aux Ckt 570 BU Blade Cushion Sal 144 GN Aux Ckt 575 YL Wiper - Aux (Park) 149 PU Aux Ckt 576 PK Wiper - Aux (Low) 151 GN Aux Ckt 577 PU Wiper - Aux (HI) 152 BU Aux Ckt 578 BU Washer - Aux 158 BR Aux Ckt 584 YL Wiper SW Jumper 160 PU Aux Ckt 592 BU DC/DC Converter Power Output 165 YL Aux Ckt 593 GN Condensor Fan Relay To Motors 169 PK Aux Ckt 597 PU A/C HI Press. Coutout SW To Low Press. SW 173 YL Aux Ckt A503 PK Front Defroster Fan (Low) 176 OR Aux Ckt A504 GN Rear Defroster Fan (Low) A506 OR Front Defroster Fan (HI) 200 BK Main Chassis A507 YL Rear Defroster Fan (HI) 201 BK Operator Monitor Return A513 PK DC/DC Converter Memory Output 202 BK XMSN Ctrl 203 BK Chassis Diagnostic 600 BR Dash Lamp Basic 207 BK Starter Diagnostic 601 GY Dash Lamp Hi 277 BK XMSN Ctrl Ident Code 1 603 PK Rotary Beacon 278 BK XMSN Ctrl ldent Code 2 604 OR Stop Lamp 605 YL Turn Lamp Left 301 BU Starter No. 1 Sol 606 GY Turn Lamp - Right 302 OR Starter No. 1 Resistor to Diagnostic 608 GN Flood Lamp - Rear 304 WH Starter Relay No. 1 Output 609 YL Flood Lamp - Side 306 GN Starter Relay Coil To Neut Start SW Or Key SW 611 PU HeadLamp Hi 307 OR Key SW To Neut Start SW 614 PU Park/Tail/Dash/Lamp 308 YL Main Power Relay Coil 619 GN Head Lamp Lo 310 PU Start Aid SW To Start Aid Sol 629 PK Aux Head Lamp 311 WH Start Aid Sal To Temp SW 321 BR Bckp Alarm Lamp Travel Alarm 710 GN XSMN Speed Pickup Signal 322 GY Warning Horn (Forward) 727 GN Suppl Ster Motor Relay 326 PU Key SW “C” Term. 728 BU Suppl Ster Cant SW 327 PK Shutdown Sol 751 ON XMSN Shift Sal No. I Or 3 334 BU Start Aid Sol #2 752 YL XMSN Shift Sol No. 2 373 GN Start Aid Switch To Timer 754 BU XMSN Shift Sal No. 3 Or 1 755 OR XMSN Shift Sal No. 4 Or 5 Ground Circuits Connector Location Machine Location CONN 1 D-15 27 CONN 2 E-15 27 CONN 3 E-15 27 CONN 4 F-14 36 CONN 5 F-14 41 CONN 6 Start and Charge Diag. E-14 42 CONN 7 A-14 25 CONN 8a A-14 43 CONN 8b A-14 43 CONN 9 B-13 37 CONN 10 B-13 37 CONN 11 B-13 37 CONN 12 D-13 37 CONN 13 D-13 37 CONN 14 D-13 37 CONN 15 E-13 37 CONN 16 F-12 37 CONN 17 F-12 39 CONN 18 E-12 39 Off Machine Switch Specification Part No. Function Actuate Deactuate Contact Position 2M-9346 Brake Air Pressure (Stop Lamp) 45 kPa MAX (6.5 psi MAX) 5 kPa MIN (0.5 psi MIN) Normally Open 3E-2033 Brake/Park Brake Air Pressure 640 kPa MAX (92.0 psi MAX) 530±40 kPa (77.0 ± 6.0 psi) Normally Open 7N-9785 Engine Coolant Temp 107.2 ± 2.8°C (225 ± 5°F) 93.0°C MIN (200°F MIN) Normally Closed 8N-1 693 Coolant Temperature (Start Aid) 37.8 ± 2.8°C (100 ± 5°F) 26.7°C MIN (80°F MIN) Normally Closed 8N-2248 Hyd Oil Temperature 101 .7°C MIN (215°F MIN) 93.3°C MIN (200°F MIN) Normally Closed 1206 kPa MAX (l75psiMAX) 700 ± 103 kPa (101.5±l5psi) 1-2 NO 1-3 NC 9W-3187 Fuel Pressure (EMS) 93 ±21 kPa (13.5 ± 3.0 psi) 69 ±21 kPa (10.0 ± 3.0 psi) Normally Closed 9X-0378 Engine Oil Pressure 62.0 kPa MAX (9.0 psi MAX) 38 ± 20 kPa (5.5 ± 3.0 psi) Normally Open 111-7088 Inching Pedal Pressure 75.0 kPa MAX (10.9 psi MAX) 50.0 kPa MIN (7.3 psi MIN) Normally Open 8T-8640 Steering Press 275 to 1750 kPa ¹ (40 to 255 psi) 114-5334 Refrigerant Pressure (A/C) - 403 GN Alternator (R) Term. 758 GM AWD Clutch SW 404 YL Opr Mon Hyd Oil Temp 795 YL Dual Hp Sal ² Contact position at the contacts of the harness connector. 405 GY Opr Mon Oil Press. (Low Setting) B751 GN Centershift Lock Sol 406 PU Opr Mon Coolant Temp F769 BU AWD Ta Inch Pedal SW 408 WH Opr Mon System Air Press. 892 BR 409 OR Opr Mon Neut 893 410 WH Opr Mon Fault Alarm B899 411 PK Opr Mon Master 413 BR Opr Mon Fuel Press. 415 GN 417 Component Location Start Mod Right (-) Part/CAT Data Link (-) Resistor - Blower Speed (Heater) GN Start Mad Right (+) Part/CAT Data Link (+) Alternator (60A STD) D-14 2 Resistor - Panel Lamp Dimmer E-9 B OR AWO Agressiveness Cant Lever 900 PU E-14 3 Resistor - Starter/Diag. Conn C-14 42 XMSN Shift Sal No. 4 Arc - Suppressor 901 WH XMSN Shift Sal Na. 6 Battery C-14 5,6 Sender-Articulation C-12 23 Opr Man Test SW 902 BR XMSN Shift Sol No. 7 Beacon C-10 7 Sender - Engine Coolant Temp A-14 24 GY Primary Ster SW 903 GY XMSN Shift Sal No. 8 Beacon A-12 7 Sender- Fuel Level A-13 25 419 YL Opr Mon Parking Brake 921 WH XMSN Sal Na 1 Or 3 Return Breaker - Alternator (60A) D-13 8 Sender - Transmission Speed D-15 28 439 YL Lamp Indicator 977 YL CST Autoshift - Auto/Manual SW 1 Breaker - Convertor (15A) F-11 13 Sensor - Engine Speed B-14 26 441 OR Eng Coolant Temp Gage E937 PU MG MESH CNTL - Redundant Neutral 447 PK Fuel Level Gage E938 OR MG MESH CNTL - First Gear Breaker - Headlamp (15A) D-10 B Solenoid - A/C Clutch A-13 22 449 BU Spdom Sender (Signal No. 1) E939 WH MG MESH CNTL - Second Gear Breaker - Lightbar (15A) D-10 B Solenoid - Centershift B-3 29 450 YL Tach Sender (+) E940 BU MG MESH CNTL - Third Gear Control - Engine Shutdown E-13 9 Solenoid - Differential Unlock E-14 4 A-8 10 Solenoid - Dual Horsepower A-13 22 Component Resistor - Blower Speed (A/C) Schematic Location B-11 Machine Location 15 A-11 E 462 YL Suppl Ster Motor Indicator E941 YL MG MESH CNTL - Fourth Gear Control - Neutral Start 467 WH System Fault (Xmsn) E942 GN MG MESH CNTL - Fifth Gear Control - Secondary Steer E-13 9 Solenoid - Dual HP/Shutdown A-12 22 485 YL Opr Mon Panel AWD Fault E943 BR MG MESH CNTL - Sixth Gear A-7 C 22 WH Air SW to AIR SW Jumper E944 GY Solenoid - Engine Shutdown D-13 488 Control - Transmission MG MESH CNTL - Seventh Gear A429 YL Articulation Indicator E945 PU MG MESH CNTL - Eigth Gear Converter - Voltage F-10 12 Solenoid - Forward Horn F-3 10 G460 GN Transmission Temperature SW E946 OR MG MESH CNTL - Forward Direct Converter - Voltage F-12 13 Solenoid - Park Brake B-11 10 E947 WH MG MESH CNTL - Reverse Direct Flasher E-10 B Solenoid - Start Aid A-13 25 E948 BU MG MESH CNTL - Park Fuses D-9 B Solenoids - Blade Cushion E-2 30 E949 YL MG MESH CNTL - Neutral Fuses E-10 B Solenoids - Transmission Valve (8) D-15, E-15 27 E975 PU MESH Lamp Fuses (10A) B-6 C Switch - A/C Refrigeration A-13 22 E-12 10 CONN 20 E-12 10 CONN 21 E-12 10 CONN 22 E-12 10 CONN 23 D-12 39 CONN 24 D-12 39 CONN 25 D-12 39 Gauge - Articulation F-5 A Switch - Air Dryer F-14 31 CONN 26 B-12 10 Gauge - Engine Coolant Temperature F-5 A Switch - Beacon B-6 C CONN 27 F-11 D E-5 A C D-10 B Switch - Beacon B-10 CONN 28 Gauge - Fuel Level CONN 29 D-10 B Gauge - Speedometer F-5 A Switch - Blower (A/C) B-10 C CONN 30 D-10 39 Gauge - System Air Pressure (Left) E-5 A Switch - Blower (Heater) A-10 C CONN 31 D-10 39 Gauge - System Air Pressure (Right) E-5 A Switch - Brake Air Pressure A-2 11 CONN 32 D-10 39 Gauge - Tachometer E-5 A Switch - Brake Air Pressure A-2 11 CONN 33 C-10 33 Ground - Cab D-5 17 Switch - Centershift Indicator B-3 29 CONN 34a C-10 33 Ground - Engine C-13 19 Switch - Centershift Pin B-9 C CONN 34b C-10 33 CONN 35a A-10 38 Ground - Front Frame (A) D-6 39 Switch - Cushion Blade B-9 C CONN 35b B-11 38 16 Ground - Front Frame (ZZ) D-6 17 Switch - Defroster (Front) A-6 C CONN 35c A-11 38 13 Ground - Localized Stud F-12 D Switch - Defroster (Rear) B-6 C CONN 36 B-9 38 Ground - Rear Frame C-13 8 Switch - Differential Unlock D-9 B CONN 37 B-9 38 45 Ground - Strap C-12 23 Switch - Disconnect C-14 6 CONN 38 E-9 B D-5 A Switch - Engine Coolant Temp (Monitor) B-14 24 E-9 39 17 30 29 Lamp - AIH Indicator CONN 39 E-5 A 24 D-8 39 Switch - Engine Coolant Temp (Start Aid) A-14 CONN 40 Lamp - C Shift Pin CONN 41 D-8 39 Lamp - Master Action E-5 A Switch - Engine Oil Pressure C-13 32 CONN 42 D-8 39 Lamp - Shift Lever B-9 C Switch - Flood Lamps D-8 B CONN 43 D-8 39 Lamp - Transmission D-5 A Switch - Forward Horn E-9 B CONN 44 B-8 38 Lamp - Turn Indicator (Left) E-5 A Switch - Fuel Pressure B-13 24 CONN 45 A-8 C Lamp - Turn Indicator (Right) E-4 A Switch - Head/Tail Lamp E-8 B CONN 46 B-7 38 Meter - Service E-10 B Switch - Headlamp Dimmer D-9 B CONN 47 B-7 38 CONN 48 Service Tool B-7 C Monitor - Electronic Monitoring System(EMS) E-6 A Switch - Hydraulic Oil Temperature C-12 33 CONN 49a F-7 39 Motor - Blower A-12 15 Switch - Inching Pedal Pressure C-15 27 CONN 49b F-7 39 Motor - Blower (A/C group) B-10 14 Switch - Key Start B-9 C CONN 50 E-6 17 Motor - Blower (Heater group) A-10 E Switch - Light Bar Low Beam E-8 B CONN 51 E-6 17 21 Motor - Blower/Defroster E-4 15 Switch - Monitor (EMS) Test E-8 B CONN 52 E-6 17 18 Motor - Secondary Steer F-13 20 Switch - Panel Lamp Dimmer E-9 B CONN 53 D-6 17 CONN 54 C-6 17 Motor - Starter C-13 19 Switch - Park Brake Pressure B-11 34 CONN 55 C-6 17 Motor - Washer (Front Lower) F-6 16 Switch - Primary Steer F-10 35 CONN 56 C-6 17 Motor - Washer (Front Upper) F-6 16 Switch - Start Aid/Monitor Test E-10 B CONN 57 C-5 40 Motor - Washer (Rear) F-6 16 Switch - Stoplamp Pressure A-2 11 CONN 58 A-6 40 Motor - Wiper (Front Lower) C-4 17 Switch - Secondary Steer Test B-8 C CONN 59 C-5 40 Motor - Wiper (Front Upper) D-4 17 Switch - Tail Lamp D-8 B CONN 60 C-5 40 18 C 44 Switch - Transmission Direction & Speed A-8 B-3 Motor - Wiper (Rear) A-11 CONN 61 CONN 62 E-3 45 Motors - Condenser B-11 21 Switch - Transmission Oil Temp E-15 27 CONN 63 E-3 45 Relay - Condenser C-10 21 Switch - Turn Signal D-9 B CONN 64 F-3 45 Relay - Main D-14 8 Switch - Wiper (Front Lower) A-4 C CONN 65 F-3 45 Relay - Secondary Steer F-13 22 Switch - Wiper (Front Upper) B-4 C Relay - Start D-13 8 Switch - Wiper (Rear) A-4 C Resistor - Blower Speed A-11 E Thermostat (A/C) B-11 E Resistor - Blower Speed E-4 E The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. 28 2 8 22 19 24 37 B 18 7 23 C 10 11 7 14 40 D 15 13 43 2 1 36 24 19 26 32 8 3 27 31 28 B 9 42 5 C 45 16 12 38 35 11 39 44 30 29 10 23 4 A 17 33 22 37 6 44 38 40 E 25 A 34 5 41 15 39 E 21 33 20 D 14 35 9 42 25 1 12 32 Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. 160H: 9EJ1-509 3GM1-79 Harness And Wire Symbols Socket 34 20 Machine Harness Connector And Component Locations Wire Color Machine locations are repeated for components located close together. A = Operator’s compartment (Dash). B = Operator’s compartment (Steering console). C = Operator’s compartment (Right side console). D = Operator’s compartment (Headliner). E = Operator’s compartment (Under seat). Circuit Number Identification Component Part Number Wire, Cable, or Harness Assembly Identification Fuse AA 105-9344 1 Receptacle Wire Gauge Plug Ground Connection 1 41 4 140H: 2ZK1-2391 9ZN1-204 9TN1-399 Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Single Wire Connector F-15 43 12H, 140H And 160H Motor Graders (NA Version) Electrical System T 325-PK-14 Alarm - Backup 27 Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. A CONN 19 36 Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Pin Alarm - Action 6 This indicates that the component has a wire connected to it that is connected to ground. 12H: 4XM1-1395 2WR1-641 8MN1-499 Machine Location C 3 26 Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. Normally Open² Schematic Location B-8 31 Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kPa (25 psi). Component Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Control Circuits Monitoring Circuits Schematic Location Connector Number T Pressure Symbol Lighting Circuits Basic Machine Circuits Electrical Schematic Symbols And Definitions RENR1434 November 1997 Accessory Circuits Power Circuits Related Electrical Service Manuals Description 2 200-BK-14 Pin or Socket Number 1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Printed in U.S.A. © 1997 Caterpillar All Rights Reserved Diagnostic Code Conversion Code Flashed CID - FMI 11 N/A No diagnostics active 12 N/A No logged diagnostic codes 21 641 F05 Transmission Solenoid A open circuit 22 642 F05 Transmission Solenoid B open circuit 23 643 F05 Transmission Solenoid C open circuit 24 644 F05 Transmission Solenoid D open circuit 25 645 F05 Transmission Solenoid E open circuit 26 646 F05 Transmission Solenoid F open circuit Part No. 27 647 F05 Transmission Solenoid G open circuit 28 648 F05 3E-5383 Sender - Articulation Position Transmission Solenoid H open circuit 31 641 F06 Transmission Solenoid A short to ground 32 642 F06 Transmission Solenoid B short to ground 3E-6424 Solenoid - Dual HP Push Coil Pull Coil 4.2 ± 0.42 16.1 ± 1.61 33 643 F06 Transmission Solenoid C short to ground 34 644 F06 Transmission Solenoid D short to ground 3E-7985 35 645 F06 Transmission Solenoid E short to ground Solenoid - Engine Shutdown Start (Latch) Coil Stop (Unlatch) Coil 4.2 ± 0.42 16.1 ± 1.61 36 646 F06 Transmission Solenoid F short to ground 37 647 F06 3T-3123 Resistor - Panel Dimmer 25.0 ± .3 Transmission Solenoid G short to ground 38 648 F06 Transmission Solenoid H short to ground 6T-2217 Resistor - Starter/Diagnostic Conn 150 ± 7.5 41 641 F03 Transmission Solenoid A short to battery 42 642 F03 Transmission Solenoid B short to battery 7N-8532 Sender - Engine Coolant Temp 43 643 F03 Transmission Solenoid C short to battery 7T-4003 Resistor - Power 10.0 ± 0.5 44 644 F03 Transmission Solenoid D short to battery 45 645 F03 Transmission Solenoid E short to battery 7T-6517 Solenoid - Blade Cushion 20.1 ± 1.0 46 646 F03 Transmission Solenoid F short to battery 47 647 F03 Transmission Solenoid G short to battery 7T-9073 Solenoid - Differential Unlock 33.6 ± 1.0 48 648 F03 Transmission Solenoid H short to battery 7T-9074 Solenoid - Foward Horn/Park Brake 52 637 F06 Backup alarm short to ground 54 444 F05 Start Relay Open Circuit 8T-8610 Solenoid - Dual HP 13.5 ± 10 55 444 F06 Start Relay Short To Ground 56 444 F03 Start Relay Short To Battery 8T-8808 Solenoid - Centershift 343 ± 1.7 58 688 F06 VHP 1 solenoid short to ground 9G-1950 Resistor - Blower Speed 59 688 F03 VHP 1 solenoid short to battery 61 668 F02 Shift lever input invalid 9G-4365 Solenoid -Start Aid 62 668 F03 Shift lever open/short to +battery 63 269 F00 Sensor supply voltage above normal 9W-2739 Solenoids - Transmission 31 ± 3 64 269 F01 Sensor supply voltage below normal 101-1759 Solenoids - A/C Clutch 14.4 ± 0.6 65 701 F02 Transmission output speed signal incorrect 68 168 F01 System voltage below normal 71 520 F02 Invalid transmission configuration code 72 268 F02 Check programmable parameters 73 764 F05 Transmission indicator lamp open circuit 74 764 F06 Transmission indicator lamp short to ground 75 764 F03 76 177 F03 Transmission indicator lamp short to battery Transmission oil temperature sender short to battery or open circuit 77 177 F04 Transmission oil temperature switch short to ground Description Resistor, Sender and Solenoid Specifications Component Description ¹ At room temperature unless otherwise noted. Resistance (Ohms)¹ Range - 3 to 97 Ohms 54°C (130°F) - 560 to 716 110°C(230°F) - 72 to 82 55.17 ± 5.77 Overall 2.00 ± .10 Tap 1.00 ± .05 6
Wire Color 101 RD 102 Wire Description Wire Number Wire Color Bat + 504 YL Wiper - Rear (Low) RD Hd Lmp 505 BU Wiper - Rear (HI) 105 RD Key Start Sw 506 PU Washer - Front 107 RD Eng Shut 507 WH Washer - Rear 108 RD Aux Ckt 508 PU Radio Speaker - Left 109 RD Alt Output (+) Term. 509 WH Radio Speaker - Left (Commom) 112 PU Main Power Rly Output 511 BR Radio-Speaker - Right 113 OR Opr Mon Panel B+ Switched 512 GN Radio Speaker - Right (Common) 114 RD Warning Horn (Forward) 513 OR A/C Compressor/Refrigerant Pressure SW 115 RD Aux Ckt 515 GY Blower Motor (HI) 116 BR Aux Ckt 516 GN Blower Motor (Medium) 118 GY Aux Ckt 517 BU Blower Motor (Low) 119 PK Aux Ckt 521 YL A/C SW To Refrigerant SW Description Power Circuits Connector Location Schematic Location Machine Location CONN 1 C-15 27 CONN 2 C-15 27 CONN 3 C-15 27 CONN 4 F-14 36 CONN 5 E-14 41 CONN 6 Start and Charge Diag E-14 42 Connector Number Wire Number 16 36 27 3 26 41 4 43 42 25 1 39 E 21 24 15 D 14 35 9 32 20 13 12 6 31 B 18 A 45 17 30 29 Description Accessory Circuits (Continued) CONN 7 A-14 25 CONN 8a A-14 43 CONN 8b A-14 43 CONN 9 A-14 46 CONN 10 B-13 37 CONN 11 B-13 37 CONN 12 B-13 37 CONN 13 D-13 37 122 BU Aux Ckt 522 WH A/C Clutch To Thermostat SW CONN 14 D-13 37 124 GN A/C 537 GN Turn Signal SW To Flasher CONN 15 D-13 37 126 PK 538 OR CONN 16 E-13 37 Xmsn Ctrl Hazard Indicator CONN 17 F-13 37 130 RD Aux Ckt 539 BU Turn Signal Indicator/Basic Right CONN 18 F-12 D 134 RD Aux Ckt 556 WH Differential Lock CONN 19 F-12 39 136 GN Secondary Ster 570 BU Blade Cushion Sol CONN 20 E-12 39 141 PK AuxCkt 575 YL Wiper - Aux(Park) CONN 21 E-12 38 144 RD Aux Ckt 576 PK Wiper - Aux (Low) CONN 22 E-12 38 149 PU 577 PU CONN 23 E-12 38 AuxCkt Wiper - Aux(HI) CONN 24 D-12 39 151 GN Aux Ckt 578 BU Washer - Aux CONN 25 E-12 37 152 BU Aux Ckt 584 YL Wiper SW Jumper CONN 26 D-12 39 158 BR Aux Ckt 592 BU DC/DC Converter Power Output CONN 27 D-12 39 160 PU Aux Ckt 593 GN Condensor Fan Relay To Motors 165 YL Aux Ckt 597 PU A/C HI Press. Cut out SW To Low Press. SW 169 PK Aux Ckt A503 PK Front Defroster Fan (Low) 173 RD Aux Ckt A504 GN Rear Defroster Fan (Low) 176 OR Aux Ckt A506 OR Front Defroster Fan (HI) A507 YL Rear Defroster Fan (HI) A51 3 PK DC/DC Converter Memory Output 28 2 46 22 19 8 37 33 7 23 34 5 C 10 21 18 11 7 14 40 D 15 13 E 41 46 24 25 43 19 26 32 A B 9 42 44 38 40 C 17 33 45 22 37 16 38 39 44 30 29 CONN 28 B-12 10 CONN 29a B-11 38 CONN 29b B-11 38 CONN 29c A-11 38 CONN 30 D-11 39 CONN 31 D-11 39 CONN 32 D-11 39 200 BK Main Chassis CONN 33 D-11 B 201 BK Operator Monitor Return CONN 34 D-11 B CONN 35 E-10 B 202 BK XMSN Ctrl 600 BR Dash Lamp Basic CONN 36 D-10 B 203 BK Chassis Diagnostic 601 GY Dash Lamp Hi CONN 37 C-10 21 207 BK Starter Diagnostic 603 PK Rotary Beacon CONN 38 C-10 33 277 BK XMSN Ctrl Ident Code 1 604 OR Stop Lamp CONN 39 B-9 38 278 BK XMSN Ctrl Ident Code 2 605 YL Turn Lamp - Left CONN 40 B-9 38 606 GY Turn Lamp - Right CONN 41 F-9 39 CONN 42 E-8 39 301 BU Starter No. 1 Sol 608 GN Flood Lamp - Rear CONN 43 D-8 39 302 OR Starter No. 1 Resistor to Diagnostic 609 YL Flood Lamp - Side CONN 44 D-8 39 304 WH Starter Relay No. 1 Output 610 OR Head Lamp Basic CONN 45 B-8 38 306 GN Starter Relay Coil To Neut Start SW Or Key Start Sw 611 PU HeadLamp Hi CONN 46 A-8 C 307 OR Key Start SW To Neut Start Sw 615 YL Cab Flood Lamp/Rops CONN 47 B-7 38 308 YL Main Power Relay Coil 617 BR Tail Position Lamp - Left (Road Pkg)/ Width CONN 48 B-7 38 CONN 49 Service Tool B-7 C Alarm - Action Schematic Location B-8 310 PU Start Aid SW To Start Aid Sol 618 YL Tail Position Lamp - Right (Road Pkg/Width CONN 50 E-6 17 Alarm - Backup 311 WH Start Aid Sol To Temp Sw 619 GN Head Lamp Lo CONN 51 E-6 17 321 BR Bckp Alarm Lamp Travel Alarm 668 BU Headlamp Sw/Taillamp Relay Control Circuits CONN 52 E-6 17 322 GY Warning Horn (Forward) CONN 53 D-6 17 326 RD Key Start Sw “C” Term. 710 GN XSMN Speed Pickup Signal CONN 54 C-6 17 327 PK Shutdown Sol 727 GN Secondary Ster Motor Relay CONN 55 C-6 CONN 56 334 BU Start Aid Sol #2 728 BU Secondary Ster Cont SW 373 GN Start Aid Switch To Timer 751 GN XMSN Shift Sol No. 1 or 3 752 YL XMSN Shift Sot No. 2 2 1 8 3 5 6 27 31 36 12 35 10 23 4 28 11 34 20 Ground Circuits Machine Harness Connector And Component Locations Basic Machine Circuits Component Location This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 12H, 140H, 160H Motor Grader (ES Version) Electrical System 12H: 2LR1-294 2GS1-359 140H: 3AS1-449 8KM1-393 Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. 160H: 2HS1-379 6WM1-340 Harness And Wire Symbols Pin Single Wire Connector D-14 2 Resistor - Blower Speed (A/C) B-11 15 Arc - Suppressor E-14 3 Resistor - Blower Speed (Heater) A-11 E Battery C-14 5,6 Resistor - Panel Lamp Dimmer E-10 B 17 Beacon A-12 7 Resistor - Starter/Diag. Conn C-14 42 C-6 17 Breaker - Alternator (60A) D-13 8 Sender - Articulation C-12 23 CONN 57 C-6 40 Breaker - Cab Flood Lamp (15A) D-10 B Sender - Engine Coolant Temp A-14 24 CONN 58 A-6 40 CONN 59 C-5 40 Breaker - Convertor (15A) E-12 13 Sender - Fuel Level A-13 25 CONN 60 C-5 40 Breaker - Headlamp & Right Tail/Pos (15A) D-11 B Sender - Transmission Speed B-15 28 CONN 61 F-3 17 Breaker - Left Tail (15A) D-11 B Sensor - Engine Speed B-14 26 CONN 62 E-3 30 Control - Engine Shutdown E-13 9 Solenoid - A/C Clutch A-13 22 CONN 63 E-3 45 Control - Neutral Start A-8 10 Solenoid - Centershift B-3 29 CONN 64 D-3 17 Control - Secondary Steer E-14 9 Solenoid - Differential Unlock E-14 4 CONN 65 B-3 44 11 22 30 Solenoid - Dual Horsepower A-13 B-3 Control - Transmission A-7 CONN 66 CONN 67 F-14 36 Converter - Voltage F-11 12 Solenoid - Dual HP/Shutdown A-12 22 Converter - Voltage F-13 13 Solenoid - Engine Shutdown D-13 22 Flasher D-10 B Solenoid - Forward Horn F-3 10 Fuses D-10 B Solenoid - Park Brake B-12 10 Fuses E-11 B Solenoid - Start Aid A-13 25 Fuses (10A) B-6 C Solenoids - Blade Cushion E-2 30 Gauge - Articulation F-5 A Solenoids - Transmission Valve (8) C-15 27 Gauge - Engine Coolant Temperature F-5 A Switch - A/C Refrigeration A-13 22 Gauge - Fuel Level E-5 A Switch - Air Dryer F-15 31 Gauge - Speedometer F-5 A Switch - Autoshift A-9 C Gauge - System Air Pressure (Left) E-5 A Switch - Beacon B-6 C Gauge - System Air Pressure (Right) E-5 A Switch - Blower (A/C) B-10 C Gauge - Tachometer E-5 A Switch - Blower (Heater) A-10 C Ground - Engine C-13 19 Switch - Brake Air Pressure A-2 11 Ground - Front Frame D-5 39 Switch - Brake Air Pressure A-2 11 Ground - Localized Stud F-13 D Switch - Centershift Indicator C-3 29 Ground - Rear Frame C-13 8 Switch - Centershift Pin B-9 C Ground - Strap (Front Frame To Cab) C-5 17 Switch - Cushion Blade B-9 C Ground - Strap (Rear To Front Frame) C-12 23 Switch - Defroster (Front) A-6 C Lamp - AIH Indicator D-5 A Switch - Defroster (Rear) B-6 C Lamp - C Shift Pin E-5 Switch - Differential Unlock D-9 Lamp - Hazard Indicator E-5 A Switch - Disconnect C-14 6 Lamp - High Beam Indicator D-6 A Switch - Engine Coolant Temp (Monitor) B-14 24 Lamp - Master Action E-5 A Switch - Engine Coolant Temp (Start Aid) A-14 24 ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kPa (25 psi). Lamp - Shift Lever B-9 C Switch - Engine Oil Pressure C-13 32 ² Contact position at the contacts of the harness connector. Lamp - Transmission D-6 A Switch - Flood Lamps (Front) D-8 B Lamp - Turn Indicator E-5 A Switch - Flood Lamps (Rear) D-8 B Meter - Service Monitor - Electronic Monitoring System (EMS) E-10 B Switch - Forward Horn E-9 B E-6 A B-13 24 Motor - Blower A-12 15 Switch - Head/Tail Lamp E-8 B Motor - Blower (A/C group) B-10 14 Switch - Headlamp Dimmer E-9 B Motor - Blower (Heater group) A-10 E Switch - Hydraulic Oil Temperature C-11 33 Motor - Blower/Defroster E-4 15 Switch - Inching Pedal Pressure C-15 27 Motor - Secondary Steer F-14 20 Switch - Key Start B-9 C Motor - Starter C-13 19 Switch - Panel Lamp Dimmer E-10 B Motor - Washer (Front Lower) F-6 16 Switch - Park Brake Pressure B-11 34 Motor - Washer (Front Upper) F-6 16 Switch - Primary Steer F-12 35 3E-7985 Motor - Washer (Rear) F-6 16 Switch - Secondary Steer Test B-8 C Motor - Wiper (Front Lower) B-4 17 Switch - Start Aid/Monitor Test E-9 B 3T-3123 6T-2217 Motor - Wiper (Front Upper) C-4 17 Switch - Stoplamp Pressure A-2 11 Motor - Wiper (Rear) B-11 18 Switch - Thermostat (A/C) B-11 E Motors - Condenser B-11 21 Switch - Transmission Direction & Speed A-8 C Relay - Cab Flood Lamp E-11 B Switch - Transmission Oil Temp C-15 27 Relay - Condenser C-11 21 Switch - Turn Signal E-9 B Relay - Main D-14 8 Switch - Wiper (Front Lower) A-4 C Relay - Secondary Steer F-14 22 Switch - Wiper (Front Upper) B-4 C Relay - Start D-13 8 Switch - Wiper (Rear) A-4 C Relay - Tail Lamp (Right) E-8 B Form Number Alternator (100-5047 50A): STD SENR2082 Electronic Monitoring System SENR2945 Electronic Transmission Shift Control SENR6982 Starting And Charging Systems Starting Motor: (106-8555) Consist No. 6V-5207 Consist No. 6V-5023 Consist No. 6V-5226 SENR2947 SENR3581 SENR3536 SENR4975 A Machine locations are repeated for components located close together. A = Operator’s compartment (Dash). B = Operator’s compartment (Steering console). C = Operator’s compartment (Right side console). D = Operator’s compartment (Headliner). E = Operator’s compartment (Under seat). Switch - Fuel Pressure B Alternator (R) Term. 754 BU XMSN Shift Sol No. 3 or 1 404 YL Opr Mon Hyd Oil Temp 755 OR XMSN Shift Sol No. 4 or 5 405 GY Opr Mon Oil Press. (Low Setting) 758 GN AWD Clutch SW 406 PU Opr Mon Coolant Temp 795 YL Dual Hp Sol 408 WH Opr Mon System Air Press. F769 BU AWD To Inch Pedal SW 409 OR Opr Mon Neut F775 BU Centershift Solenoid 410 WH Opr Mon Fault Action Alarm 892 BR Start Mod Right (-) Port/CAT Data Link (-) 411 PK Opr Mon Master 893 GN Start Mod Right (+) Port/CAT Data Link (+) 413 BR Opr Mon Fuel Press. G865 BU +12 Volt Switch Power 415 GN Opr Mon Test SW 900 PU XMSN Shift Sol No. 4 417 GY Primary Ster SW 901 WH XMSN Shift Sol No. 6 419 YL Opr Mon Parking Brake 902 BR 439 YL Lamp Indicator 903 GY 441 OR Eng Coolant Temp Gauge 921 WH XMSN Sol No 1 or 3 Return 447 PK Fuel Level Gauge 977 YL CST Autoshift- Auto/Manual SW 1 449 BU Spdom Sender (Signal No. 1) E938 OR MG MESH CNTL - First Gear 450 YL Tach Sender (+) E939 WH MG MESH CNTL - Second Gear 462 YL Secondary Ster Motor Indicator E940 BU MG MESH CNTL - Third Gear 467 WH System Fault (Xmsn) E941 YL MG MESH CNTL - Fourth Gear 488 WH Air SW To Air SW Jumper E942 GN MG MESH CNTL - Fifth Gear A429 YL Articulation Indicator E943 BR MG MESH CNTL - Sixth Gear G460 GN Transmission Temperature SW E944 GY MG MESH CNTL - Seventh Gear E945 PU MG MESH CNTL - Eighth Gear Accessory Circuits Fuse AA 105-9344 1 Receptacle Wire Gauge Plug 2 200-BK-14 Pin or Socket Number 1 2 Control Circuits GN Circuit Number Identification Ground Connection E 403 Wire Color 325-PK-14 E-4 Monitoring Circuits Socket Component Part Number Wire, Cable, or Harness Assembly Identification A Resistor - Blower Speed Component Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T 1 Title Alternator (50A STD) Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. Resistor - Blower Speed Component Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Machine Location E Related Electrical Service Manuals E-15 T Pressure Symbol Schematic Location A-12 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Machine Location C Lighting Circuits Electrical Schematic Symbols And Definitions RENR1435 December 1997 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Printed in U.S.A. © 1997 Caterpillar All Rights Reserved Diagnostic Code Conversion XMSN Shift Sot No. 7 Code Flashed CID - FMI XMSN Shift Sol No. 8 11 N/A No diagnostics active 12 N/A No logged diagnostic codes 21 641 F05 Transmission Solenoid A open circuit 22 642 F05 Transmission Solenoid B open circuit Normally Open 23 643 F05 Transmission Solenoid C open circuit 24 644 F05 Normally Closed Transmission Solenoid D open circuit 25 645 F05 Transmission Solenoid E open circuit 26 646 F05 Transmission Solenoid F open circuit 27 647 F05 Transmission Solenoid G open circuit Normally Closed 28 648 F05 Transmission Solenoid H open circuit 1-2 NO 1-3 NC 31 641 F06 Transmission Solenoid A short to ground 32 642 F06 Transmission Solenoid B short to ground Normally Closed 33 643 F06 Transmission Solenoid C short to ground 34 644 F06 Transmission Solenoid D short to ground 35 645 F06 Transmission Solenoid E short to ground 36 646 F06 Transmission Solenoid F short to ground 37 647 F06 Transmission Solenoid G short to ground 38 648 F06 Transmission Solenoid H short to ground 41 641 F03 Transmission Solenoid A short to battery 42 642 F03 Transmission Solenoid B short to battery 43 643 F03 Transmission Solenoid C short to battery 44 644 F03 Transmission Solenoid D short to battery 45 645 F03 Transmission Solenoid E short to battery 46 646 F03 Transmission Solenoid F short to battery 47 647 F03 Transmission Solenoid Gshort to battery 48 648 F03 Transmission Solenoid H short to battery 52 637 F06 Backup alarm short to ground 54 444 F05 Start Relay Open Circuit 4.2 ± 0.42 16.1± 1.61 55 444 F06 Start Relay Short To Ground 56 444 F03 Start Relay Short To Battery 4.2 ± 0.42 16.1 ± 1.61 58 688 F06 VHP ¹ solenoid short to ground 59 688 F03 VHP ¹ solenoid short to battery Resistor - Panel Dimmer 25.0 ± .3 61 668 F02 Shift lever input invalid Resistor - Starter/Diagnostic Conn 150 ± 7.5 62 668 F03 Shift lever open/short to + battery 54°C (130°F) - 560 to 716 110°C (230°F) - 72 to 82 63 269 F01 Sensor supply voltage above normal 64 269 F01 Sensor supply voltage below normal 65 701 F02 Transmission output speed signal incorrect 68 168 F01 System voltage below normal 71 520 F02 Invalid transmission configuration code 72 268 F02 Check programmable parameters 73 764 F05 Transmission indicator lamp open circuit 74 764 F06 Transmission indicator lamp short to ground 75 764 F03 76 177 F03 Transmission indicator lamp short to battery Transmission oil temperature sender short to battery or open circuit 77 177 F04 Transmission oil temperature switch short to ground 500 BR Wiper - Front (Park) E946 OR MG MESH CNTL - Forward Direct 501 GN Wiper - Front (Low) E947 WH MG MESH CNTL - Reverse Direct 502 OR Wiper - Front (HI) E948 BU MG MESH CNTL - Park 503 BR Wiper - Rear (Park) E949 YL MG MESH CNTL - Neutral E975 PU MESH Lamp Off Machine Switch Specification Part No. Function 2M-9346 Brake Air Pressure (Stop Lamp) 3E-2033 Brake/Park Brake Air Pressure 7N-9785 Engine Coolant Temp 8N-1693 Coolant Temperature (Start Aid) 8N-2248 Hyd Oil Temperature 8T-8640 Steering Press 9W-3187 Fuel Pressure (EMS) 111-7088 Actuate 45 kPa MAX (6.5 psi MAX) 640 kPa MAX (92.0 psi MAX) 107.2 ± 2.8°C (225 ± 5°F) 37.8 ± 2.8°C (100 ± 5°F) 101.7°C MIN (215°F MIN) 1206 kPa MAX (l75 psi MAX) 93 ± 21kPa (13.5 ± 3.0 psi) 75.0 kPa MAX (10.9 psi MAX) 275 to 1750 kPa ¹ (40 to 255 psi) Inching Pedal Pressure 114-5334 Refrigerant Pressure (A/C) Part No. 3E-5383 3E-6424 7N-8532 7T-4003 7T-6517 7T-9073 7T-9074 8T-8610 8T-8808 Deactuate 5 kPa MIN (0.5 psi MIN) 530 ± 40 kPa (77.0 ± 6.0 psi) 93.0°C MIN (200°F MIN) 26.7°C MIN (80°F MIN) 93.3°C MIN (200°F MIN) 700 ± 103 kPa (101.5 ± 15psi) 69 ± 21kPa (10.0 ± 3.0 psi) 50.0 kPa MIN (7.3 psi MIN) — — Resistor, Sender and Solenoid Specifications Component Description Sender - Articulation Position Solenoid - Dual HP Push Coil Pull Coil Solenoid - Engine Shutdown Start (Latch) Coil Stop (Unlatch) Coil Sender - Engine Coolant Temp Resistor - Power Solenoid - Blade Cushion Solenoid - Differential Unlock Solenoid - Foward Horn/Park Brake Solenoid - Dual HP Solenoid - Centershift Resistor - Blower Speed 9G-1950 Solenoid - Start Aid 9G-4365 Solenoid - A/C Clutch 101-1759 Sender - Transmission 104-6387 ¹At room temperature unless otherwise noted. Contact Position Normally Open Normally Closed Normally Open Normally Open² Resistance (Ohms)¹ 3 to 97 10.0 ± 0.5 20.1 ± 1.0 33.6 ± 1.0 55.17 ± 5.77 13.5 ± 10 34.3 ± 1.7 Overall 2.00 ± .10 Tap 1.00 ± .05 6.0 14.4 ± 0.6 1000 to 1200 ¹ VHP (Dual Horsepower) Description
RENR1436 December 1997 Component Location Alarm — Action Schematic Location B-8 Alarm — Backup F-15 1 Sender — Engine Oil Pressure B-13 13 26 Alternator D-14 2 Sender — Transmission Speed D-15 14 26 Battery C-14 3 Solenoid — Centershift B-3 16 F-14 6 Battery C-14 4 Solenoid — Differential Unlock E-14 17 CONN 4 F-14 22 CONN 5 A-14 5 Breaker — Alternator D-13 5 Solenoid — Dual Horsepower A-13 5 CONN 6 A-14 30 Breaker — Headlamp D-10 B Solenoid — Engine Shutdown D-13 5 CONN 7 B-13 29 Control — Neutral Start A-8 10 Solenoid — Forward Horn A-3 16 CONN 8 B-13 29 Control — Transmission A-7 E Solenoid — Park Brake B-12 16 CONN 9 D-13 29 Solenoid — Start Aid A-13 18 CONN 10 E-12 21 CONN 11 E-12 25 CONN 12 E-12 25 CONN 13 E-12 25 CONN 14 D-12 21 CONN 15 D-12 21 CONN 16 B-12 CONN 17 A-11 CONN 18 Connector Location Component 1 Schematic Location Machine Location CONN 1 C-15 CONN 2 E-15 CONN 3 Connector Number 3 6 26 8 23 Machine Location C Component Sender — Engine Coolant Temperature Schematic Location B-14 Machine Location 11 Control — Transmission Direction and Speed SW A-8 C Solenoids — Transmission Valves E-15 14 Fuses Block D-9 B Switch — Beacon B-6 C Fuses (10A) B-6 C Switch — Blower (Heater Group) A-10 C Gauge — Cluster F-5 A Switch — Brake Air Pressure A-2 16 Ground — Engine C-13 12 Switch — Centershift Indicator B-3 19 25 Ground — Frame Cab D5,6 24 Switch — Centershift Pin B-8 C C Ground — Front, Rear Frame C-12 20 Switch — Defrost, Front A-6 C D-10 B CONN 19 B-9 25 Ground — Front Frame D-6 21 Switch — Defrost, Rear B-6 C CONN 20 E-9 B Ground — Rear Frame C-13 28 Switch — Differential Unlock D-9 B CONN 21 E-9 23 Horn — Forward F-3 16 Switch — Disconnect C-14 13 CONN 22 A-8 C Meter — Service E-10 B Switch — Engine Coolant Temp (Start Aid) A-14 11 CONN 23 B-7 25 Motor — Blower E-4 E Switch — Flood Lamp D-8 B CONN 24 B-7 C Motor — Blower (Heater Group) A-10 E Switch — Forward Horn E-9 B Motor — Blower, Defroster A-11 E Switch — Fuel Pressure B-13 13 Motor — Starter 18 14 13 11 22 7 17 1 2 5 12 30 B E 20 29 C 28 25 4 E-6 24 CONN 26 E-6 24 CONN 27 C-6 24 CONN 28 C-6 24 CONN 29 C-6 27 CONN 30 A-6 27 CONN 31 C-S 27 CONN 32 C-5 27 CONN 33 B-3 15 CONN 34 E-3 23 CONN 35 F-3 23 CONN 36 F-3 23 CONN 37 D-10 23 A 9 19 24 27 Service Tool Connector CONN 25 21 D 16 10 15 D 27 A 30 18 22 B 11 C 12 2 14 4 3 29 28 26 20 25 10 15 19 16 21 7 17 CONN 38 D-10 23 1 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. 23 8 5 6 24 E 13 1 9 C-13 5 Switch — Head/Tail Lamp E-8 B Motor — Washer, Front Lower F-6 8 Switch — Headlamp Dimmer E-9 B Motor — Washer, Front Upper F-6 8 Switch — Inching Pedal Pressure D-15 14 Motor — Washer, Rear F-5 8 Switch — Key Start B-9 C Motor — Wiper, Front Lower C-4 9 Switch — Park Brake Pressure B-11 16 Motor — Wiper, Front Upper D-4 D Switch — Start Aid E-8 B Motor - Wiper, Rear B-11 D Switch — Stop Lamp Pressure A-2 16 Relay — Start D-13 5 Switch — Tail Lamp D-8 B Relay — Transmission Action Lamp C-10 8 Switch — Transmission Oil Temp D-15 26 Resistor — Blower Speed B-11 E Switch — Wiper, Front Lower A-5 C Resistor — Blower Speed E-4 E Switch — Wiper, Front Upper B-5 C Resistor — Blower Speed (Heater Group) A-10 E Switch — Wiper, Rear A-5 C Sender — Articulation C-12 7 12H, 140H, And 160H Motor Graders (Standard Version) Electrical System 12H: 4ER1-499 140H: 5HM1-1149 8JM1-279 160H: 2FM1-399 9JM1-349 Machine locations are repeated for components located close together A = Operator’s compartment (Dash). B = Operator’s compartment (Steering console). Machine Harness Connector And Component Locations C = Operator’s compartment (Right side console). D = Operator’s compartment (Headliner). E = Operator’s compartment (Under seat). Printed in U.S.A. ©1997 Caterpillar All Rights Reserved Part No. Transmission Diagnostic Code Conversion Code Flashed CID - FMI 11 N/A No diagnostics active 12 N/A No logged diagnostic codes 21 641 F05 Transmission Solenoid A open circuit 22 642 F05 Transmission Solenoid B open circuit 23 643 F05 Transmission Solenoid C open circuit 24 644 F05 Transmission Solenoid 0 open circuit 25 645 F05 Transmission Solenoid E open circuit 26 646 F05 27 28 Description 2M-9346 Function Off Machine Switch Specification Actuate Fuel Pressure 8N-1693 Engine Coolant Temp 111-7088 Inching Pedal Pressure Deactuate 45.0 kPa Max 5.0 kPa MIN (6.5 psi Max) (0.5 psi MIN) 93.0 ± 20.8 kPa 69 ± 21 kPa (13.5 ± 3.0 psi) (10 ± 3 psi) Stop Lamp Pressure 3T-4418 Wire Number 37.8 ± 2.8°C 26.7°C MIN (100 ± 5°F) (80.0°F MIN) 75.0 kPa MAX 50.0 kPa MIN (10.9 psi MAX) (7.3 psi MIN) 640 kPa MAX 530 ± 40 kPa (92.0 psi MAX) (77.0 ± 6.0 psi) Contact Position Normally Open Normally Open Normally Closed Normally Open Wire Description Wire Color Description Harness And Wire Electrical Schematic Symbols Wire Number Wire Color Power Circuits Description 101 RD Bat(+) 506 PU Washer — Front 102 BU HdLmp 507 WH Washer — Rear 103 YL Aux Ckt 515 GY Blower Motor (HI) 105 BR Key Start Sw 516 GN Blower Motor (Medium) 108 BU Aux Ckt 517 BU Blower Motor (Low) 109 OR Alt Output (+) Term. 521 YL A/C SW To Refrigerant SW 113 OR Opr Mon Panel 522 WH A/C Clutch To Thermostat SW 114 GN Warning Horn (Forward) 556 WH Differential Lock 116 BR AuxCkt 575 YL Wiper — Aux (Park) 118 GY AuxCkt 576 PK Wiper — Aux (Low) 119 PK AuxCkt 577 PU Wiper — Aux (HI) 124 GN A/C 578 BU Washer — Aux Transmission Solenoid F open circuit ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25psi). 130 GN AuxCkt 584 YL Wiper SW Jumper 647 F05 Transmission Solenoid G open circuit ² Contact postion at the contacts of the harness connector. 141 PK AuxCkt A503 PK Front Defroster Fan (Low) 648 F05 Transmission Solenoid H open circuit 144 GN AuxCkt A504 GN Rear Defroster Fan (Low) 31 641 F06 Transmission Solenoid A short to ground 149 Pu Aux Ckt A506 OR Front Defroster Fan (HI) 32 642 F06 Transmission Solenoid B short to ground 151 GN Aux Ckt A507 YL Rear Defroster Fan (Hi) 33 643 F06 Transmission Solenoid C short to ground 152 BU AuxCkt 34 644 F06 Transmission Solenoid 0 short to ground 165 YL Aux Ckt 35 645 F06 Transmission Solenoid E short to ground 36 646 F06 Transmission Solenoid F short to ground 200 BK Main Chassis 37 647 F06 Transmission Solenoid G short to ground 7N-8532 202 BK 38 648 F06 Transmission Solenoid H short to ground 7T-4003 277 41 641 F03 Transmission Solenoid A short to battery 7T-9073 278 42 642 F03 Transmission Solenoid B short to battery 43 643 F03 Transmission Solenoid C short to battery 7T-9074 44 644 F03 Transmission Solenoid D short to battery 8T-8610 Solenoid - Dual Horsepower 13.5 ± 1.35 45 645 F03 Transmission Solenoid E short to battery 8T-8808 Solenoid - Centershift 34.3 ± 1.7 46 646 F03 Transmission Solenoid F short to battery 9G-1950 47 647 F03 Transmission Solenoid G short to battery 9G-4365 48 648 F03 Transmission Solenoid H short to battery 52 637 F06 Backup alarm short to ground 54 444 F05 Starter relay open circuit 55 444 F06 Starter relay short to ground 56 444 F03 Starter relay short to battery 58 688 F06 59 688 F03 VHP solenoid short to battery 61 668 F02 Shift lever input invalid 62 668 F03 Shift lever open/short to +battery 63 269 F00 Sensor supply voltage above normal 64 269 F01 Sensor supply voltage below normal 65 701 F02 Transmission output speed signal incorrect 68 168 F01 System voltage below normal 71 520 F02 Invalid transmission configuration code 72 268 F02 Check programmable parameters 73 764 F05 Transmission indicator lamp open circuit 74 764 F06 Transmission indicator lamp short to ground 75 764 F03 77 762 F04 Transmission indicator lamp short to battery Transmission oil temperture switch short to ground 112-2404 Brake/Park Brake Air Pressure Part No. Resistor, Sender and Solenoid Specifications Component Description 3E-5383 Sender - Articulation Position Normally Closed Resistance (Ohms)¹ 3 to 97 Start (Latch) 1.55 ± 0.15 3E-7985 Solenoid - Engine Shutdown Stop (Unlatch) 10.30 ± 1.03 54°C (130°F) -560 to 716 Sender - Engine Coolant 110°C (230°F) - 72 to 82 Resistor 10.0±0.5 Solenoid - Differential Unlock 33.6 ± 1.0 Solenoid - Forward Horn 55.17 ± 5.77 Park Brake Resistor- Blower Speed Overall 2.00 ± .10 Tap 1.00 ±.05 Solenoid - Start Aid 6.0 21.5 - 49.5 @ 552 kPa (80.1 psi) 116-9937 Sender - Engine Oil Pressure 127-0574 227 - 257 @ 21 kPa (3.0 psi) Solenoid - Transmission 31 ± 3 ¹ At room temperature unless otherwise noted. VHP solenoid short to ground Related Electrical Service Manuals Title Form Number Alternator (6N-9294): PK Rotary Beacon 604 OR Stop Lamp 608 GN Flood Lamp — Rear XMSN Ctrl 609 YL Flood Lamp — Side BK XMSN Ctrl ldent Code 1 611 PU Head Lamp Hi BK XMSN Ctrl Ident Code 2 614 PU Park/Tail/Dash/Lamp 619 GN Head Lamp Lo 710 GN XMSN Speed Pickup Signal 751 GN XMSN Shift Sol No. 1 Or 3 752 YL XMSN Shift Sol No. 2 Basic Machine Circuits BU Starter No. 1 Sol 304 WH Starter Relay No. 1 Output 306 GN 307 OR Starter Relay Coil To Neut Start SW Or Key Start SW Key Start SW To Neutral Start SW 308 YL Main Power Relay Coil 754 BU XMSN Shift Sal No. 3 Or 1 310 PU Start Aid SW To Start Aid Sol 755 OR XMSN Shift Sal No. 4 Or 5 311 WH Start Aid Sol To Temp SW 758 GN AWD Clutch SW 321 BR Backup Alarm Lamp Travel Alarm 795 YL Dual hp Sol 322 GY Warning Horn (Forward) B751 BU (NFND) Centershift Lock Sal 326 PU Key Start SW “C” Term. 892 BR Start Mod Right (-) Port/CAT Data Link (-) Monitoring Circuits 893 GN Start Mod Right (+) Port/CAT Data Link (+) G865 BU +12 Volt Switch Power 403 GN Alternator (R) Term. 439 YL Lamp Indicator 900 PU XMSN Shift Sal No. 5 or 4 441 OR Eng Coolant Temp Gauge 901 WH XMSN Shift Sol No. 6 A429 YL Articulation Indicator 902 BR XMSN Shift Sal No. 7 A476 PU Eng Oil Press Gauge To Sender — Eng #1 903 GY XMSN Shift Sal No. 8 B476 BU (NFND) Transmission Indicator Lamp 921 WH XMSN Sal No 1 Or 3 Return SENR4978 C491 PU Park Brake Pressure E937 PU MG MESH CNTL — Redundant Neutral Consist No. 7N-9720 SENR2082 E458 YL Low Air Pressure Lamp E938 OR MG MESH CNTL - First Gear Consist No. 9G-4574 SENR4130 E459 WH Low Air Pressure Alarm E939 WH MG MESH CNTL - Second Gear E460 BR Trans CntI To Relay Coil E940 BU MG MESH CNTL - Third Gear G460 GN Transmission Temperature E941 YL MG MESH CNTL — Fourth Gear Accessory Circuits E942 GN MG MESH CNTL - Fifth Gear 500 BR Wiper - Front (Park) E943 BR MG MESH CNTL - Sixth Gear 501 GN Wiper - Front (Low) E944 GY MG MESH CNTL - Seventh Gear Consist No. 100-5045 SENR4130 Consist No. 100-5046 SENR2082 Electronic Transmission Shift Control SENR6982 Starting Motor: (106-8555) Electrical Schematic Symbols And Definitions Consist No. 6V-5207 SENR3581 502 OR Wiper - Front (HI) E945 PU MG MESH CNTL — Eighth Gear Consist No. 6V-5023 SENR3536 503 BR Wiper - Rear (Park) E946 OR MG MESH CNTL — Forward Direct Consist No. 6V-5226 SENR4975 504 YL Wiper - Rear (Low) E947 WH MG MESH CNTL - Reverse Direct 505 BU Wiper - Rear (HI) E948 BU MG MESH CNTL - Park E949 YL MG MESH CNTL - Neutral E975 PU MESH Lamp Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 2 T Pressure Symbol Temperature Symbol Level Symbol 1 2 1 2 1 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Flow Symbol Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector C Normally open switch that will close with an increase of a specific condition (temp-press-etc.). A A 325-PK-14 Pin Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. AA 1 Normally closed switch that will open with an increase of a specific condition. 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Control Circuits 301 Consist No. 3T-6352 Alternator (100-5047): AA Lighting Circuits 603 Ground Circuits A Accessory Circuits (Continued) Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. The circle indicates that the component has screw terminals and a wire can be disconnected from it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. No circle indicates that the wire cannot be disconnected from the component. T This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Connector Location Schematic Location B-8 Component Location Machine Location C Schematic Location A-13 Machine Location 25 28 Schematic Location Machine Location CONN 1 C-15 3 CONN 2 C-15 3 Alarm - Backup F-15 1 Senders - Trans. SPD (Speedometer) C-15 CONN 3 C-15 27 Alternator D-14 2 Sensor - AWD Control Lever D-7 B CONN 4 D-15 27 Batteries - 12 Volt C-14 5,6 Sensor - AWD Pump Pressure D-2 44 CONN 5 F-14 36 Breaker - Alternator (60A) D-13 8 Sensor - Engine Speed B-14 26 CONN 6 F-14 7 CONN 7 Start and Charge Diag. E-14 48 Breaker - Converter (25A) F-11 13 Sensor - Ground Speed (Radar) F-7 30 CONN 8 A-14 8 Breaker - Headlamp (1 5A) D-10 B Sensor - Trans. Oil Temp. E-15 27 CONN 9a A-14 30 Breaker - Lightbar Low Beam (1 5A) D-10 B Solenoid - Air Conditioning Clutch A-13 22 CONN 9b A-14 30 Control - All Wheel Drive C-2 17 Solenoid - AWD Displacement (Forward) C-15 3 CONN 10 A-14 44 Control - Engine Shutdown E-13 9 Solenoid - AWD Displacement (Reverse) C-15 3 CONN 11 B-13 37 Control - Neutral Start A-8 10 Solenoid - Blade Cushion E-2 45 CONN 12 B-13 37 CONN 13 B-13 37 Control - Secondary Steering E-13 9 Solenoid - Centershift B-3 29 CONN 14 D-13 37 Control - Transmission A-7 11 Solenoid - Differential Unlock E-14 4 CONN 15 D-13 37 Converter - 24V to l2V F-10 12 Solenoid - Drive Pressure D-2 46 CONN 16 D-13 37 Converter - 24V to 1 2V F-12 13 Solenoid - Dual Horsepower/Shutdown A-13 22 CONN 17 E-13 37 Flasher E-9 B Solenoid - Forward Horn F-3 10 CONN 18 F-12 37 Fuses B-6 C Solenoid - Freewheel D-2 47 CONN 19 F-12 39 CONN 20 E-12 39 Fuses D-9 B Solenoid - Motor Displ E-2 47 CONN 21 E-12 38 Fuses E-10 B Solenoid - Park Brake B-11 10 CONN 22 E-12 38 Gauge - L/S System Air Press. E-5 A Solenoid - Start Aid A-13 25 CONN 23 E-12 37 Gauge - R/S System Air Press. E-5 A Solenoid - System Charge D-2 47 CONN 24 D-12 39 Gauge - Speedometer E-5 A Solenoids - Trans. Control D-15, E-15 27 CONN 25 D-12 39 Gauge - Tachometer E-5 A Suppressor - Arc (A/C Clutch) A-13 22 CONN 26 D-12 39 Gauge Cluster F-5 A Suppressor - Arc (Duff. Unlock) E-14 3 CONN 27 B-12 10 CONN 28a A-10 C Ground - Cab D-5 17 Switch - A/C Refrigerant A-13 22 CONN 28b B-11 C Ground-Engine C-13 22 Switch-Air Dryer F-14 31 CONN 28c A-11 C Ground - Frame (Front) D-6 39 Switch - Autoshift A-9 C CONN 29 F-11 41 Ground - Frame (Rear) C-13 8 Switch - AWD Hydraulic Temp (EMS) C-2 46 CONN 30 D-10 B Ground - Frame To Cab (Front) D-6 17 Switch - AWD Mode B-8 C CONN 31 D-10 B Ground - Localized Stud F-12 D Switch - Beacon B-6 C CONN 32 D-10 39 CONN 33 D-10 39 Ground - Strap C-12 23 Switch - Beacon B-10 C CONN 34 D-10 39 Lamp - AIH Indicator D-5 A Switch - Blade Cushion B-8 C CONN 35 C-10 21 Lamp - Centershift Pin E-5 A Switch - Blower (A/C) B-10 C CONN 36 C-10 33 Lamp - Cold Temp. E-5 A Switch - Blower (Heater) A-10 C CONN 37a B-10 C Lamp - Master Action E-5 A Switch - Centershift Indicator B-3 29 CONN 37b A-9 C Lamp - Panel Shift Lever B-8 C Switch - Centershift Pin B-9 C CONN 38 B-9 39 CONN 39 B-9 38 Lamp - Trans E-5 A Switch - Coolant B-14 24 CONN 40 E-9 B Lamp - Turn Indicator (Left) E-5 A Switch - Coolant Temp. B-14 24 CONN 41 E-9 39 Lamp - Turn Indicator (Right) E-4 A Switch - Defrost (Front) A-6 C CONN 42 D-8 39 E-10 B Switch - Defrost (Rear) B-6 C CONN 43 D-8 39 E-6 A Switch - Differential Unlock D-9 B CONN 44 B-8 38 CONN 45 A-8 E Meter - Service Monitor - Electronic Monitoring System (EMS) Motor- Blower A-12 15 Switch - Disconnect CONN 46 B-7 38 Motor - Blower (A/C) B-10 14 Switch - EMS Test (Start Aid) CONN 47 B-7 38 Motor - Blower (Defrost) E-4 15 CONN 48 Service Tool B-7 C Motor - Blower (Heater) A-10 E CONN 49 D-7 17 Motor - Secondary Steering F-13 CONN 50 F-7 17 CONN 51a F-7 20 Motor - Starter CONN 51b F-7 20 CONN 52 E-6 17 CONN 53 E-6 17 CONN 54 E-6 Connector Number Component Alarm - Action 36 1 31 27 30 7 4 3 26 32 28 22 20 41 D 42 14 35 9 25 44 2 8 19 12 6 16 13 39 E 24 21 18 33 34 37 23 5 B 2 1 36 7 44 25 40 41 D 27 31 28 8 19 26 32 3 24 22 37 15 13 B 9 A C 33 5 6 42 16 38 12 35 11 23 34 4 47 43 C 38 40 E 30 A 46 45 29 17 11 10 21 14 18 15 17 39 43 46 45 47 29 10 20 E20377 Component Sender - Fuel Level C-14 6 E-10, E-8 B Switch - Engine Oil C-13 32 Switch - Flood Lamp D-8 B 20 Switch - Fuel B-13 34 C-13 19 Switch - Headlamp/Tail E-8 B Motor - Washer (Front Lower) F-6 16 Switch - Headlight Dimmer D-9 B Motor - Washer (Front Upper) F-6 16 Switch - Horn E-9 B Motor - Washer (Rear) F-6 16 Switch - Inching Pedal (AWD) D-15 3 17 Motor - Wiper (Front Lower) C-4 17 Switch - Inching Pedal (Transmission) C-15 3 D-4 17 Switch - Key Start B-9 C B Machine Harness Connector And Component Locations CONN 55 C-6 17 Motor - Wiper (Front Upper) CONN 56 C-6 17 Motor - Wiper (Rear) C-11 18 Switch - Light Bar Low Beam E-8 CONN 57 C-6 17 CONN 58 C-6 40 Motors - Condenser B-10 21 Switch - Panel Lamp Dimmer E-9 B CONN 59 A-6 40 Relay - Condenser C-10 21 Switch - Parking Brake Press. B-11 34 CONN 60 C-5 40 Relay - Main D-14 8 Switch - Primary Steering F-10 35 CONN 61 C-5 40 Relay - Secondary Steering F-13 22 Switch - Secondary Steering Test B-8 C CONN 62 B-3 43 Relay - Start D-13 8 Switch - Service Clear (Front Loc) B-2 44 CONN 63 E-3 17 Resistor - Blower Motor A-12 E Switch - Service Mode (Rear Loc) B-2 44 CONN 64 F-3 42 CONN 65 F-3 17 Resistor - Blower Switch (A/C) B-11 E Switch - Stop Lamp A-2 11 Resistor - Blower Switch (Heater) A-11 E Switch - Tail Lamp D-8 B Resistor - Defrost Motor E-4 E Switch - Thermostat B-11 E Resistor - Panel Lamp Dimmer E-9 B Switch - Turn Signal E-9 B Resistor - Start and Charge Diag C-14 22 Switch - Wiper (Front Upper) B-4 C Sender - Articulation C-12 23 Switch - Wiper (Rear) A-4 C D-2 46 Switch - Wiper (Front Lower) A-4 C Switches - Brake Air A-2 11 CONN 66 F-3 17 ¹ The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. CID Component Identifiers (CID¹) and Module Identifier (MID²) Component All Wheel Drive ECM (MID No. 75) 084 Ground Speed Sensor (Radar) 168 Electrical System Voltage 190 Engine Speed Sensor 248 CAT Data Link 296 Transmission ECM 380 AWD Modulation Pressure Switch 390 Forward Pump Displacement Solenoid 391 Reverse Pump Displacement Solenoid 392 Charge Solenoid 393 Drive Solenoid 394 Motor Displacement Solenoid 395 Pump Pressure Solenoid 396 AWD Mode Lamp 397 Charge Pump Pressure 398 Pump Pressure Sensor 517 AWD Mode Switch 520 Transmission Configuration Code 600 Hydraulic Temperature Switch ¹ The CID is a diagnostic code that indicates which component is faulty. ² The MID is a diagnostic code that indicates which electronic control module diagnosed the fault. Transmission Diagnostic Code Conversion Flash Codes CID - FMI 11 N/A No diagnostics active 12 N/A No logged diagnostic codes 21 641 F05 Transmission Solenoid A open circuit 22 642 F05 Transmission Solenoid B open circuit 23 643 F05 Transmission Solenoid C open circuit 24 644 F05 Transmission Solenoid D open circuit 25 645 F05 Transmission Solenoid E open circuit 26 646 F05 Transmission Solenoid F open circuit 27 647 F05 Transmission Solenoid G open circuit 28 648 F05 Transmission Solenoid H open circuit 31 641 F06 Transmission Solenoid A short to ground 32 642 F06 Transmission Solenoid B short to ground 33 643 F06 Transmission Solenoid C short to ground 34 644 F06 Transmission Solenoid D short to ground 35 645 F06 Transmission Solenoid E short to ground 36 646 F06 Transmission Solenoid F short to ground 37 647 F06 Transmission Solenoid G short to ground 38 648 F06 Transmission Solenoid H short to ground 41 641 F03 Transmission Solenoid A short to battery 42 642 F03 Transmission Solenoid B short to battery 43 643 F03 Transmission Solenoid C short to battery 44 644 F03 Transmission Solenoid D short to battery 45 645 F03 Transmission Solenoid E short to battery 46 646 F03 Transmission Solenoid F short to battery 47 647 F03 Transmission Solenoid G short to battery 48 648 F03 Transmission Solenoid H short to battery 52 637 F06 Backup alarm short to ground 54 444 F05 Starter relay open circuit 55 444 F06 Starter relay short to ground 56 444 F03 Starter relay short to battery Description Sender - Awd Hydraulic Temp Sender - Coolant Temp A-14 24 Machine Locations are repeated for components located close together. A = Operator’s compartment (Dash). B = Operator’s compartment (Steering console). C = Operator’s compartment (Right side console). D = Operator’s compartment (Headliner). E = Operator's compartment (Under seat). Related Electrical Service Manuals Title Form Number All Wheel Drive Electronic Control Alternator: 100-5047 Consist No. 100-5045 Consist No. 100-5046 Electronic Monitoring System Starting Motor: 106-8555 Consist No. 6V-5023 Consist No. 6V-5207 Consist No. 6V-5226 Transmission Electronic Control SENR6983 SENR4130 SENR2082 SENR2945 SENR3536 SENR3581 SENR4975 RENR1437 December 1997 143H & 163H Motor Grader (NA Version) Electrical System 143H: 1AL1-407 163H: 5AK1-155 Wire Number Wire Color 101 102 103 105 107 108 109 112 113 114 115 116 118 119 122 124 126 130 134 136 141 144 149 151 152 158 160 165 169 173 176 RD RD RD RD RD RD RD PU OR RD RD BR GY PK BU GN PK RD RD GN PK RD PU GN BU BR PU YL PK RD OR 200 201 202 203 207 277 278 BK BK BK BK BK BK BK 301 302 304 306 307 308 310 311 321 322 326 327 334 373 BU OR WH GN OR YL PU WH BR GY RD PK BU GN 403 404 405 406 408 409 410 411 413 415 417 419 439 441 447 449 450 462 467 482 485 486 488 A429 G460 GN YL GY PU WH OR WH PK BR GN GY YL YL OR PK BU YL YL WH WH YL PK WH YL GN 500 501 502 503 504 505 BR GN OR BR YL BU Wire Description Chart Description Power Circuits Bat(+) HdLmp Aux Ckt Key Start Sw Eng Shutdown Aux Ckt Alt Output (+) Term. Main Power Rly Output Opr Mon Panel B+ Switched Warning Horn (Forward) Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt A/C Xmsn Ctrl Aux Ckt Aux Ckt Secondary Star Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt AuxCkt Ground Circuits Main Chassis Operator Monitor Return XMSN Ctrl Chassis Diagnostic Starter Diagnostic XMSN Ctrl Ident Code 1 XMSN Ctrl Ident Code 2 Basic Machine Circuits Starter No.1 Sol Starter No. 1 Resistor to Diagnostic Starter Relay No. 1 Output Starter Relay Coil Key Start Switch Main Power Relay Coil Engine Test SW To Start Aid Sol Start Aid Sol To Temp SW Bckp Alarm Warning Horn (Forward) Key Start SW "C" Term Shutdown Sol Start Aid Sol #2 Start Aid Switch To Timer Monitoring Circuits Alternator (R) Term Opr Mon Hyd Oil Temp Opr Mon Oil Press. (Low Setting) Opr Mon Coolant Temp Opr Mon System Air Press. Opr Mon Neut Opr Mon Action Alarm Opr Mon Master Opr Mon Fuel Press. Opr Mon Test SW Primary Star SW Opr Mon Parking Brake Lamp Indicator Eng Coolant Temp Gauge Fuel Level Gauge Trans Spd Sender) Tach Sender (+) Secondary Ster Motor Indicator System Fault (Xmsn) AWD Hyd Oil Temp SW Opr Mon Panel AWD Fault AWD On/Off Lamp Brake Air Switches Articulation Indicator Transmission Temperature SW Accessory Circuits Wiper - Front (Park) Wiper - Front (Low) Wiper - Front (HI) Wiper - Rear (Park) Wiper - Rear (Low) Wiper - Rear (HI) Wire Number Wire Color 506 507 508 509 511 512 513 515 516 517 521 522 537 556 570 575 576 577 578 584 592 593 597 A503 A504 A506 A507 A513 PU WH PU WH BR GN OR GY GN BU YL WH GN WH BU YL PK PU BU YL BU GN PU PK GN OR YL PK 600 601 603 604 605 606 608 609 611 614 619 629 BR GY PK OR YL GY GN YL PU PU GN PK 710 718 719 727 728 751 752 754 755 758 759 760 795 796 797 F769 823 824 826 878 892 893 G865 900 901 902 903 909 911 912 921 977 989 E937 E938 E939 E940 E941 E942 E943 E944 E945 E946 E947 E948 E949 E975 GN BU GY GN BU GN YL BU OR GN OR PK YL BR PU BU GN YL OR OR BR GN BU PU WH BR GY BU YL GY WH YL YL PU OR WH BU YL GN BR GY PU OR WH BU YL PU Description Accessory Circuits (Continued) Washer - Front Washer - Rear Radio Speaker - Left Radio Speaker - Left (Common) Radio Speaker - Right Radio Speaker - Right (Common) A/C Compressor/Refrigerant Pressure SW Blower Motor (HI) Blower Motor (Medium) Blower Motor (Low) A/C SW To Refrigerant SW A/C Clutch To Thermostat SW Turn Signal SW To Flasher Differential Lock Blade Cushion Sol Wiper - Aux (Park) Wiper - Aux (Low) Wiper - Aux (HI) Washer - Aux Wiper SW Jumper DC/DC Converter Power Output Condenser Fan Relay To Motors A/C Refrigerant Press SW Front Defroster Fan (Low) Rear Defroster Fan (Low) Front Defroster Fan (HI) Rear Defroster Fan (HI) DC/DC Converter Memory Output Lighting Circuits Dash Lamp Basic Dash Lamp Hi Rotary Beacon Stop Lamp Turn Lamp - Left Turn Lamp - Right Flood Lamp- Rear Flood Lamp - Side Head Lamp Hi Park/Tail/Dash/Lamp Head Lamp Lo Aux Head Lamp Control Circuits XMSN Speed Pickup Signal AWD Normal Mode AWD Aggressive Mode Secondary Ster Motor Relay Secondary Ster Cont SW XMSN Shift Sol No. 1 Or 3 XMSN Shift Sol No. 2 XMSN Shift Sol No. 3 Or 1 XMSN Shift Sol No. 4 Or 5 AWD Clutch SW AWD Pump Press. AWD Freewheel Sol Dual Hp Sol AWD Pump Displacement Forward AWD Pump Displacement Reverse AWD To Inch Pedal SW AWD “Off Mode AWD Press. Sensor Sol AWD Test SW Displacement Sol CAT Data Link (-) CAT Data Link (+) +12 Volt Switch Power XMSN Shift Sol No. 4 XMSN Shift Sol No. 6 XMSN Shift Sol No. 7 XMSN Shift Sol No. 8 AWD Service Mode SW AWD Mode SW Jumper AWD Sol Return XMSN Sol No 1 Or 3 Return CST Autoshift- Auto/Manual SW 1 AWD Charge Flow Dump Valve MG MESH CNTL - Redundant Neutral MG MESH CNTL - First Gear MG MESH CNTL - Second Gear MG MESH CNTL - Third Gear MG MESH CNTL - Fourth Gear MG MESH CNTL - Fifth Gear MG MESH CNTL - Sixth Gear MG MESH CNTL - Seventh Gear MG MESH CNTL - Eighth Gear MG MESH CNTL - Forward Direct MG MESH CNTL - Reverse Direct MG MESH CNTL - Park MG MESH CNTL - Neutral MESH Lamp Printed in U.S.A. © 1997 Caterpillar All Rights Reserved Electrical Schematic Symbols And Definitions Part No. Function Off Machine Switch Specifications 2M-9346 Brake Air Pressure (Stop Lamp) 3E-2033 Brake Air Pressure Park Brake Air Pressure 3E-7811 Inching Pedal Pressure (AWD) 3T-0190 AWD - Hydraulic Oil Temperature (EMS) 7N-9785 Engine Coolant Temp (EMS) 8N-1693 Coolant Temperature (Start Aid) 8T-8640 Primary Steering Pressure 9W-3187 Fuel Pressure (EMS) 9X-0378 Engine Oil Pressure 111-7088 Inching Pedal Pressure (Transmission) 114-5334 A/C Refrigerant Pressure Actuate 45 kPa MAX (6.5 psi MAX) 640 kPa (92.0 psi) 160 ± 20 kPa (23.2 ± 2.9 psi) 87.78 ± 2.8°C (190 ± 5°F) 107.2 ± 2.8°C (225 ± 5°F) 37.8 ± 2.8°C (100 ± 5°F) 1206 kPa MAX (175 psi MAX) 93 ± 21 kPa (13.5 ± 3.0 psi) 62.0 kPa MAX (9.0 psi MAX) 75 kPa (10.9 psi) 275 to 1750 kPa ² (40 to 255 psi) Deactuate 5 kPa MIN (0.5 psi MIN) 530 ± 40 kPa (77.0 ± 6.0 psi) 120 kPa (17.4 psi) 79.44°C MIN (1 75°F MIN) 93.0°C MIN (200°F MIN) 26.7°C MIN (80°F MIN) 700 ± 103 kPa (100 ± 15 psi) 69 ± 21 kPa (10.0 ± 3.0 psi) 38.0 ± 20.0 kPa (5.5 ± 3.0 psi) 50 kPa (7.3 psi) - T Contact Position¹ Pressure Symbol Normally Open Normally Open Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally Open Normally Closed Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. Normally Closed Normally Closed A-B, Normally Open A-C, Normally Closed This indicates that the component has a wire connected to it that is connected to ground. Normally Closed This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Normally Open Normally Open Normally Open Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. ¹ Contact position at the contacts of the harness connector. ² With increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kPa (25psi). SENR6982 Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. FMI No. Failure Mode Identifiers (FMI) List Failure Description Part No. Resistor, Sender and Solenoid Specifications Component Data valid but above normal operational range. 1 Data valid but below normal operational range. 3E-5383 Sender - Articulation Position 2 Data erratic, intermittent, or incorrect. 3 Voltage above normal or shorted high. 3E-6424 Solenoid - Dual Horsepower/Shutdown 3T-3123 Resistor - Dimmer Switch 25.0 ± .3 6T-2217 Resistor - Starter/Diagnostic Conn Solenoid - Freewheel Motor Displacement System Charge 150 ± 7.5 58 688 F06 VHP solenoid short to ground 59 688 F03 VHP solenoid short to battery 61 668 F02 Shift lever input invalid 62 668 F03 Shift lever open/short to +battery 4 Voltage below normal or shorted low. 63 269 F00 Sensor supply voltage above normal 5 Current below normal or open circuit. 64 269 F01 Sensor supply voltage below normal 6 Current above normal or grounded circuit. 65 701 F02 Transmission output speed signal incorrect 7 Mechanical system not responding properly. 68 168 F01 System voltage below normal 8 Abnormal frequency, pulse width, or period. 71 520 F02 Invalid transmission configuration code 9 Abnormal update. 10 Abnormal rate of change. 72 268 F02 Check programmable parameters 11 Failure mode not identifiable. 73 764 F05 Transmission indicator lamp open circuit 12 Bad device or component. 74 764 F06 Transmission indicator lamp short to ground 13 Out of calibration. 75 764 F03 77 762 F04 Transmission indicator lamp short to battery Transmission oil temperature switch short to ground 6T-5859 7N-8532 Sender - Coolant Temperature 7T-4003 Resistor - Defroster Blower Motor Defroster Blower Motor 7T-6517 9G-4365 Solenoids - Blade Cushion Solenoid - Forward Horn Park Brake Solenoid - Centershift Resistor - A/C Blower Motor Heater Blower Motor Solenoid - Start Aid 101-1759 Solenoid - A/C Clutch 104-6387 Sender - Transmission Speed 134-2845 Sender - AWD Hydraulic Temperature 136-1678 Solenoid - Injector (Trans) 7T-9074 8T-8808 9G-1950 ¹ At room temperature. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Resistance (Ohms)¹ 0 6.0 ± 3 MIN 92 ± 5 MAX 4.2 ± 0.416.1 ± 1.6 Harness And Wire Symbols 33.7 ± 1.0 560 - 716 @ 54°C (130°F) 72-82 @ 110°C(230°F) Pin Socket Wire Color A 10.0 ± 0.5 20.1 ± 1.0 Component Part Number Wire, Cable, or Harness Assembly Identification Fuse AA 105-9344 1 325-PK-14 55.2 ± 5.8 34.3 ± 1.7 Overall 2.0 ± .1; Tap 1.0 ± .05 Single Wire Connector 14.4 ± 0.6 Receptacle Wire Gauge Ground Connection 6 1000- 1200 158 - 202 @ 54 °C (129.2 °F) 63 - 79 @ 82 °C (179.6 °F) 31 ±3 Circuit Number Identification Plug 2 200-BK-14 Pin or Socket Number 1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.
Component Location Connector Location Schematic Location Machine Location CONN 1 D-15 31 CONN 2 E-15 31 CONN 3 E-15 31 CONN 4 A-14 41 CONN 5 A-14 27 CONN 6a A-14 8 CONN 6b A-14 8 CONN 7 Starting and Charging Diagnostic E-14 45 CONN 8 F-14 36 16 CONN 9 F-14 42 13 CONN 10 B-13 37 Connector Number Schematic Location Machine Location Alarm - Action B-8 C Alarm - Backup F-15 1 Alternator (35A STD) D-14 Battery Beacon Component CONN 11 B-13 37 CONN 12 B-13 37 27 36 1 31 12 6 42 4 3 26 32 45 25 41 28 21 24 15 47 44 D 39 43 E B 18 29 E-14 4 2 Solenoid - Dual Horsepower A-1 3 22 C-14 5,6 Solenoid - Engine Shutdown D-13 22 A-12,C-10 7 Solenoid - Forward Horn F-3 10 8 Solenoid - Park Brake B-1 2 10 Breaker - Convertor 13 Solenoid - Start Aid A-1 3 25 Breaker - Headlamp D-1 0 B Solenoids - Blade Cushion E-2 30 Breaker - Lightbar D-10 B Solenoids - Transmission Valve (8) D-15, E-15 31 Control - Neutral Start A-8 10 Speedometer E-1 3 9 F-5 A Switch - A/C Refrigeration A-13 22 A-7 11 Switch - Air Dryer F-14 31 Converter - Voltage F-10 12 Switch - Autoshift A-9 C Converter - Voltage F-1 2 13 Switch - Beacon B-5,10 C E-6 A Switch - Blower (A/C) B-10 C E-10 B Switch - Blower (Heater) A-10 C B-6 C Switch - Brake Air Pressure A-2 11 Fuses D-9 B Switch - Centershift Indicator B-3 29 Fuses E-10 B Switch - Centershift Pin B-9 C F-5 A Switch - Coolant Temp (Monitor) B-14 24 Gauge - Coolant Temperature F-5 A Switch - Coolant Temp (Start Aid) A-14 24 Gauge - Fuel Level E-5 A Switch - Cushion Blade B-9 C Ground - Cab Frame to Front Frame D-5 17 Switch - Defroster (Front) A-5 C Flasher 17 30 29 B-3 Solenoid - Differential Unlock F-11 Electronic Monitoring System(EMS) A Solenoid - Centershift D-13 Control - Transmission 14 35 9 Machine Location Breaker - Alternator Control - Supplement Steer 20 Schematic Location Component Fuses CONN 13 D-13 22 CONN 14 D-13 37 CONN 15 D-13 37 CONN 16 E-13 3 CONN 17 B-12 10 CONN 18 D-12 43 CONN 19 D-12 43 Ground - Front Frame D-6 39 Switch - Defroster (Rear) B-5 C CONN 20 D-12 43 Meter - Service E-10 B Switch - Differential Unlock D-9 B CONN 21 E-12 43 Motor - Blower (A/C group) B-10 14 Switch - Disconnect C-14 6 CONN 22 E-12 43 Motor - Blower (Heater group) A-10 E Switch - Engine Oil Pressure C-13 32 CONN 23 E-12 43 A-12,E-4 15 Switch - Flood Lamps D-8 B CONN 24 E-12 43 CONN 25 F-12 43 CONN 26a A-11 38 CONN 26b B-11 38 CONN 26c A-11 38 CONN 27 F-11 44 CONN 28a B-10 C CONN 28b A-9 C CONN 29a C-10 33 CONN 29b C-10 33 CONN 30 C-10 21 CONN 31 D-10 39 CONN 32 D-10 39 CONN 33 D-10 39 CONN 34 D-10 B CONN 35 D-10 B CONN 36 B-9 38 CONN 37 B-9 38 CONN 38 E-9 39 CONN 39 F-9 39 CONN 40 A-8 10 CONN 41 B-8 38 CONN 42 D-8 39 CONN 43 D-8 39 CONN 44 D-8 39 CONN 45 D-8 39 CONN 46 B-7 38 CONN 47 B-7 38 CONN 48 Service Tool B-7 C CONN 49a F-7 20 CONN 49b F-7 20 2 22 19 8 33 37 7 34 23 5 11 C 10 38 46 40 Gauge - Articulation Motor - Defroster 21 18 7 44 14 D 40 15 13 E 27 45 41 25 2 1 B 9 42 24 19 26 32 22 37 8 3 5 C 12 6 16 38 35 4 34 30 29 11 10 23 28 17 33 31 36 A 39 46 43 20 E25310 Machine Harness Connector And Component Locations Wire Number Wire Color Description Wire Number Wire Color Description Accessory Circuits (Continued) Power Circuits 101 RD Bat (+) 503 BR Wiper - Rear (Park) 102 BU Hd Lmp 103 YL 504 YL Wiper - Rear (Low) Aux Ckt 505 BU 105 BR Wiper - Rear (HI) Key Sw 506 PU Washer - Front 107 108 WH Eng Shut 507 WH Washer - Rear BU Aux Ckt 508 PU Radio Speaker - Left 109 OR Alt Output (+) Term. 509 WH Radio Speaker - Left (Commom) 112 PU Main Power Rly Output 511 BR Radio Speaker - Right 113 OR Opr Mon Panel B+ Switched 512 GN Radio Speaker - Right (Common) 114 GN Warning Horn (Forward) 513 OR A/C Compressor/Refrigerant Pressure SW 115 PK Aux Ckt 515 GY Blower Motor (HI) 116 BR Aux Ckt 516 GN Blower Motor (Medium) 118 GY Aux Ckt 517 BU Blower Motor (Low) 119 PK Aux Ckt 521 YL A/C SW To Refrigerant SW 122 BU Aux Ckt 522 WH A/C Clutch To Thermostat SW GN A/C 537 GN Turn Signal SW To Flasher CONN 51 C-6 40 CONN 52 C-6 17 CONN 53 C-6 17 CONN 54 C-6 17 CONN 55 D-6 17 124 CONN 56 E-6 17 126 PK Xmsn Ctrl 556 WH Differential Lock CONN 57 E-6 17 130 GN Aux Ckt 570 BU Blade Cushion Sol 134 YL Aux Ckt 575 YL Wiper - Aux (Park) CONN 58 E-6 17 136 GN Suppl Ster 576 PK Wiper - Aux (Low) CONN 59 C-5 40 141 PK Aux Ckt 577 PU Wiper - Aux(Hi) CONN 60 C-5 40 144 GN Aux Ckt 578 BU Washer—Aux 149 PU Aux Ckt 584 YL Wiper SW Jumper CONN 61 B-3 46 151 GN Aux Ckt 592 BU DC/DC Converter Power Output CONN 62 E-3 47 152 BU Aux Ckt 593 GN Condensor Fan Relay To Motors CONN 63 E-3 47 158 BR Aux Ckt 597 PU A/C HI Press. Coutout SW To Low Press. SW 160 PU Aux Ckt A503 PK Front Defroster Fan (Low) CONN 64 F-3 17 165 YL Aux Ckt A504 GN Rear Defroster Fan (Low) CONN 65 F-3 17 169 PK Aux Ckt A506 OR Front Defroster Fan (HI) CONN 66 F-12 37 173 YL Aux Ckt A507 YL Rear Defroster Fan (HI) 176 OR Aux Ckt A513 PK DC/DC Converter Memory Output Ground Circuits BK Main Chassis 600 BR Dash Lamp Basic 201 BK Operator Monitor Return 601 GY Dash Lamp Hi 202 BK XMSN Ctrl 604 PK Rotary Beacon 203 BK Chassis Diagnostic 604 OR Stop Lamp 207 BK Starter Diagnostic 605 YL Turn Lamp—Left 277 BK XMSN Ctrl Ident Code 1 606 GY Turn Lamp - Right 278 BK XMSN Ctrl Ident Code 2 608 GN Flood Lamp - Rear 609 YL Flood Lamp - Side PU Head Lamp Hi 301 Alternator: 100-5047 (50A) Atch Consist No. 100-5046 Consist No. 100-5045 Electronic Monitoring System Form Number SENR4978 SENR2082 SENR4130 SENR2082 SENR4130 SENR2945 Transmission Electronic Shift Control SENR6982 Starting And Charging Systems Starting Motor: 106-8558 Consist No. 106-8557 Consist No. 106-8559 SENR2947 SENR3559 SENR3581 Lighting Circuits 200 Basic Machine Circuits Title Switch - Forward Horn E-9 B 20 Switch - Fuel Pressure B-13 24 Motor - Washer (Front Lower) F-6 16 Switch - Head/Tail Lamp E-8 B Motor - Washer (Front Upper) F-6 16 Switch - Headlamp Dimmer D-9 B Motor - Washer (Rear) F-6 16 Switch - Hydraulic Oil Temperature C-11 33 Motor - Wiper (Front Lower) C-4 17 Switch - Inching Pedal Pressure D-15 31 Motor - Wiper (Front Upper) D-4 17 Switch - Key Start B-9 C Motor - Wiper (Rear) B-11 18 Switch - Light Bar Low Beam E-8 B Motors - Condenser C-11 21 Switch - Monitor (EMS) Test E-8 B Relay - Condenser C-11 21 Switch - Panel Lamp Dimmer E-9 B Relay - Main D-14 8 Switch - Park Brake Pressure B-11 34 Relay - Start D-13 8 Switch - Primary Steer F-10 35 E-10 B A-2 11 C F-13 22 Switch - Start Aid/Monitor Test A-11 ,E-4 E Switch - Stoplamp Pressure Resistor - Blower Speed (A/C) B-11 15 Switch - Supplemental Steer Test B-8 Resistor - Blower Speed (Heater) A-11 E Switch - Tail Lamp D-8 B Resistor - Panel Lamp Dimmer E-9 B Switch - Transmission Direction & Speed A-B C Resistor - Starting/Charging Diagnostic C-14 19 Switch - Transmission Oil Temp E-15 31 Sender - Articulation C-12 23 Switch - Turn Signal D-9 B Sender - Engine Coolant Temp A-14 24 Switch - Wiper (Front Lower) A-4 C Sender - Fuel Level A-13 25 Switch - Wiper (Front Upper) B-4 C Sender - Transmission Speed D-15 28 Switch - Wiper (Rear) A-4 C Sensor - Engine Speed B-1 4 26 Tachometer E-5 A Solenoid - A/C Clutch A-1 3 22 Thermostat (A/C) B-11 E Electrical Schematic Symbols And Definitions T Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. 120H and 135H Motor Graders, NA Version 120H Motor Grader, Australian Version Electrical System 120H: 4MK1-403 2AN1-103 Normally closed switch that will open with an increase of a specific condition. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. The circle indicates that the component has screw terminals and a wire can be disconnected from it. 135H: 3YK1-266 No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. A =Operator’s compartment (Dash). B =Operator’s compartment (Steering console). C =Operator’s compartment (Right side console). D =Operator’s compartment (Headliner). E =Operator’s compartment (Under seat). Part No. Function 2M-9346 Stop Lamp Pressure 3E-2033 Brake/Park Brake Air Pressure Off Machine Switch Specification Actuate Deactuate Contact Position 45 kPa (6.5 psi) 5.0 kPa MIN (0.7 psi MIN) Normally Open 640 kPa MAX (92.0 psi MAX) 530 ±40 kPa (77.0 ± 6.0 psi) Normally Open 27.0 °C MIN (80.6°F MIN) Normally Closed Harness And Wire Electrical Schematic Symbols Code Flashed CID - FMI 11 N/A No diagnostics active No logged diagnostic codes Coolant Temperature 8T-8640 Steering Pressure 1206 kPa MAX (175.0 psi MAX) 700.0 ± 103 kPa (101.5 ± 15.0 psi) 1-2 Normally Open 1-3 Normally Closed 12 N/A 74.00 °C MIN (165.2°F MIN) 641 F05 Transmission Solenoid A open circuit Hydrualic Oil Temperature 82.22 ± 2.78 °C (180.0 ± 5.00 °F) 21 8T-9705 Normally Closed 22 642 F05 Transmission Solenoid B open circuit 8T-9793 Engine Coolant Temperature 107.0 ± 3.0 °C (224.6 ± 5.4 °F) 93.00 °C (199.4 °F) Normally Closed 23 643 F05 Transmission Solenoid C open circuit 24 644 F05 Transmission Solenoid D open circuit 9X-0378 Engine Oil Pressure 62.0 kPa MAX (9.00 psi MAX) 38 ± 20 kPa (5.5 ± 3.0 psi) Normally Open 25 645 F05 Transmission Solenoid E open circuit 50.0 kPa MIN (7.30 psi MIN) 646 F05 Transmission Solenoid F open circuit Inching Pedal Pressure 75.0 kPa MAX (10.9 psi MAX) 26 111-7088 Normally Open 27 647 F05 Transmission Solenoid G open circuit 114-5334 Refrigerant Pressure (A/C) 275 to 1750 kPa¹ (40 to 255 psi) — — Normally Open² 28 648 F05 Transmission Solenoid H open circuit 31 641 F06 Fuel Pressure 93.0±21 kPa (13.5 ± 3.0 psi) 69±21 kPa (10 ± 3.0 psi) Transmission Solenoid A short to ground 115-7103 Normally Closed 32 642 F06 Transmission Solenoid B short to ground 33 643 F06 Transmission Solenoid C short to ground 34 644 F06 Transmission Solenoid D short to ground 35 645 F06 Transmission Solenoid E short to ground ² Contact position at the contacts of the harness connector. 611 302 OR Starter Resistor to Diagnostic 614 PU Park/Tail/Dash/Lamp 36 646 F06 Transmission Solenoid F short to ground 304 WH Starter Relay No. 1 Output 619 GN Head Lamp Lo 37 647 F06 306 GN 629 PK Transmission Solenoid G short to ground Starter Relay Coil To Neut Start SW Or Key SW Aux Head Lamp 307 OR Key SW To Neut Start SW 38 648 F06 Transmission Solenoid H short to ground 308 YL Main Power Relay Coil 710 GN XMSN Speed Pickup 41 641 F03 Transmission Solenoid A short to battery 310 PU Start Aid SW To Start Aid Sol 727 GN Suppl Ster Motor Relay 42 642 F03 Transmission Solenoid B short to battery 311 WH Start Aid Sol To Temp SW 728 BU Suppl Ster Cont SW 321 BR Bckp Alarm Lamp Travel Alarm 751 GN XMSN Shift Sol No. 1 Or 3 43 643 F03 Transmission Solenoid C short to battery 322 GY Warning Horn (Forward) 752 YL XMSN Shift Sol No. 2 44 644 F03 Transmission Solenoid D short to battery 326 PU Key SW “C” Term. 754 BU XMSN Shift Sol No. 3 Or 1 45 645 F03 Transmission Solenoid E short to battery 334 BU Start Aid Sol #2 755 OR XMSN Shift Sol No. 4 Or 5 373 GN GN 646 F03 Start Aid Switch To Timer 758 46 AWD Clutch Sw Transmission Solenoid F short to battery 796 YL Dual Hp Sol 47 647 F03 Transmission Solenoid G short to battery 403 GN Alternator (R) Term. B751 BU Centershift Lock 48 648 F03 Transmission Solenoid H short to battery 404 YL Opr Mon Hyd Oil Temp F769 BU AWD To Inch Pedal SW 52 637 F06 405 GY 892 BR Backup alarm short to ground Opr Mon Oil Press. (Low Setting) Start Mod Right (-) Port/CAT Data Link (-) 406 PU Opr Mon Coolant Temp 893 GN Start Mod Right (+) Port/CAT Data Link (+) 54 444 F05 Starter relay open circuit 408 WH Opr Mon System Air Press. B899 OR AWD Agressiveness Cont Lever Resistance (Ohms)¹ 55 444 F06 Starter relay short to ground 409 OR Opr Mon Neut G865 BU 12 Volt Switch Power 3E-1906 Solenoid - A/C Clutch 17.6±0.6 56 444 F03 WH Opr Mon Fault Alarm 900 PU XMSN Shift Sol No. 4 3E-5383 Sender - Articulation 3 to 97 Starter relay short to battery 410 411 PK Opr Mon Master 901 WH XMSN Shift Sol No. 6 688 F06 BR Opr Mon Fuel Press. 902 BR XMSN Shift Sol No. 7 Resistor - PanelDimmer VHP solenoid short to ground 413 3T-3123 58 59 688 F03 VHP solenoid short to battery 415 GN Opr Mon Test SW 903 GY XMSN Shift Sol No. 8 61 668 F02 Shift lever input invalid 417 GY Primary Ster SW 921 WH XMSN Sol No 1 Or 3 Return 419 YL 977 YL 62 668 F03 Opr Mon Parking Brake CST Autoshift - Auto/Manual SW 1 Shift lever open/short to +battery 439 YL Lamp Indicator E937 PU MG MESH CNTL - Redundant Neutral 63 269 F00 Sensor supply voltage above normal 441 OR Eng Coolant Temp Gage E938 OR MG MESH CNTL - First Gear 64 269 F01 Sensor supply voltage below normal 447 PK Fuel Level Gage E939 WH MG MESH CNTL - Second Gear 65 701 F02 449 BU E940 BU Transmission output speed signal incorrect Spdom Sender (Signal No. 1) MG MESH CNTL - Third Gear 450 YL Tach Sender (+) E941 YL MG MESH CNTL - Fourth Gear 68 168 F01 System voltage below normal 462 YL Suppl Ster Motor Indicator E942 GN MG MESH CNTL - Fifth Gear 71 520 F02 Invalid transmission configuration code 467 WH System Fault (Xmsn) E943 BR MG MESH CNTL - Sixth Gear 72 268 F02 Check programmable parameters 485 YL Opr Mon Panel AWD Fault E944 GY MG MESH CNTL - Seventh Gear 488 WH Air SW To Air SW Jumper E945 PU MG MESH CNT - Eighth Gear 73 764 F05 Transmission indicator lamp open circuit A429 YL Articulation Indicator E946 OR MG MESH CNTL - Forward Direct 74 764 F06 Transmission indicator lamp short to, ground B426 BU AWD Hydraulic Temp Sensor E947 WH MG MESH CNTL - Reverse Direct 75 764 F03 G460 GN Transmission Temperature SW E948 BU MG MESH CNTL - Park E949 YL MG MESH CNTL - Neutral 77 762 F04 Transmission indicator lamp short to battery Transmission oil temperture switch short to ground Control Circuits 500 BR Wiper - Front (Park) E975 PU MESH Lamp 501 GN Wiper - Front (Low) M917 PK TOS Sensor + 502 OR Wiper - Front (HI) M918 GN TOS Sensor - M998 OR Transmission Autoshift Mode 4W-9972 6T-2217 7T-4003 7T-6517 7T-9073 7T-9074 8C-3663 8T-8808 9G-1950 9G-4365 9W-2739 104-6387 Resistor, Sender and Solenoid Specifications Component Description Sender - Coolant Temperature Resistor Resistor Solenoid Solenoid Solenoid - Starting/Charging Diagnostic - Power - Blade Cushion - Differential Unlock - Forward Horn/Park Brake 25.0 ± .3 560 to 716 @ 54°C (130°F) 72 to 82 @ 110°C(230°F) 150 ± 7.5 10.0±0.5 20.1 ± 1.0 33.6 ± 1.0 55.17 ± 5.77 Solenoid - Engine Shutdown Start (Latch) Coil Stop (Unlatch) Coil 1.55 ± 0.15 10.3± 1.03 Solenoid - Centershift Resistor - Blower Speed Solenoid - Start Aid Solenoid - Transmission Sender - Transmission Speed 34.3 ± 1.7 Overall 2.00 ± .10 Tap 1.00 ± .05 6 31 ± 3 1000 to 1200 ¹ At room temperature unless otherwise noted. AA Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 Description 8C-3569 ¹A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kPa (25 psi). A Transmission Diagnostic Code Conversion 38.00 ± 3.0 °C (1 00.4° ± 5.4 °F) Part No. Printed in U.S.A. © 1998 Caterpillar All Rights Reserved Starter Sol Accessory Circuits Flow Symbol Level Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). BU Monitoring Circuits Temperature Symbol Pressure Symbol Machine Locations are repeated for components located close together. Wire Description 40 Alternator: 6N-9294 (35A) Std Consist No. 3T-6352 Consist No. 7N-9720 Consist No. 9G-4574 19 F-13 Resistor - Blower Speed A-6 Related Electrical Service Manuals C-13 Motor - Supplemental Steer Relay - Supplemental Steer CONN 50 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Motor - Starter RENR1438 February 1998 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector C A A 325-PK-14 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Connector Location1 Schematic Location Machine Location CONN 1 C-15 31 CONN 2 D-15 31 CONN 3 C-15 31 CONN 4 A-14 41 CONN 5 A-14 27 CONN 6a A-14 8 CONN 6b A-14 8 CONN 7 Starting and Charging Diagnostic E-14 45 CONN 8 F-14 36 CONN 9 E-14 42 CONN 10 B-13 37 CONN 11 B-13 37 CONN 12 B-13 37 CONN 13 D13 CONN 14 D-13 CONN 15 D-13 37 CONN 16 E-13 3 Connector Number Air Dryer Component Location Machine Location 31 Component Sender- Fuel Level Schematic Location A-13 Machine Location 25 Alarm - Action B-8 C Sender - Transmission Speed B-15 28 Alarm - Backup E-15 1 Sensor - Engine Speed B-14 26 Alternator D-14 2 Solenoid - A/C Clutch A-13 22 Battery C-14 5,6 Solenoid-Centershift B-3 29 Beacon A-12 7 Solenoid - Differential Unlock E-14 4 Breaker-Alternator D-13 8 Solenoid-Dual Horsepower A-13 22 Breaker - Cab Flood Lamp D-10 B Solenoid - Engine Shutdown D-13 22 Breaker - Converter F-12 13 Solenoid - Forward Horn F-3 10 Breaker - Headlamp and Right Tail! Pos D-10 B Solenoid - Park Brake B-12 10 Breaker - Left Tail Lamp D-10 B Solenoid - Start Aid A-13 25 22 Buss Bar C-13 5 Solenoids - Blade Cushion E-2 30 37 Control - Neutral Start A-8 10 Solenoids - Transmission Valve (8) D-15 31 Control - Secondary Steer E-14 9 Speedometer Control - Transmission A-7 11 Switch - A/C Refrigeration 16 27 36 1 31 42 4 25 28 26 3 45 41 2 8 19 21 24 22 D 14 35 9 32 20 13 12 6 33 37 39 43 E B 18 7 15 44 A 34 23 5 17 30 29 47 C 10 11 38 46 40 F-5 A A-13 22 CONN 17 B-12 10 CONN 18 D-12 43 Converter-Voltage F-11 12 Switch -Air Inlet Heater B-8 C CONN 19 D-12 43 Converter-Voltage F-13 13 Switch-Beacon B-6 C CONN 20 D-12 43 CONN 21 E-12 43 Electronic Monitoring System(EMS) E-6 A Switch - Blower (A/C) B-10 C CONN 22 E-12 43 D-10 B Switch - Blower (Heater) A-10 C CONN 23 E-12 43 Fuses B-6 C Switch - Brake Air Pressure A-2 11 CONN 24 E-12 43 21 Fuses D-10 B Switch-Centershift Indicator C-3 29 CONN 25 F-12 43 CONN 26a A-11 38 18 Fuses E-11 B Switch - Centershift Pin B-9 C CONN 26b B-11 38 Gauge - Articulation F-5 A Switch - Coolant Temp (Monitor) B-14 24 CONN 26c A-11 38 Gauge - Coolant Temperature F-5 A Switch - Coolant Temp (Start Aid) A-14 24 Gauge - Fuel Level E-5 A Switch - Cushion Blade B-9 C Ground - Cab Frame to Front Frame C-5 17 Switch - Defroster (Front) A-5 C Ground - Front Frame D-5 39 Switch - Defroster (Rear) B-5 C Ground Strap - Rear Frame to Front Frame C-12 23 Switch - Differential Unlock D-9 B Heater-Air Intake B-15 31 Switch-Disconnect C-14 6 Meter - Service E-10 B Switch - EMS Test E-8 B Motor - Blower (A/C group) B-10 14 Switch - Engine Oil Pressure C-13 32 Motor - Blower (Heater group) A-10 E Switch - Flood Lamps D-9 B Flasher 7 44 14 D 40 15 13 E B A CONN 27 F-12 44 CONN 28a B-10 C CONN 28b A-9 C CONN 29 C-10 33 CONN 30 F-14 36 CONN 31 D-11 39 CONN 32 D-11 39 CONN 33 D-11 39 CONN 34 D-11 B CONN 35 D-11 B CONN 36 B-9 38 Motor-Defroster A-12,E-4 15 Switch-Forward Horn E-10 B CONN 37 B-9 38 Motor-Secondary Steer F-14 20 Switch-Fuel Pressure B-13 24 CONN 38 E-10 39 CONN 39 F-9 39 Motor- Starter C-13 19 Switch - Head/Tail Lamp E-8 B CONN 40 A-8 10 Motor - Washer (Front Lower) B-6 16 Switch - Headlamp Dimmer E-9 B CONN 41 B-8 38 Motor - Washer (Front Upper) C-6 16 Switch - Hydraulic Oil Temperature C-11 33 CONN 42 E-8 39 Switch - Inching Pedal Pressure C-15 31 CONN 43 D-8 39 CONN 44 D-8 39 C CONN 45 D-8 39 CONN 46 B-7 38 CONN 47 B-7 38 B-7 C CONN 49 E-3 30 CONN 50 A-6 40 CONN 51 C-6 40 CONN 52 C-6 17 CONN 53 C-6 CONN 54 C-6 CONN 55 CONN 48 Service Tool 27 42 9 25 2 1 45 41 C 24 33 19 26 32 22 37 8 3 5 12 6 31 36 16 38 35 10 23 4 28 17 34 30 29 11 39 46 43 20 Machine Harness Connector and Component Locations Wire Number Wire Color Wire Description Description Power Distribution Circuits Wire Number Wire Color Description Accessory Circuits (Continued) Motor - Washer (Rear) F-6 16 Motor - Wiper (Front Lower) C-4 17 Switch - Key Start B-9 Motor - Wiper (Front Upper) D-4 17 Switch - Panel Lamp Dimmer E-10 B Motor - Wiper (Rear) B-11 18 Switch - Park Brake Pressure B-11 34 Relay - AIH B-15 31 Switch - Primary Steer F-12 35 Relay - Cab Flood Lamp E-10 B Switch - Rear Flood Lamp D-8 B Relay - Flood/Tail Lamp D-8 B Switch - Secondary Steer Test B-8 C E-9 B Switch - Start Aid/Monitor Test E-l 1 B D-14 8 Switch - Stoplamp Pressure A-2 11 101 RD Bat (+) 506 PU Washer - Front 102 RD Hd Lmp 507 WH Washer - Rear 17 105 RD Key Sw 508 PU Radio Speaker- Left 17 107 RD Eng Shut 509 WH Radio Speaker - Left (Commom) D-6 17 CONN 56 E-6 17 108 RD Aux Ckt 511 BR Radio Speaker - Right CONN 57 E-6 17 109 RD Alt Output (+) Term. 512 GN Radio Speaker - Right (Common) CONN 58 E-6 17 112 PU Main Power Rly Output 513 OR A/C Compressor/Refrigerant Pressure SW CONN 59 C-5 40 113 OR Opr Mon Panel B+ Switched 515 GY Blower Motor (HI) CONN 60 C-5 40 CONN 61 B-3 46 114 RD Warning Horn (Forward) 516 GN Blower Motor (Medium) CONN 62 D-3 47 115 RD Aux Ckt 517 BU Blower Motor (Low) 116 BR Aux Ckt 521 YL A/C SW To Refrigerant SW 118 GY Aux Ckt 522 WH A/C Clutch To Thermostat SW 119 PK Aux Ckt 537 GN Turn Signal SW To Flasher 122 BU Aux Ckt 538 OR Hazard Indicator A = Operator’s compartment (Dash). 124 GN A/C 539 BU Turn Signal B = Operator’s compartment (Steering console). 126 PK Xmsn Ctrl 556 WH Differential Lock C = Operator’s compartment (Right side console). 130 RD Aux Ckt 570 BU Blade Cushion Sol 134 RD Aux Ckt 575 YL Wiper - Aux (Park) 136 GN Sec Ster 576 PK Wiper-Aux (Low) 141 PK Aux Ckt 577 PU Wiper-Aux (HI) 144 RD Aux Ckt 578 BU Washer-Aux 149 PU Aux Ckt 584 YL Wiper SW Jumper 151 GN Aux Ckt 592 BU DC/DC Converter Power Output 152 BU Aux Ckt 597 PU A/C HI Press. Coutout SW To Low Press. SW 160 PU Aux Ckt A50 PK Front Defroster Fan (Low) 165 YL AuxCkt A50 GN Rear Defroster Fan (Low) Part No. 169 PK Aux Ckt A50 OR Front Defroster Fan (HI) 2M-9346 173 RD Aux Ckt A50 YL Rear Defroster Fan (HI) 176 OR Aux Ckt A51 PK DC/DC Converter Memory Output CONN 63 CONN 64 CONN 65 1 Schematic Location F-15 Component E-3 F-3 F-13 47 17 37 The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Ground Circuits Related Electrical Service Manuals Title Form Number Alternator: 100-5047 (50A) Atch Relay - Main Relay - Right Tail Lamp E-8 B Switch - Transmission Direction & Speed A-9 C Relay - Secondary Steer F-14 22 Switch - Transmission Oil Temp C-15 31 Relay - Start D-13 8 Switch - Turn Signal E-10 B A-11,E-4 E Switch - Wiper (Front Lower) A-4 C Resistor - Blower Speed (A/C) B-11 15 Switch - Wiper (Front Upper) B-4 C Resistor - Blower Speed (Heater) A-11 E Switch - Wiper (Rear) A-4 C Resistor - Panel Lamp Dimmer E-10 B Tachometer E-5 A Resistor - Starting/Charging Diagnostic C-14 19 Thermostat (A/C) B-11 E Sender-Articulation C-12 23 D-7 B Sender- Coolant Temp A-14 24 Resistor - Blower Speed BK Main Chassis 600 BR Dash Lamp Basic 201 BK Operator Monitor Return 601 GY Dash Lamp Hi 202 BK XMSN Ctrl 603 PK Rotary Beacon 203 BK Chassis Diagnostic 604 OR Stop Lamp 207 BK Starter Diagnostic 605 YL Turn Lamp - Left 277 BK XMSN Ctrl Ident Code 1 606 GY Turn Lamp - Right 278 BK XMSN Ctrl ldent Code 2 608 GN Flood Lamp - Rear 609 YL Flood Lamp - Side 301 BU Starter Sol 610 OR Head Lamp 302 OR Starter Resistor to Diagnostic 611 PU Head Lamp Hi 304 WH Starter Relay No. 1 Output 614 PU Park/Tail/Dash/Lamp 306 GN Starter Relay Coil To Neut Start SW Or Key SW 615 YL Cab Flood Lamp 307 OR Key SW To Neut Start SW 617 BR Tail/Position Lamp 308 YL Main Power Relay Coil 618 YL Tail/Position Lamp 310 PU Start Aid SW To Start Aid Sol 619 GN Head Lamp Lo Timer-AIH Electrical Schematic Symbols And Definitions T Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. 120H Motor Grader (ES Version) Electrical System No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. D = Operator’s compartment (Headliner). E = Operator’s compartment (Under seat). Harness And Wire Electrical Schematic Symbols 3E-2033 Function Off Machine Switch Specification Transmission Diagnostic Code Conversion Code Flashed CID - FMI Deactuate Contact Position 45 kPa 5.0 kPa MIN Normally Open 11 N/A No diagnostics active (6.5 psi) (0.7 psi MIN) 12 N/A No logged diagnostic codes Normally Open 21 641 F05 Transmission Solenoid A open circuit 22 642 F05 Transmission Solenoid B open circuit Normally Closed 23 643 F05 Transmission Solenoid C open circuit 24 644 F05 Transmission Solenoid D open circuit Normally Closed 25 645 F05 Transmission Solenoid E open circuit 26 646 F05 Transmission Solenoid F open circuit 27 647 F05 Transmission Solenoid G open circuit 28 648 F05 Transmission Solenoid H open circuit 641 F06 Transmission Solenoid A short to ground Stop Lamp Pressure 640 kPa MAX 530 ± 40 kPa (92.0 psi MAX) (77.0 ± 6.0psi) 38.00 ± 3.0 °C 27.0 °C MINJ (100.4° ± 5.4 °F) (80.6 °F MIN) 101.7 °C MIN 93.3 °C MIN (215°F MIN) (200°F MIN) 1206 kPa MAX 700.0 ± 103 kPa 1-2 Normally Open (175.0 psi MAX) (101.5 ± 15.0 psi) 1-3 Normally Closed 107.0 ± 3.0 °C 93.00 °C Normally Closed 31 (224.6 ± 5.4 °F) (199.4 °F) 32 642 F06 Transmission Solenoid B short to ground 62.0 kPa MAX 38 ± 20 kPa Normally Open 33 643 F06 Transmission Solenoid C short to ground (9.00 psi MAX) (5.5 ± 3.0 psi) 34 644 F06 Transmission Solenoid D short to ground 75.0 kPa MAX 50.0 kPa MIN Normally Open 35 645 F06 Transmission Solenoid E short to ground (10.9 psi MAX) (7.30 psi MIN) 36 646 F06 Transmission Solenoid F short to ground Normally Open² 37 647 F06 Transmission Solenoid G short to ground 38 648 F06 Transmission Solenoid H short to ground Normally Closed 41 641 F03 Transmission Solenoid A short to battery 42 642 F03 Transmission Solenoid B short to battery ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25psi). 43 643 F03 Transmission Solenoid C short to battery 44 644 F03 Transmission Solenoid D short to battery ² Contact postion at the contacts of the harness connector. 45 645 F03 Transmission Solenoid E short to battery Brake/Park Brake Air Pressure 8C-3569 8N-2248 8T-8640 8T-9793 9X-0378 111-7088 114-5334 115-7103 Coolant Temperature Hydrualic Oil Temperature Steering Pressure Coolant Temperature Engine Oil Pressure Inching Pedal Pressure Refrigerant Pressure (A/C) 275 to 1750 kPa¹ - (40 to 255 psi) - 93.0 ± 21 kPa 69 ± 21 kPa (13.5 ± 3.0 psi) (10 ± 3.0 psi) 646 OR Sw to Front Flood Relay Consist No. 100-5045 SENR4130 321 BR Bckp Alarm Lamp Travel Alarm 668 BU Head Lamp/Tail Lamp Sw Electronic Monitoring System SENR2945 322 Transmission Electronic Shift Control SENR6982 326 RD Key SW “C’ Term. 710 GN XMSN Speed Pickup Starting And Charging Systems SENR2947 334 BU Start Aid Sol #2 727 GN Sec Ster Motor Relay 373 GN Start Aid Switch To Timer 728 BU Sec Ster Cont SW 46 646 F03 Transmission Solenoid F short to battery 751 GN XMSN Shift Sol No. 1 Or 3 47 647 F03 Transmission Solenoid G short to battery 403 GN Alternator (R) Term. 752 YL XMSN Shift Sol No. 2 48 648 F03 Transmission Solenoid H short to battery 404 YL Opr Mon Hyd Oil Temp 754 BU XMSN Shift Sol No. 3 Or 1 52 637 F06 Backup alarm short to ground 405 GY Opr Mon Oil Press. (Low Setting) 755 OR XMSN Shift Sol No. 4 Or 5 54 444 F05 Starter relay open circuit 406 PU Opr Mon Coolant Temp 758 GN AWD Clutch Sw 408 WH Opr Mon System Air Press. 795 YL 55 444 F06 Starter relay short to ground Dual Hp Sol 409 OR Opr Mon Neut F76 BU AWD To Inch Pedal SW 56 444 F03 Starter relay short to battery 410 WH Opr Mon Fault Alarm F77 BU Centershift Sol Resistance (Ohms)¹ 58 688 F06 VHP solenoid short to ground 3 to 97 411 PK Opr Mon Master 892 BR 59 688 F03 VHP solenoid short to battery 413 BR Opr Mon Fuel Press. 893 25.0 ± .3 61 668 F02 Shift lever input invalid 415 GN Opr Mon Test SW G86 560 to 716 @ 54°C (130°F) 62 668 F03 Shift lever open/short to +battery 417 GY Primary Ster SW 72 to 82 @ 110°C (230°F) 63 269 F00 Sensor supply voltage above normal 419 YL 64 269 F01 Sensor supply voltage below normal 439 65 701 F02 Transmission output speed signal incorrect 441 68 168 F01 System voltage below normal 447 71 520 F02 Invalid transmission configuration code 72 268 F02 Check programmable parameters 73 764 F05 Transmission indicator lamp open circuit 34.3 ± 1.7 74 764 F06 Transmission indicator lamp short to ground Overall 2.00 ± .10 Tap 1.00 ± .05 75 764 F03 Transmission indicator lamp short to battery 762 F04 Transmission oil temperture switch short to ground SENR3536 Consist No. 6V-5207 SENR3581 Consist No. 6V-5226 SENR4975 Monitoring Circuits Fuel Pressure Part No. Resistor, Sender and Solenoid Specifications Component Description 3E-5383 Sender - Articulation Start Mod Right (-) Port/CAT Data Link (-) GN 3T-3123 Resistor - Panel Dimmer Start Mod Right (+) Port/CAT Data Link (+) BU +12 Volt Switch Power 4W-9972 Sender - Coolant Temperature 900 PU XMSN Shift 501 No. 4 Opr Mon Parking Brake 901 WH XMSN Shift Sol No. 6 YL Lamp Indicator 902 BR XMSN Shift Sol No. 7 OR Eng Coolant Temp Gage 903 GY XMSN Shift Sol No. 8 PK Fuel Level Gage 921 WH XMSN Sol No 1 Or 3 Return 449 BU Spdom Sender (Signal No. 1) 977 YL CST Autoshift- Auto/Manual SW 1 450 YL Tach Sender (+) E93 PU MG MESH CNTL - Redundant Neutral 462 YL Sec Ster Motor Indicator E93 OR MG MESH CNTL - First Gear 467 WH System Fault (Xmsn) E93 WH MG MESH CNTL - Second Gear 8T-8808 6T-2217 Resistor - Starting/Charging Diagnostic 150 ± 7.5 7T-4003 Resistor - Power 10.0 ± 0.5 7T-9073 Solenoid - Differential Unlock 7T-9074 Solenoid - Forward Horn/Park Brake 8C-3663 Solenoid - Engine Shutdown 1.55 ± 0.15 Stop (Unlatch) Coil 10.3 ± 1.03 Solenoid - Centershift 488 WH Air SW To Air SW Jumper E94 BU MG MESH CNTL - Third Gear 9G-1950 Resistor - Blower Speed YL Articulation Indicator E94 YL MG MESH CNTL - Fourth Gear 9G-4365 Solenoid - Start Aid G46 GN Transmission Temperature SW E94 GN MG MESH CNTL - Fifth Gear 101-1759 Solenoid - A/C Clutch E94 BR MG MESH CNTL - Sixth Gear 104-6387 500 BR Wiper - Front (Park) E94 GY MG MESH CNTL - Seventh Gear 111-0570 501 GN Wiper - Front (Low) E94 PU MG MESH CNTL - Eighth Gear 127-0574 502 OR Wiper - Front (HI) E94 OR MG MESH CNTL - Forward Direct 503 BR Wiper - Rear (Park) E94 WH MG MESH CNTL - Reverse Direct 504 YL Wiper - Rear (Low) E94 BU MG MESH CNTL - Park 505 BU Wiper - Rear (HI) E94 YL MG MESH CNTL - Neutral E97 PU MESH Lamp ¹ At room temperature. 55.17 ± 5.77 Start (Latch) Coil A42 Accessory Circuits 33.6 ± 1.0 Sender - Transmission Speed Solenoid - Dual HP Solenoids - Transmission 6.0 14.4 ± 0.6 1000 to 1200 31.1 ± 2.4 31.0 ± 3.0 77 A Description Actuate Start Aid SoI To Temp SW Consist No. 6V-5023 Printed in U.S.A. ©1998 Caterpillar All Rights Reserved WH Starting Motor: 106-8555 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. The circle indicates that the component has screw terminals and a wire can be disconnected from it. 311 Control Circuits Normally closed switch that will open with an increase of a specific condition. 120H: 6NM1-254 9YR1-329 SENR2082 Warning Horn (Forward) Flow Symbol Level Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Consist No. 100-5046 GY Temperature Symbol Pressure Symbol Machine locations are repeated for components located close together. Lighting Circuits 200 Basic Machine Circuits Relay - Left Tail Lamp RENR1439 March 1998 AA Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector C A A 325-PK-14 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
RENR1440 January 1998 Alarm - Action Alarm - Backup F-15 1 Solenoid - Centershift B-3 16 Alternator (35A STD) D-14 2 Solenoid - Differential Unlock E-14 17 Battery C-14 3,4 Solenoid - Dual Horsepower A-13 5 Breaker - Alternator (35A) D-13 5 Solenoid - Engine Shutdown D-13 5 Breaker - Headlamp (15A) D-10 B Solenoid - Forward Horn A-3 16 Control - Neutral Start A-6 10 Solenoid - Park Brake B-12 16 Control - Transmission A-7 E Solenoid - Start Aid A-13 18 Fuses B-6 C Solenoids - Transmission Valve (8) D-15,E-15 14 Fuses D-9 B Switch - Beacon B-16 C Gauge Cluster F-5 A Switch - Blower (Heater) A-10 C C-13 12 Switch - Brake Air Pressure A-2 16 Ground - Front Frame D-6 21 Switch - Centershift Indicator B-3 19 C-13 28 Switch - Centershift Pin B-8 C Component Connector Location 3 6 26 8 23 Component Location Schematic Location B-8 Machine Location C Component Sender - Transmission Speed Schematic Location C-15 Machine Location 14 Schematic Location Machine Location CONN 1 C-15 26 CONN 2 E-15 26 CONN 3 F-14 6 CONN 4 A-14 5 CONN 5 B-13 29 CONN 6 B-13 29 CONN 7 D-13 30 CONN 8 D-13 29 CONN 9 E-12 21 CONN 10 E-12 25 CONN 11 E-12 25 CONN 12 E-12 25 Ground - Rear Frame D-6 24 Switch - Defroster (Front) A-6 C C Connector Number 18 14 13 11 22 7 17 1 2 12 5 B E 20 30 29 21 D 9 A 24 C 28 25 4 19 16 10 27 15 Ground - Engine CONN 13 D-12 21 Ground Strap - Cab to Front Frame CONN 14 D-12 21 Ground Strap - Front Frame to Rear Frame C-12 20 Switch - Defroster (Rear) B-6 CONN 15 B-12 25 Horn - Forward E-3 16 Switch - Differential Unlock D-8 B CONN 16 D-10 23 CONN 17 C-10 23 Meter - Service E-10 B Switch - Disconnect C-14 13 CONN 18 A-11 C Motor - Blower (Heater group) A-10 E Switch - Engine Coolant Temp (Start Aid) A-14 11 CONN 19 B-9 25 Motor - Blower/Defroster A-11 E Switch - Flood Lamp D-8 B CONN 20 E-9 B Motor - Blower/Defroster E-4 E Switch - Forward Horn E-9 B CONN 21 A-8 C Motor - Starter C-13 S Switch - Fuel Pressure B-13 13 CONN 22 B-7 25 Motor - Washer (Front Lower) F-6 8 Switch - Head/Tail Lamp E-8 B CONN 23 Service Tool B-7 C Motor - Washer (Front Upper) F-6 8 Switch - Headlamp Dimmer E-9 B CONN 24 E-6 24 Motor - Washer (Rear) F-6 8 Switch - Inching Pedal Pressure D-15 14 CONN 25 E-6 24 Motor - Wiper (Front Lower) C-4 9 Switch - Key Start CONN 26 C-6 24 Motor - Wiper (Front Upper) D-4 D Switch - Park Brake Pressure CONN 27 C-6 27 CONN 28 A-6 27 Motor - Wiper (Rear) B-11 D Switch - Start Aid E-8 B CONN 29 C-5 27 Relay - Start D-13 5 Switch - Stoplamp Pressure A-2 16 CONN 30 C-5 27 CONN 31 B-3 15 CONN 32 E-3 23 CONN 33 F-3 23 CONN 34 F-3 23 27 D A 18 B 11 22 12 1 6 2 14 4 24 E 13 5 9 C 30 3 29 28 23 8 20 26 25 10 15 19 16 21 7 17 E20367 Machine Harness Connector And Component Locations The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. B-9 C B-11 16 Relay - Transmission Action Lamp C-10 8 Switch - Tail Lamp D-8 B Resistor - Blower Speed A-12 E Switch - Transmission Direction & Speed A-8 C Resistor - Blower Speed E-4 E Switch - Transmission Oil Temperature D-15 26 Resistor - Blower Speed (Heater) A-10 E Switch - Wiper (Front Lower) A-5 C Sender - Articulation C-1 2 7 Switch - Wiper (Front Upper) B-5 C Sender - Engine Coolant Temp A-14 11 Switch - Wiper (Rear) A-5 C Sender - Engine Oil Pressure B-14 13 120H, 135H Motor Grader (Standard Version) Electrical System 120H: 5FM1-799 6TM1-365 135H: 7MM1-248 8WN1-349 Machine locations are repeated for components located close together A= Operator’s compartment (Dash). B= Operator’s compartment (Steering console). C= Operator’s compartment (Right side console). D= Operator’s compartment (Headliner). E= Operators compartment (Under seat). Related Electrical Service Manuals Title Form Number Alternator (6N-9294 35A): STD Consist No. 3T-6352 Consist No. 7N-9720 Consist No. 9G-4574 SENR4978 SENR2082 SENR4130 Alternator (100-5047 50A): ATT SENR2082 Transmission Electronic Shift Control SENR6982 Starting Motor: (106-8558) Consist No. 106-8557 Consist No. 106-8559 SENR3559 SENR3581 Printed in U.S.A. © 1998 Caterpillar All Rights Reserved Transmission Diagnostic Code Conversion Resistor, Sender and Solenoid Specifications Part No. Component Description Wire Number Description 506 PU Washer - Front Range - 3 to 97 Ohms 102 BU Hd Lmp 507 WH Washer - Rear 560 to 716 @ 54°C (130°F) 72 tO 82 @ 110°C(230°F) 103 YL Aux Ckt 515 GY Blower Motor (HI) 105 BR Key Start Sw 516 GN Blower Motor (Medium) No diagnostics active 12 N/A No logged diagnostic codes 21 641 F05 Transmission Solenoid A open circuit 22 642 F05 Transmission Solenoid B open circuit 23 643 F05 Transmission Solenoid C open circuit 24 644 F05 Transmission Solenoid D open circuit 25 645 F05 Transmission Solenoid E open circuit 26 646 F05 Transmission Solenoid F open circuit 27 647 F05 Transmission Solenoid G open circuit 28 648 F05 Transmission Solenoid H open circuit 31 641 F06 Transmission Solenoid A short to ground 32 642 F06 Transmission Solenoid B short to ground 33 643 F06 Transmission Solenoid C short to ground 34 644 F06 Transmission Solenoid D short to ground 35 645 F06 Transmission Solenoid E short to ground 36 646 F06 Transmission Solenoid F short to ground 37 647 F06 Transmission Solenoid G short to ground 200 BK 38 648 F06 Transmission Solenoid H short to ground 201 41 641 F03 Transmission Solenoid A short to battery 277 42 642 F03 Transmission Solenoid B short to battery 43 643 F03 Transmission Solenoid C short to battery 44 644 F03 Transmission Solenoid D short to battery 45 645 F03 Transmission Solenoid E short to battery 46 646 F03 Transmission Solenoid F short to battery 47 647 F03 Transmission Solenoid G short to battery 48 648 F03 Transmission Solenoid H short to battery 52 637 F06 Backup alarm short to ground 54 444 F05 Starter relay open circuit 55 444 F06 Starter relay short to ground 56 444 F03 Starter relay short to battery 58 688 F06 VHP solenoid short to ground 59 688 F03 VHP solenoid short to battery 61 668 F02 Shift lever input invalid 62 668 F03 Shift lever open/short to +battery 63 269 F00 Sensor supply voltage above normal 64 269 F0l Sensor supply voltage below normal 65 701 F02 Transmission output speed signal incorrect 68 168 F0l System voltage below normal 71 520 F02 Invalid transmission configuration code 72 268 F02 Check programmable parameters 73 764 F05 Transmission indicator lamp open circuit 74 764 F06 Transmission indicator lamp short to ground 75 764 F03 Transmission indicator lamp short to battery 500 BR 77 762 F04 Transmission oil temperture switch short to ground 501 502 503 3E-5383 Sender - Articulation Position 7N-8532 Sender - Engine Coolant Temp 7T-4003 Resistors - Defroster Blower 10.0 ± 0.5 108 BU Aux Ckt 517 BU Blower Motor (Low) 7T-9073 Solenoid - Differential Unlock 33.6 ± 1.0 109 OR Alt Output (+) Term. 521 YL A/C SW To Refrigerant SW 7T-9074 Solenoids - Forward Horn Park Brake 113 OR Opr Mon Panel 522 WH A/C Clutch To Thermostat SW 114 GN Warning Horn (Forward) 556 WH Differential Lock 116 BR Aux Ckt 575 YL Wiper - Aux (Park) 8C-3663 Solenoid - Engine Shutdown Start (Latch) Coil Stop (Unlatch) Coil 118 GY Aux Ckt 576 PK Wiper - Aux (Low) 119 PK Aux Ckt 577 PU Wiper - Aux (Hl) 124 GN A/C 578 BU Washer - Aux 130 GN Aux Ckt 584 YL Wiper SW Jumper 141 PK Aux Ckt A503 PK Front Defroster Fan (Low) 144 GN Aux Ckt A504 GN Rear Defroster Fan (Low) 149 PU Aux Ckt A506 OR Front Defroster Fan (HI) 151 GN Aux Ckt A507 YL Rear Defroster Fan (HI) 152 BU Aux Ckt 165 YL Aux Ckt 55.17 ± 5.77 1.55 ± 0.1510.3 ± 1.03 8T-8808 9G-1950 9G-4365 104-6387 111-0570 Solenoid - Centershift Resistor - Blower Speed Solenoid - Start Aid Sender - Transmission Speed Solenoid - Dual Horsepower 34.3 ± 1.7 Overall 2.00 ± .10 Tap 1.00 ± .05 6 1000 to 1200 31.1 ± 2.4 116-9937 Sender - Engine Oil Pressure 21.5- 49.5 @552 kPa (80.1 psi) 227 - 257 @ 21 kPa (3.0 psi) 127-0574 Solenoids - Transmission ¹ At room temperature unless otherwise noted. 31 ± 3 PK Rotary Beacon 604 OR Stop Lamp Main Chassis 608 GN Flood Lamp - Rear BK XMSN CtrI 609 YL Flood Lamp - Side BK XMSN Ctrl Ident Code 1 611 PU Head Lamp Hi 278 BK XMSN CtrI Ident Code 2 614 PU Park/Tail/Dash/Lamp 619 GN Head Lamp LoControl Circuits 301 BU Starter No. 1 Sol 304 WH Starter Relay No. 1 OutpuT 306 GN 307 OR Starter Relay Coil To Neut Start SW Or KeyStart SW Key Start SW To Neutral Start SW 308 YL Main Power Relay Coil 310 PU Start Aid SW To Start Aid Sol 311 WH Start Aid Sol To Temp SW 321 BR Backup Alarm Lamp Travel Alarm 322 GY Warning Horn (Forward) 326 PU Key Start SW C Term. Basic Machine Circuits 112-2024 115-7103 Function Stop Lamp Pressure Coolant Temperature (Start Aid) Inching Pedal Pressure Off Machine Switch Specification Actuate Deactuate Contact Position 45 kPa MAX (6.5 psi MAX) 5 kPa MIN (0.5 psi MIN) NormallyOpen 38 ± 3°C (1 00.4° ± 5.4°F) 75.0 kPa MAX (10.9 psi MAX) 27 °C MIN (80.6°F MIN) 50.0 kPa MIN (7.3 psi MIN) NormallyClosed NormallyOpen Brake Air Park Brake Pressure 640 kPa MAX (92.0 psi MAX) 530 ± 40 kPa (77.0 ± 6.0 psi) NormallyOpen Fuel Pressure (EMS) 93 ± 21 kPa (13.5 ± 3.0 psi) 69 ± 21 kPa (10.0 ± 3.0 psi) Normally Closed Monitoring Circuits A AA 2 GN XMSN Speed Pickup Signal 751 GN XMSN Shift Sol No. 1 Or 3 752 YL XMSN Shift Sol No. 2 754 BU XMSN Shift Sol No. 3 Or 1 755 OR XMSN Shift Sol No. 4 Or 5 758 GN AWD Clutch SW 795 YL Dual Hp Sol B751 BU (NFND) Centershift Lock Sol 892 BR Start Mod Right (-) Port/CAT Data Link (-) 893 GN Start Mod Right (+) Port/CAT Data Link (+) G865 BU +12 Volt Switch Power 404 GN Alternator (R) Term. 439 YL Lamp Indicator 900 PU XMSN Shift Sol No. 5 or 4 441 OR Eng Coolant Temp Gauge 901 WH XMSN Shift Sol No. 6 A429 YL Articulation Indicator 902 BR XMSN Shift Sol No. 7 A476 PU Eng Oil Press Gauge To Sender - Eng #1 903 GY XMSN Shift Sol No. 8 B476 BU (NFND) Transmission Indicator Lamp 921 WH XMSN Sol No 1 Or 3 Return C491 PU Park Brake Pressure E937 PU MG MESH CNTL - Redundant Neutral E458 YL Low Air Pressure Lamp E938 OR MG MESH CNTL - First Gear E459 WH Low AIr Pressure Alarm E939 WH MG MESH CNTL - Second Gear E460 BR Trans Cntl To Relay Coil E940 BU MG MESH CNTL - Third Gear G460 GN Transmission Temperature E941 YL MG MESH CNTL - Fourth Gear Accessory Circuits E942 GN MG MESH CNTL - Fifth Gear Wiper - Front (Park) E943 BR MG MESH CNTL - Sixth Gear GN Wiper - Front (Low) E944 GY MG MESH CNTL - Seventh Gear OR Wiper - Front (HI) E945 PU MG MESH CNTL - Eighth Gear BR Wiper - Rear (Park) E946 OR MG MESH CNTL - Forward Direct 504 YL Wiper - Rear (Low) E947 WH MG MESH CNTL - Reverse Direct 505 BU Wiper - Rear (HI) E948 BU MG MESH CNTL - Park E949 YL MG MESH CNTL - Neutral E975 PU MESH Lamp Electrical Schematic Symbols And Definitions Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. T Pressure Symbol Pin or Socket Number Wire, Cable, or Harness Assembly Identification C A A 325-PK-14 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 Level Symbol Flow Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T Temperature Symbol Component Part Number Single Wire Connector Control Circuits 710 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 Lighting Circuits 603 Ground Circuits 111-7088 Description Accessory Circuits (Continued) Bat (+) N/A 8C-3569 Harness And Wire Electrical Schematic Symbols RD 11 2W-9346 Wire Color 101 Resistance (Ohms)¹ CID - FMI Part No. Wire Number Power Circuits Code Flashed Description Wire Description Wire Color SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. Normally closed switch that will open with an increase of a specific condition. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. The circle indicates that the component has screw terminals and a wire can be disconnected from it. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.
R esist or - Def r ost Mo tor E- 4 E 101 RD B at (+) 441 OR E ng Coo lant T emp G aug e 1 Blow er Mo t or A- 12 E 102 RD Hd Lm p 447 PK F uel Level Ga uge D -14 2 R esist or - P ane l L am p D i mm er E- 9 B 103 RD A ux Ckt 450 YL T ac h S ender (+) B at ter i es - 12 Volt E- 13 5, 6 R esist or - St ar te r E- 13 19 105 RD K ey S w 462 YL S eco nda ry S ter Mo tor Ind ic ator B r eak er - A lt er nat or ( 60A) D -13 8 Sen de r - Ar t ic u lat i on C -12 23 108 RD A ux Ckt 488 WH A ir SW T o Air S W J ump er B r eak er - C onv er te r F -11 13 Sen de r - Co ol ant T em p. A- 14 24 109 RD A lt Ou tpu t (+) T erm . 498 WH Diff . Lock Indic a tor B r eak er - H ead la mp D -10 B Sen de r - F uel L evel A- 13 25 112 PU M ain P ower R Iy Outpu t A 429 YL A rticul ation Indic ator B r eak er - L ig ht bar L ow Be am D -10 B Sol e noi d - A / C C lut c h A- 13 22 113 OR Opr Mon P anel B+ S witched B uss B ar E- 12 5 Sol e noi d - Bl ade Cu shi o n E- 2 30 114 RD Wa rnin g H orn (F orwa rd) 500 BR Wi per - F ro nt (Park ) C ont r ol - Se con dar y St eer in g E- 13 9 Sol e noi d - Ce nte r shi f t C onv e rt er - 24V t o 12V F -10 12 Sol e noi d - Di f fer en tial Unl oc k C onv e rt er - 24V t o 12V F -12 12 Sol e noi d - Fo rwar d H or n D io de As - ( A/ C C lut ch Sol ) A- 13 22 F la sh er E- 9 F us es R esist or - Bl owe r S wit ch (H eat er ) A la rm - Ac ti on B- 8 C A la rm - Bac k up E- 15 A lt er nat or Co nn ec tor De scrip ti on M o ni tor i ng C ir cu its (CO NT 'D ) P o wer Cir cu its Acces so ry Cir cu its 29 115 RD A ux Ckt 501 GN Wi per - F ront (Lo w) 4 116 BR A ux Ckt 502 OR Wi per - F ro nt (HI ) F -3 10 118 GY A ux Ckt 503 BR Wi per - Re ar (Park ) Sol e noi d - P ar k Br ak e B- 12 10 119 PK A ux Ckt 504 YL Wi per - R ear (Lo w) B Sol e noi d - Sh ut dow n D -13 22 121 RD B ack A larm T o Lamp 505 BU Wi per - Re ar (HI) B- 5 C Sol e noi d - St ar t Aid A- 13 25 122 BU A ux Ckt 506 PU Wa sher - F ro nt F us es D -9 B Swit c h - A/ C Ref r i ge r ant A- 12 22 123 WH A ux Ckt 507 WH Wa sher - R ear F us es E- 10 B Swit c h - B ack - Up Ala rm F -14 4 124 GN 508 PU A Swit c h - Beac on B- 6 C Radio S pea k er - Le ft G aug e - US S ys t em Ai r P r es s E- 5 A /C 129 BU 509 WH A Swit c h - Beac on B- 10 C Radio S peake r - L ef t (C omm om ) G aug e - R/ S Sy s te m Air Pr es s E- 5 A ux Ckt 130 RD 511 BR A Swit c h - Bl ade Cu sh i on B- 8 C Radio S pea k er - Ri g ht G aug e Clus te r F -5 A ux Ckt 134 RD 512 GN 17 Swit c h - Bl owe r (A /C ) B- 10 C Radio S peake r - R ig ht (C om mon ) G r ound - Cab D -5 A ux Ckt 135 BU 513 OR 22 Swit c h - Bl owe r (H e at er) A- 10 C A /C Com presso r/Refrige rant Pre ss ure SW G r ound - Eng ine E- 12 A ux Ckt 136 GN 515 GY 39 Swit c h - B r ake A ir A- 2 11 B lo wer M otor (HI) G r ound - F ram e ( F r on t ) D -6 S eco nda ry St er E- 12 8 C PK A ux Ckt 516 GN B lo wer M oto r (Med ium) Swit c h - Cent er s hi f t Pin B- 9 141 G r ound - F ra me (Re ar) A- 14 24 BU Swit c h - Cool a nt A ux Ckt 517 G r ound - Loc al ize d S tu d D RD S E NR2 94 5 F -12 144 B lo wer M oto r (Low ) B- 14 24 YL Swit c h - Cool a nt Te mp . A ux Ckt 521 Ground Strap - Front Frame to Rear Frame 23 RD A /C SW To Re f rig eran t S W S E NR3 53 6 S E NR3 58 1 S E NR4 97 5 C -12 147 A C A ux Ckt 522 WH Swit c h - Def r ost ( Fr ont ) A- 6 PU L am p - M as te r Ac t ion E- 5 149 A /C Clu tch To T h erm ostat SW A C A ux Ckt 537 GN Swit c h - Def r ost ( Rea r) B- 6 GN L ig ht B ar - L ow Be am E- 8 151 T urn S ignal SW To F la she r B B A ux Ckt 556 WH Swit c h - Dif fer en tial U nlo ck D -9 BU M e ter - Se rv i c e M o nit or - E lec t ro nic M on it or in g Sy st e m ( E MS) E- 10 152 Diff erent ial Lock 158 BR A ux Ckt 570 BU B la de Cushio n So l E- 6 A E- 12 6 165 YL A ux Ckt 575 YL Wi per - Aux (P ark) M o tor - Bl o wer (A/ C) B- 10 1 Swit c h - Engi n e O il C -13 32 169 PK A ux Ckt 576 PK Wi per - A ux (Lo w) M o tor - Bl o wer (He ate r ) A- 10 E Swit c h - Flo od La mp D -8 B 173 RD A ux Ckt 577 PU Wi per - Aux (H I ) M o tor - Conde ns er B- 10 21 Swit c h - Fuel B- 13 24 176 OR A ux Ckt 578 BU Wa sher - Au x M o tor - Conde ns er C -11 21 Swit c h - H ead la mp /T ail E- 8 B 584 YL Wi per SW Jum per M o tor - Def ro st E- 4 15 Swit c h - H ead li ght Di m mer D -9 B 200 BK 592 BU DC/D C Conv erter P owe r Out p ut M o tor - Def ro st er ( Bl ow er) A- 12 15 Swit c h - Horn E- 9 B 201 BK 593 GN Condensor F an Re la y To Mo t ors M o tor - Se co nda r y St eeri ng F -13 20 Swit c h - Hy d. O i l Te mp. C -12 33 597 PU A /C HI Pre s s. C outo ut SW T o Lo w P ress. SW M o tor - St ar t er E- 12 19 Swit c h - Ke y St art B- 9 C 301 BU S tart er No. 1 S ol A 503 PK F ront Defros t er F an (Low ) M o tor - W ash er ( Fr on t Low er ) F -6 16 Swit c h - Neut r al/ Star t E- 14 4 304 WH S tart er Relay No . 1 Out put A 504 GN Rear Defros ter F an (Low ) M o tor - W ash er ( Fr on t Up per ) F -6 16 Swit c h - P ane l La mp D im m er E- 9 B 306 GN S tart er Relay C oi l T o Neut St art SW Or Key SW A 506 OR F ront Defroste r F an (HI) M o tor - W ash er ( Rea r) F -6 16 Swit c h - P ar king B ra ke P r ess . B- 11 34 307 OR K ey St art SW T o Neut S tart SW O r Se nsor M odul e A 507 YL Rear Def rost e r F a n (HI) M o tor - W ip er ( F ron t Low er ) C -4 17 Swit c h - Pr i mar y St eer ing F -10 35 308 YL M ain P ow er Relay Coi l A 513 PK DC/D C Conve rter Me mory O utp ut M o tor - W ip er ( F ron t Upper ) D -4 17 Swit c h - Sec ond ar y St e er i n g T es t B- 8 C 310 PU S tart A id SW T o S tart A id S ol M o tor - W ip er ( R ear ) C -11 18 Swit c h - St ar t Ai d EM S T es t E- 8 B 311 WH S tart A id So l To T em p SW 600 BR Dash Lam p Ba si c S E NR4 13 0 S E NR4 13 0 S E NR2 08 2 Elect ronic Monit oring S yste m Starter Motor: 10 6 - 855 5 C onsist N o. 6 V -50 2 3 C onsist N o. 6 V -52 0 7 C onsist N o. 6 V -52 2 6 E B- 3 Fo rm Nu mb er C onsist N o. 1 0 0-5 0 46 D escri pt ion L o cati on¹ Swit c h - Disc on ne c t Gr o u nd Cir cu its M ain Chass is O pe rat or M onito r Return Basic M ach in e Ci r cu its 7WJ1-663 L ig h tin g Ci rc u i ts R ec ept ic al - Au x. Sta r t D -12 3 Swit c h - S top Lam p A- 2 11 321 BR B ckp A larm Lam p T rav el A larm 601 GY Dash Lam p Hi R el ay - C onde nse r C -10 21 Swit c h - Ta il Lam p D -8 B 322 GY Wa rnin g H orn (F orwa rd) 603 PK Rotary B eaco n R el ay - Mai n D -14 8 Swit c h - Tur n Signal E- 9 B 326 RD K ey St art SW ‘C” T erm . 604 OR S top Lamp R el ay - Se co nda r y St ee r ing F -13 22 Swit c h - Wi per (F r ont L ow er ) A- 4 C 605 YL T urn Lam p - Left R el ay - St ar t D -13 8 Swit c h - Wi per (F r ont U pp er ) B- 4 C 403 GN A lt ernat or (R ) T erm . 606 GY T urn Lam p - Rig ht R es is to r - Bl o wer Swi t ch ( A/ C) B- 11 15 Swit c h - W i per ( Re ar) A- 4 C 404 YL Opr M on Hyd Oi l T em p 608 GN F lo od Lam p - Rea r T her mos t at B- 11 E 405 GY Opr M on Oil Press . (Lo w S et ting) 609 YL F lo od Lam p - Side M a ch ine loc ati ons are r e pea ted f or c om pon ents loc at ed c los e t og ether . 406 PU Opr M on Coolant T em p 611 PU Head Lam p Hi A = O per at or ’ s Co mpa rt m ent ( D as h) . 408 WH Opr M on S ys tem Air P ress. 614 PU P ark/ T ail/D ash/ L am p B = O per at or ’ s Co mpa rt m ent ( S te eri ng C ons o le) . 409 OR Opr Mon N eut 619 GN Head Lam p L o C = Oper a tor ’ s Co mpar tm ent (R ig ht S ide Co nso le) . 410 WH Opr M on A ct ion Al arm 629 PK A ux Head L am p M o ni tor i ng Cir cu its M ac hi ne Lo ca ti on C ONN 1 Starting/C har gi ng Dia g nos t ic E -14 45 C ONN 2 F-1 4 36 D = O pe r at or’ s C om par t men t ( Hea dli ner ) . C ONN 3 F-1 4 7 411 PK Opr M on M as t er C ONN 4 B -14 8 E = O per at or ’ s Co mpa rt m ent ( U nde r Seat ) . 413 BR Opr M on F ue l P ress. 727 GN S eco nda ry Ste r Mo t or Re lay C ONN 5 B -14 11 F = L oc at ed unde r c ab f loor pl ate. 415 GN Opr M on T es t S W 728 BU S eco nda ry Ste r Con t SW C ONN 6 A -14 27 417 GY P rim ary S ter S W E 773 YL Center Sh ift So l Pu sh C ONN 7 A -14 26 419 YL Opr Mon P ark ing B rak e F 775 BU Centers hif t S oleno id C ONN 8 A -14 8 C ONN 9 B -13 37 C ONN 10 B -13 37 C ONN 11 B -13 37 C ONN 12 D- 13 22 C ONN 13 D- 13 37 C ONN 14 D- 13 37 16 C ONN 15 F-1 2 37 13 41 20 C ONN 16 B -12 10 C ONN 17a A -10 C C ONN 17b B -11 C C ONN 17c A -11 C C ONN 18 D- 12 44 C ONN 19 F-1 1 28 C ONN 20 D- 10 B C ONN 21 D- 10 B C ONN 22 D- 10 39 C ONN 23 D- 10 39 C ONN 24 D- 10 39 C ONN 25 C- 10 21 C ONN 26a C- 10 33 C ONN 26b C- 10 33 C ONN 27a B -10 C C ONN 27b A -9 C C ONN 28 B -9 38 C ONN 29 B -9 38 31 36 27 6 4 7 1 2 23 3E-79 85 17 30 29 34 11 C 10 21 39 C ONN 33 D- 8 39 C ONN 34 B -8 38 C ONN 35a Seco nd a ry S te eri n g F-7 20 7 C ONN 35b F-7 20 25 17 A 3T -3123 43 38 40 6T -2217 7T -9074 D- 8 C- 6 B 3E-53 83 7T -6517 C ONN 32 C ONN 38 39 18 33 37 44 42 7T -4003 39 17 8 19 28 P ar t N o. 7N-8532 39 C- 6 22 D 15 E 21 5 A -9 C ONN 37 24 26 E -9 40 18 14 D 9G-1950 28 40 E 27 24 19 8 3 41 A B 101-175 9 C 5 6 17 33 42 32 22 37 2 1 9X-9482 9 45 26 9G-4365 15 13 16 38 12 35 39 11 43 30 6. 0 ± 3 (M IN) 92 ± 5 (M AX ) S end er - A rti culati on P osit io n S ol enoi d - E ngine Sh utdown St art (Lat c h) Coil St op (Unl at ch) Coil 1. 5 5 ± 0. 1 5 10 . 3 ± 1. 0 3 Receptacle Plug 15 0 ± 7.5 Resisto r - S tart er/Diagnos tic Conn 10 . 0 ± 0. 5 Resisto r - D efros ter/Bl ower M otor 20 . 1 ± 1. 0 S ol enoi ds - B lade Cus hio n * C-C4* AG-C3 130-6795 130-6795 55 . 2 ± 5. 8 S ol enoi d - F orward H ornP ark B rak e Resisto r - A /C B low er M ot or Heate r B l ower M ot or Overall 2.0 ± .1;Tap 1.0 ±.05 6. 0 S ol enoi d - S tart Aid 68 S ol enoi d - Centers hift 14 . 4 ± 0. 6 S ol enoi d - A /C C lu tch Pin C- 6 17 44 C ONN 41 E -6 17 P ar t N o. C ONN 42 E -6 17 C ONN 43 E -6 17 2M -93 46 C ONN 44 C- 5 40 C ONN 45 C- 5 40 C ONN 46 C- 5 40 C ONN 47 F-3 17 C ONN 48 F-3 17 C ONN 49 E -3 42 C ONN 50 E -3 42 C ONN 51 B -3 43 C ONN 52 D- 12 44 C ONN 53 E -12 44 C ONN 54 E -12 44 C ONN 55 E -14 3 23 34 1 Fu nct io n 3E-6425 A ct uat e D eact uate Conta ct Positio n 5 kP a MIN (0. 5 psi MI N ) No rmall y O pen 640 kP a (92 psi ) 530 ± 4 0 kP a (77 ± 6 ps i) No rmall y O pen 38 ± 3 °C (100 ± 5°F ) 27 °C M IN (81 °F MIN) No rmall y C lo sed E ngi ne Coolant T em p (E MS ) 107.2 ± 2.8°C (225 ± 5°F ) 93. 0°C MIN (20 0°F MIN ) 7N-9785 No rmall y C lo sed 8N-1693 Coolant Tem perature (St art A id) 37.8 ± 2.8°C (100 ± 5°F ) 26. 7°C MIN (80 °F MIN) No rmall y C lo sed 8N-2248 Hy draul ic Oil Tem perature 101.7°C M IN (215°F MI N) 93. 3°C MIN (20 0°F MIN ) No rmall y C lo sed 8T -8640 9W -3187 9X-0378 114-533 4 Coolant Tem perature (St art A id) 1206 kP a (M A X) (175 ps i M A X ) 700 ± 1 03 k Pa (100 ± 15 psi) A-B , Norm all y O pen A-C , Norm al ly Cl os ed F uel Pres sure (EM S ) 93 ± 21 k Pa (13.5 ± 3.0 ps i) 69 ± 2 1 k Pa (10. 0 ± 3. 0 ps i) No rmall y C lo sed E ngi ne Oil (P ress ure) 62 kP a (M A X) (9 p si M AX) 38 ± 2 0 k Pa (5.5 ± 3.0 p si ) No rmall y O pen P rim ary S teeri ng Pre ssure A /C Ref rige rant (Pressu re ) 25 to 1750 kP a ¹ (40 to 255 psi ) — — Temperature Symbol Level Symbol Flow Symbol Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Harness identification code This example indicates wire 32 in harness "L'. Normally closed switch that will open with an increase of a specific condition. Socket * Harness identification letter(s) and a serializing code. The "C" stands for connector and the number indicates which connector in the harness. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. 200-L32 BK-14 2 Circuit Number Identification Wire Color Wire Gauge The circle indicates that the component has screw terminals and a wire can be disconnected from it. Electrical Schematic Symbols And Definitions 45 k Pa M A X (6.5 ps i M AX ) S top Lam p P ressure P ark B rake Ai r P ressure 3E-2033 B rake A ir Pres sure Pressure Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Single Wire Connector Of f M ac h in e S w it c h S p e ci f ic at i on 20 T 9X-1123 44 D- 12 4 L-C12* 3E-5179 AG-C4* 111-7898 325-A135 PK-14 10 31 Wire, Cable, or Harness Assembly Identification Pin or Socket Number 560 to 716 @ 54 °C (130 °F) 72 to 82 @110 °C (230 °F) S end er - C ool ant T em pe rature Component Part Number 2 25 . 0 ± .3 Resisto r - P anel Lam p Dim m er Swi tch Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 Resi st ance (O hm s)¹ ¹ A t room tem pera ture unless otherwise not ed. C ONN 40 36 C omp on ent D esc ript io n Electrical Schematic Symbols And Definitions 1 2 1 2 L-C12 * 3E-5179 AG-C4 * 111-7898 29 C ONN 39 ¹ The c onnec tors sh o wn in th is ch ar t are f or ha rn ess to h arn e s s c onn e cto r s. C onnectors t hat jo in a ha rn ess to a c om pon e nt ar e gen er a lly lo ca te d at or n ear th e component . See th e Co mpo nen t L oca tion Cha rt . Harness And Wire Electrical Schematic Symbols R e s is t or , S e n de r a n d S o le n oi d S pe ci f ic at ions 14 35 9 32 45 C ONN 31 A -6 3 25 C ONN 30 C ONN 36 Co n tr ol Cir cu its Part Numbers For Connector Assembly 12 Printed in U.S.A. © 1997 Caterpillar All Rights Reserved Sc he mat ic Lo ca ti o n C o n ne cto r Num be r 14H Motor Grader (NA Version) Electrical System 325-L25 PK-14 9 C om po n en t E- 14 Rela ted E lec tric al Se r vic e M anuals Alternator (100-5 04 7 )(A tch) : C onsist N o. 1 0 0-5 0 45 Wi re Wi re N umber C olor M ach in e L oc ati o n M ach in e L oc ati o n A ir D r y er Alternator: 6N- 92 94 C ons is t No. 9 G - 457 4 Wi re Wi re N umber C olor Sch em ati c L oc ati o n A- 11 Sch em ati c L oc ati o n F -14 C om po n en t Tit le RENR1441 October 1997 W ir e De s cr ip t io n C omp onent Locatio n No rmall y O pen ² ¹ Contact position at the contacts of the harness connector. ² A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing - pressure the closed condition can be maintained down to 170 kPa (25 psi). FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.
Connector Location Schematic Location Machine Location CONN 1 B-15 8 CONN 2 B-15 42 CONN 3 F-14 36 CONN 4 F-14 28 CONN 5 A-14 2 CONN 6 A-14 42 CONN 7 B-13 37 CONN 8 B-13 37 CONN 9 B-13 37 CONN 10 D-13 37 CONN 11 D-13 3 CONN 12 F-12 37 CONN 13 F-12 39 CONN 14 E-12 39 CONN 15 D-12 39 CONN 16 D-12 39 CONN 17 D-12 39 CONN 18 B-12 10 CONN 19a B-11 38 CONN 19b B-11 38 CONN 19c A-11 38 CONN 20 F-11 D CONN 21 D-10 B CONN 22 D-10 B CONN 23 D-10 39 CONN 24 D-10 39 CONN 25 D-10 39 CONN 26 C-10 33 CONN 27a B-10 C CONN 27b A-10 C CONN 28 B-9 38 CONN 29 B-9 38 CONN 30 E-9 B CONN 31 E-9 39 CONN 32 D-8 39 CONN 33 D-8 39 CONN 34 B-8 38 CONN 35a F-7 39 CONN 35b F-7 39 CONN 36 E-6 17 CONN 37 E-6 17 CONN 38 E-6 17 CONN 39 C-6 17 CONN 40 C-6 17 CONN 41 C-6 17 CONN 42 C-6 40 CONN 43 A-6 40 CONN 44 C-5 40 CONN 45 C-5 40 CONN 46 B-3 27 CONN 47 E-3 27 CONN 48 E-3 29 CONN 49 F-3 26 CONN 50 F-3 26 CONN 51 Diagnostic Conn F-3 45 Connector Number Part No. 16 36 12 6 31 4 3 4132 28 42 43 D 20 B 21 18 7 14 1 36 42 2 43 8 31 24 B 19 3 32 22 41 C 33 37 5 6 4 16 38 12 35 11 23 34 Deactuate Contact Position 640 kPa (92.0 psi) 530 ± 40 kPa (77.0 ± 6.0 psi) Normally Open 3E-2033 Brake Air Pressure 7N-9785 Engine Coolant Temp (EMS) 107.2 ± 2.8°C (225 ± 5°F) 93.0°C MIN (200°F MIN) Normally Closed 8N-1 693 Coolant Temperature (Start Aid) 37.8 ± 2.8°C (100 ± 5°F) 26.7°C MIN (80°F MIN) Normally Closed 8N-2248 Hydraulic Oil Temperature 101 .7°C MIN (21 5°F MIN) 93.3°C MIN (200°F MIN) Normally Closed 9X-0378 Engine Oil Pressure 62.0 kPa MAX (9.0 psi MAX) 38.0 ± 20.0 kPa (5.5 ± 3.0 psi) Normally Open 9W-3187 Fuel Pressure (EMS) 93 ± 21 kPa (13.5 ± 3.0 psi) 69 ± 21 kPa (10.0 ± 3.0 psi) Normally Closed 114-5334 Refrigerant Pressure (AC) 125-9352 Stop Lamp Pressure 275 to 1750 kPa ¹ (40 to 255 psi) - 83 kPa MAX (12 psi MAX) RENR1442 April 1998 Normally Open ² 48 ± 20 kPa MIN (7 ± 3 psi MIN) Normally Open ¹A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kPa (25 psi). ² Contact position at the contacts of the harness connector. 17 30 29 27 15 13 9 Actuate 16H (NA) Motor Grader Electrical Grader 40 D E 25 A 11 10 C 38 40 5 28 15 39 26 E 24 21 18 7 33 34 37 23 22 2 8 19 14 35 9 25 1 13 Off Machine Switch Specification Function Resistor, Sender and Solenoid Specifications Part No. A 17 26 39 27 30 29 10 20 E42037 Machine Harness Connector And Component Locations Component Description Resistance (Ohms)¹ 3E-5383 Sender - Articulation Position 3 to 97 3E-7985 Solenoid - Engine Shutdown Start (Latch) 1.55 ± 0.15 Stop (Unlatch) 10.30 ± 1.03 6T-2217 Resistor - Starter/Diagnostic Conn 7N-8532 Sender - Engine Coolant 7T-4003 Resistor 10.0 ± 0.5 7T-6517 Solenoid - Blade Cushion 20.1 ± 1.0 7T-9074 Solenoid - Forward Horn Park Brake 55.17 ± 5.77 9G-1950 Resistor - Blower Speed Overall 2.00 ± .10 Tap 1.00 ± .05 9G-4365 Solenoid - Start Aid 6 9X-9482 Solenoid - Centershift 68 101-1759 Solenoid - A/C Clutch 14.4 ± 0.6 16H: 6ZJ1-330 150 ± 7.5 54°C (130°F) - 560 to 716 110°C (230°F) - 72 to 82 ¹ At room temperature unless otherwise noted. The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Component Title Form Number Alternator: 100-5047 Consist No. 100- 5046 Consist No. 100-5045 SENR2082 SENR4130 Electronic Monitoring System (EMS) SENR2945 Schematic Location Wire Description Component Location Machine Location Component Schematic Location A-11 Machine Location E Wire Number Wire Color E-9 B 101 RD Wire Number Wire Color Bat (+) 441 OR Eng Coolant Temp Gauge Description Description B-8 C Resistor - Blower Speed (Heater) Alarm - Backup F-15 1 Resistor - Panel Lamp Dimmer Resistor - Starter Motor E-1 3 32 102 RD Hd Lmp 447 PK Fuel Level Gauge Sender-Articulation C-12 23 103 RD Aux Ckt 450 YL Tach Sender(+) A-14 24 105 RD Key Start Sw 462 YL Secondary Ster Motor Indicator D-14 2 Battery E-13,A-12 5,6 Beacon C-10 7 Sender- Engine Coolant Temp Beacon A-12 7 Sender-Fuel Level A-13 25 108 RD Aux Ckt 488 WH Brake Air Switches Breaker - Alternator (60A) D-13 8 Solenoid - A/C Clutch A-1 3 22 109 RD Alt Output (+) Term. A429 YL Articulation Indicator Breaker - Convertor (15A) F-1 1 13 Solenoid - Differential Unlock E-1 4 4 112 PU Main Power Rly Output Breaker - Headlamp (l5A) D-10 B Solenoid - Engine Shutdown D-13 22 113 OR Opr Mon Panel B+ Switched 500 BR Wiper - Front (Park) Breaker - Lightbar (15A) D-10 B Solenoid - Forward Horn F-3 10 114 RD Warning Horn (Forward) 501 GN Wiper - Front (Low) Control - Secondary Steer E-13 9 Solenoid - Park Brake B-12 10 115 RD Aux Ckt 502 OR Wiper - Front (Hi) Converter - Voltage F-10 12 Solenoid - Start Aid A-1 3 25 116 BR Aux Ckt 503 BR Wiper - Rear (Park) Converter - Voltage F-12 13 Solenoids - Blade Cushion E-2 30 118 GY Aux Ckt 504 YL Wiper - Rear (Low) Flasher E-10 B Solenoids - Centershift B-3 29 119 PK Aux Ckt 505 BU Wiper - Rear (Hi) Fuses D-9 B Switch-A/C Refrigeration A-12 22 121 RD Centershift Solenoid 506 PU Washer - Front Fuses E-10 B Switch - Air Dryer F-14 31 122 BU Aux Ckt 507 WH Washer - Rear Fuses (10A) B-6 C Switch-Back-Up Alarm F-14 3 124 GN A/C 508 PU Radio Speaker - Left Gauge - Articulation F-5 A Switch - Beacon B-6 C 129 BU Aux Ckt 509 WH Radio Speaker - Left (Common) Gauge - Engine Coolant Temperature F-5 A Switch - Beacon B-10 C 130 RD Aux Ckt 511 BR Radio Speaker - Right Gauge - Fuel Level E-5 A Switch - Blade Cushion B-9 C 134 RD Aux Ckt 512 GN Radio Speaker - Right (Common) E-5 A Switch - Blower (A/C) B-10 C 135 BU Aux Ckt 513 OR A/C Compressor/Refrigerant Pressure Sw Gauge - System Air Pressure (Right) E-5 A Switch - Blower (Heater) A-10 C 136 GN Secondary Ster 515 GY Blower Motor (Hi) Ground - Cab D-5 17 Switch - Brake Air Pressure A-2 11 141 PK Aux Ckt 516 GN Blower Motor (Medium) E-12 32 Switch - Brake Air Pressure A-2 11 144 RD Aux Ckt 517 BU Blower Motor (Low) Ground - Front Frame (ZZ) D-6 17 Switch - Centershift Pin B-9 C 147 RD Aux Ckt 521 YL A/C Sw To Refrigerant Sw Ground - Front Frame D-6 39 Switch - Defroster (Front) A-6 C 149 PU Aux Ckt 522 WH A/C Clutch To Thermostat Sw Ground - Localized Stud F-12 D Switch - Defroster (Rear) B-6 C 151 GN Aux Ckt 537 GN Turn Signal Sw To Flasher Ground - Rear Frame E-12 41 Switch - Differential Unlock D-9 B 152 BU Aux Ckt 556 WH Differential Lock Ground - Strap C-12 23 Switch - Disconnect E-12 43 165 YL Aux Ckt 570 BU Blade Cushion Sol Lamp - Master Action E-5 A Switch - Engine Coolant Temp (Monitor) B-14 24 169 PK Aux Ckt 575 YL Wiper - Aux (Park) Lamp - Shift Lever B-8 C Switch - Engine Coolant Temp (Start Aid) A-14 24 173 RD Aux Ckt 576 PK Wiper - Aux (Low) Lamp - Turn Indicator (Left) E-5 A Switch - Engine Oil Pressure C-13 32 176 OR Aux Ckt 577 PU Wiper - Aux (Hi) Lamp - Turn Indicator (Right) E-4 A Switch - Flood Lamps D-8 B 578 BU E-10 B Switch - Forward Horn E-9 B Washer - Aux Meter-Service Monitor - Electronic Monitoring System (EMS) 200 BK Main Chassis 584 YL Wiper Sw Jumper E-6 A B-13 24 201 BK Operator Monitor Return 592 BU DC/DC Converter Power Output Motor - Blower A-12 15 Switch - Head/Tail Lamp E-8 B 597 PU A/C Ref rigerent Press Sw Motor - Blower (A/C group) B-10 14 Switch - Headlamp Dimmer D-9 B Motor - Blower (Heater group) A-10 E Switch - Hydraulic Oil Temperature C-12 Motor - Blower/Defroster E-4 15 Switch - Key Start A-9 Motor - Secondary Steer F-13 20 Switch - Light Bar Low Beam Motor - Starter E-12 32 Motor - Washer (Front Lower) F-6 16 Motor - Washer (Front Upper) F-6 16 Motor - Washer (Rear) F-6 16 Motor - Wiper (Front Lower) C-4 17 Switch - Fuel Pressure Ground Circuits Basic Machine Circuits 301 BU Starter No.1 Sol A503 PK Front Defroster Fan (Low) 33 304 WH Starter Relay No. 1 Output A504 GN Rear Defroster Fan (Low) C 306 GN Starter Relay Coil A506 OR Front Defroster Fan (Hi) E-8 B 307 OR Key Start Switch A507 YL Rear Defroster Fan (Hi) Switch - Monitor (EMS) Test E-8 B 308 YL Main Power Relay Coil A513 PK DC/DC Converter Memory Output Switch - Neutral/Start E-14 3 310 PU Engine Test Sw To Start Aid Sol Switch - Panel Lamp Dimmer E-9 B 311 WH Start Aid Sol To Temp Sw 600 BR Dash Lamp Basic Switch - Park Brake Pressure B-11 34 321 BR Bckp Alarm 601 GY Dash Lamp Hi Switch - Primary Steer F-10 35 322 GY Warning Horn (Forward) 603 PK Rotary Beacon 326 RD Key Start Sw “C” Term. 604 OR Stop Lamp D-4 17 Switch - Secondary Steer Test B-8 C Motor - Wiper (Rear) C-11 21 Switch - Stop Lamp Pressure A-2 11 605 YL Turn Lamp - Left Relay-Main D-14 8 Switch - Tail Lamp D-8 B 403 GN Alternator (R) Term. 606 GY Turn Lamp - Right Relay - Secondary Steer F-13 22 Switch-Turn Signal D-9 B 404 YL Opr Mon Hyd Oil Temp 608 GN Flood Lamp - Rear Relay - Start D-13 8 Switch - Wiper (Front Lower) A-5 C 405 GY Opr Mon Oil Press. (Low Setting) 609 YL Flood Lamp - Side Resistor - Blower Speed E-4 E Switch - Wiper (Front Upper) B-5 C 406 PU Opr Mon Coolant Temp 611 PU Head Lamp Hi Resistor - Blower Speed (A/C) B-11 15 Switch - Wiper (Rear) A-5 C 408 WH Opr Mon System Air Press. 614 PU Park/Tail/Dash/Lamp Resistor - Blower Speed (Defroster) A-12 E Thermostat (A/C) B-11 E 409 OR Opr Mon Neut 619 GN Head Lamp Lo Machine locations are repeated for components located close together. 410 WH Opr Mon Action Alarm 629 PK Aux Head Lamp A = Operator’s compartment (Dash). 411 PK Opr Mon Master B = Operator’s compartment (Steering console). 413 BR Opr Mon Fuel Press. 727 GN Secondary Ster Motor Relay C = Operator’s compartment (Right side console). 415 GN Opr Mon Test Sw 728 BU Secondary Ster Cont Sw D = Operator’s compartment (Headliner). 417 GY Primary Ster Sw E773 YL Centershift Solenoid E = Operator’s compartment (Under seat). 419 YL Opr Mon Parking Brake F775 BU Centershift Solenoid A AA 2 T Pressure Symbol Temperature Symbol Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug Level Symbol Flow Symbol 1 2 1 2 1 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector Normally open switch that will close with an increase of a specific condition (temp-press-etc.). C A A 325-PK-14 Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Pin AA 1 Normally closed switch that will open with an increase of a specific condition. Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. The circle indicates that the component has screw terminals and a wire can be disconnected from it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. No circle indicates that the wire cannot be disconnected from the component. T This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. 200-BK-14 Circuit Number Identification Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. This indicates that the component has a wire connected to it that is connected to ground. 9X-1123 325-PK-14 Wire Color Socket 2 Lighting Circuits Motor - Wiper (Front Upper) Monitoring Circuits Electrical Schematic Symbols And Definitions Accessory Circuits Gauge - System Air Pressure (Left) Ground - Engine Harness And Wire Electrical Schematic Symbols Monitoring Circuits (cont'd) Power Circuits Alarm - Action Alternator (50A STD) Related Electrical Service Manuals Printed in U.S.A. © 1998 Caterpillar All Rights Reserved SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Control Circuits MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
Connector Location¹ Schematic Location B-15 B-14 C-13 C-12 C-12 D-11 E-12 B-11 A-10 B-10 B-10 A-10 A-10 B-10 A-9 E-7 A-7 C-7 D-7 E-7 F-7 F-5 F-4 F-4 F-4 E-4 E-4 C-4 C-3 E-3 C-2 D-2 Connector Number CONN 1 CONN 2 CONN 3 CONN 4 CONN 5 CONN 6 Service Tool CONN 7 CONN 8 CONN 9 CONN 10 CONN 11 CONN 12 CONN 13 CONN 14 CONN 15 CONN 16 CONN 17 CONN 18 CONN 19 CONN 20 CONN 21 CONN 22 CONN 23 Diagnostic CONN 24 CONN 25 CONN 26 CONN 27 CONN 28 CONN 29 CONN 30 CONN 31 CONN 32 Machine Location 1 32 32 31 17 D A 33 33 33 33 27 27 D D C C 11 8 8 E 8 B B B B B 18 34 D 34 6 RENR1447 November 1998 Electrical Schematic Symbols And Definitions T Pressure Symbol 14 Normally open switch that will close with an increase of a specific condition (temp-press-etc.). 25 5 34 4 2 29 13 28 30 22 24 18 19 17 10 11 8 26 15 A 7 33 23 20 Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. 31 1 16 Normally closed switch that will open with an increase of a specific condition. E D 6 27 32 C 12 9 623F Wheel Tractor-Scraper Electrical System 21 B 7 Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. The circle indicates that the component has screw terminals and a wire can be disconnected from it. 3XW1-UP 5EW1-UP 9 31 E No circle indicates that the wire cannot be disconnected from the component. Related Electrical Service Manuals Title Form Number SENR2945 EPTCII for ICM Transmissions SENR9122 Starting and Charging Systems SENR2947 Starting Motor: 8T-9685 SENR3581 Flow Symbol Level Symbol 3 ¹The connectors shown in this chart are harness to harness and special use connectors. Connectors which join a harness to a component are generally located at on near the component. See the component location chart. Electronic Monitoring System (EMS) Temperature Symbol A 5 13 2 25 34 26 30 22 18 6 12 B 14 21 28 4 15 10 D 24 C 29 8 17 19 32 This indicates that the component has a wire connected to it that is connected to ground. 33 27 23 20 11 1 16 3 This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. E79930 Machine Harness Connector and Component Location Printed in U.S.A. ©1998 Caterpillar All Rights Reserved Component Identifiers (CID)¹ for the Transmission Control (EPTC II) CID No. Component 0168 System Voltage 0190 Eng Speed Sensor Signal 0248 Data Link 0269 Sensor Supply 0627 Parking Brake Press Switch 0650 Harness Code 0700 Transmission Gear Switch 0701 Transmission Output Speed Sensor 0702 Shift Lever Switch 0704 Service Brake Pressure Switch 0705 Body Raise Switch 0706 Body Up Switch 0707 Up Solenoid 0708 Down Solenoid 0709 Lockup Solenoid ¹The CID is a diagnostic code that indicates which component is faulty. FMI No. Failure Mode Identifiers (FMI)¹ Failure Description 0 Data valid but above normal operational range. 1 Data valid but below normal operational range. 2 Data erratic, intermittent, or incorrect. 3 Voltage above normal or shorted high. 4 Voltage below normal or shorted low. 5 Current below normal or open circuit. 6 Current above normal or grounded circuit. 7 Mechanical system not responding properly. 8 Abnormal frequency, pulse width, or period. 9 Abnormal update. 10 Abnormal rate of change. 11 Failure mode not identifiable. 12 Bad device or component. 13 Out of calibration. 14 Parameter failures. 15 Parameter failures. 16 Parameter not available. 17 Module not responding. 18 Sensor supply fault. 19 Condition not met. 20 Parameter failures. ¹The FMI is a diagnostic code that indicates what type of failure has occurred. Machine Code Machine Code 637 613 Component Location Schematic Machine Component Location Location Actuator - Water Valve C-1 6 Air Dryer A-3 5 Alarm - Action A-6 A Alarm - Backup B-15 1 Alternator B-3 2 Batteries A-4 3 Breaker - Alt F-2 B Breaker - Blower Motor F-3 B Breaker - Converter E-3 B Breaker - Head Lamp F-3 B Breaker - Panel, Dome, Stop/Tail Lamp F-3 B Control - Engine Shutdown A-8 D Control - Stop/Tail Lamp B-14 4 Control - Throttle Lock A-9 D Control - Transmission (EPTC) D-10 D Control Board Assembly D-1 6 Converter - Voltage D-3 D Distributor - XMSN Speed B-8 D Electronic Monitoring System (EMS) E-9 A Flasher F-9 E Fuse Block E-4 B Gauge - Air Pressure B-8 A Gauge - Converter Temp E-9 A Gauge - Coolant Temp E-8 A Gauge - Fuel E-8 A Gauge - Speedometer F-8 A Gauge - Tach/Hour Meter F-9 A Ground - Cab E-2 D Ground - Frame B-7 D Ground Strap - Cab to Frame E-2 D Master Action Lamp D-11 A Motor - Blower C-1 6 Motor - Front Washer E-3 6 Motor - Front Wiper F-6 7 Motor - Rear Washer E-3 6 Motor - Rear Wiper E-7 9 Motor - Starter B-5 10 Potentiometer - Temperature Selector D-14 A Relay - Bail C-9 D Relay - Control Group A-9 D Relay - Cush Hitch C-9 D Relay - Implement Detents C-8 D Relay - Headlamp F-15 D Relay - Main E-2 12 Relay - Start E-2 12 Resistor - Blower Motor Speed C-1 6 Resistor - Starter/Diagnostic B-5 10 Sender - Conv Retr Temperature A-4 10 Sender - Coolant Temperature A-4 13 Sender - Fuel Level B-14 14 Sender - Tachometer A-4 15 Sender - Transmission Speed A-10 16 Sensor - Throttle Lock Press A-9 D Solenoid - Air Conditioner Clutch B-3 2 Machine locations are repeated for components located close together. A = Located in Tractor dash. B = Located in cab on relay panel. Component Solenoid - CH Solenoid - Differential Lock Solenoid - Downshift Solenoid - Ejector Detent Solenoid - Engine Shutdown Solenoid - Forward 1 Mag Detent Solenoid - Forward Horn Solenoid - Front Throttle Lock Solenoid - Reverse Mag Detent Solenoid - Start Aid Solenoid - Upshift Solenoid - Valve Group Switch - Air Pressure Switch - A/C High/Low Pressure Switch - Backup Alarm Switch - CH Switch - Clear Switch - Conv Retr Temperature Switch - Coolant Flow Switch - Coolant Temperature Switch - Coolant Temperature Switch - Differential Switch - Disconnect Switch - Door Dome Lamp Switch - Ejector Kickout Pressure Switch - EMS Test Switch - Engine Oil Pressure Switch - Engine Oil Pressure Switch - Fan Speed Switch - Flood Lamp Switch - Forward Horn Switch - Front Wiper Switch - Fuel Pressure Switch - Headlamp Switch - Headlight Dimmer Switch - Heat or A/C Switch - Key Start Switch - Neutral Run Switch - Park Brake Pressure Switch - Rear Wiper Switch - Set Switch - Shift Lever Switch - Side Flood Switch - Slip Limiter Switch - Start Aid Switch - Steering Flow Switch - Stop Lamp Switch - Thermostat Switch - Throttle Lock Switch - Transmission Switch - Turn Signal Switch - Washer Front & Rear Switch - XMSN Hold C = Located in operator's right console. D = Located under Tractor cab. E = Located in Tractor cab. Schematic Location B-9 B-10 A-10 C-7 C-4 C-7 B-3 B-9 C-7 A-3 A-10 D-7 B-5 C-3 A-5 D-8 C-10 B-4 A-4 B-4 A-4 B-9 A-5 E-6 C-8 E-12 A-4 B-4 F-11 F-13 E-14 F-10 A-4 F-14 F-14 F-12 D-15 E-13 A-10 E-11 C-11 A-5 F-12 E-8 E-14 A-10 A-9 C-2 E-13 A-10 F-9 E-10 B-8 Machine Location 19 D 20 21 22 C 24 D C 25 20 C 26 2 C C D 10 22 28 28 D C E 21 A 29 29 A A E A 30 A E A A A 27 A D C A A A 23 D 6 A 27 E A C Off Machine Switch Specification Part No. 3E-2028 Function Actuate Deactuate Contact Position Coolant Temperature 107.0 ± 3.0° C 93.0° C Normally (224.6 ± 5.4° C) (199.4° C) Closed 3E-6245 Coolant Temperature 38.0 ± 3.0° C 27.0° C Normally (100.4 ± 5.4° C) (80.6° C) Closed 3E-6453 Conv Retr Temperature 129.0 ± 3.0° C 118.0° C Normally (264.0 ± 6.0° C) (244.0° C) Closed 7X-1598 Ejector Kickout Pressure 15200 ± 280 kPa 13800 kPa MIN Normally Closed pin 1-3 Hyd Pilot Filter Pressure (2200 ± 40 psi) (2000 psi MIN) Normally Open pin 1-2 8T-9792 Air Pressure 517.0 ± 35.0 kPa 448.0 ± 35.0 kPa Normally Closed pin 1-3 Parking Brake Pressure (75.0 ± 5.0 psi) (65.0 ± 5.0 psi) Normally Open pin 1-2 107-0612 Engine Oil Pressure 93.0 ± 21.0 kPa 70.0 ± 21.0 kPa Normally (13.5 ± 3.0 psi) (10.2 ± 3.0 psi) Open 107-0616 Fuel Pressure 93.0 ± 21.0 kPa 69.0 ± 21.0 kPa Normally (13.5 ± 3.0 psi) (10.0 ± 3.0 psi) Closed 114-5333 Refrigerant Pressure (AC) 275 to 1750 kpa¹ -Normally ² (40 to 255 psi) -Open 125-9352 Stop Lamp Pressure 83.0 kPa MAX 48.0 ± 20.0 kPa MIN Normally (12.0 psi MAX) (7.0 ± 3.0 psi MIN) Open 134-6547 Steering Flow 4.0 g MAX 1.5 g MIN Normally (0.14 oz MAX) (0.05 oz MIN) Open ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). ² Contact position at the contacts of the harness connector. Resistor, Sender, and Solenoid Specifications Part No. Component 3E-7259 3E-7886 6N-5926 Sender - Conv Retr Temp Sender - Tachometer Sender - Coolant Temperature 6T-2217 7T-9074 8C-9634 8C-9635 Resistor - Starter/Diagnostic Solenoid - Forward Horn Valves Solenoid - Ejector Detent Solenoid - Forward 1 Mag Detent Reverse Mag Detent Solenoid - CH Valve Resistor - Blower Motor Speed Solenoid - Start Aid Solenoid - Front Throttle Lock Diff Lock Solenoid - A/C Clutch Solenoid - Engine Shutdown Potentiometer - Temp Selector Solenoid - Upshift Downshift 8T-8692 9G-1950 9G-4365 9X-9482 102-0347 110-6465 116-8653 144-6292 ¹ At room temperature. Resistance (Ohms)¹ 6 110-200 524-586 @ 115.6 C (240.1 F) 5806-7264 @ 54.4 C (129.9 F) 150 ± 7.5 74.0 ± 7.4 34 110 ± 6.0; Max 198 34.2 Overall 2.0 ± 0.1; Tap 1.0 ± .05 6 68 14.4 ± 0.6 5.12 ± 0.26 5000 ± 500 32.6 ± 1.6 Wire Number Wire Color 101 102 103 105 107 109 112 113 114 117 118 119 120 121 122 123 124 125 126 141 148 165 173 176 RD BU YL BR WH OR PU OR GN YL GY PK YL YL BU WH GN OR PK PK WH YL YL OR 200 201 202 203 204 207 BK BK BK BK BK BK 301 302 304 306 307 308 310 311 321 322 323 324 326 327 366 BU OR WH GN OR YL PU WH BR GY WH BU PU PK PK 403 405 406 407 408 409 410 411 412 413 415 417 419 421 422 423 441 444 445 447 449 450 B435 B485 B486 B487 GN GY PU PK WH OR WH PK BU BR GN GY YL BU YL PU OR BU GN PK BU YL PU BU YL WH 500 501 502 503 504 505 506 507 508 509 511 512 BR GN OR BR YL BU PU WH PU WH BR GN Wire Description Description Power Distribution Circuits Bat (+) Hd Lmp Aux Ckt Key Sw Eng ShutDown Alt Output (+) Term. Main Power Rly Output Opr Mon Panel B+ Switched Warning Horn (Forward) Aux Ckt Aux Ckt Aux Ckt Aux Ckt Back Alarm To Lamp Aux Ckt Aux Ckt A/C Aux Ckt Xmsn Ctrl Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Ground Circuits Main Chassis Operator Monitor Return XMSN Ctrl Chassis Diagnostic Opr Mon Panel Starter Diagnostic Basic Machine Circuits Starter No. 1 Sol Starter No. 1 Resistor To Diagnostic Starter Relay No. 1 Output Starter Relay Coil To Neut Start SW Or Key SW Key SW To Neutral Start SW Main Power Relay Coil Start Aid SW To Start Aid Sol Start Aid Sol To Temp SW Backup Alarm Warning Horn (Forward) Fuel Pump Power Differential Lock Sol Key SW "C" Term. Shutdown Solenoid Coil To Eng Oil Press SW Monitoring Circuits Alternator (R) Term. Opr Mon Oil Press. (Low Setting) Opr Mon Coolant Temp Opr Mon Converter/Retarder Oil Temp Opr Mon System Air Press. Opr Mon Neut Opr Mon Action Alarm Opr Mon Master Opr Mon Cool Flow Opr Mon Fuel Press. Opr Mon Test SW Primary Ster SW Opr Mon Parking Brake Opr Mon Fault Lamp Opr Mon Warning Horn Opr Mon Test SW Eng Coolant Temp Gauge Converter/Retarder Oil Temp Gauge Converter/Retarder Oil Temp Gauge Fuel Level Gauge Spdom Sender (Signal No. 1) Tach Sender (+) Eng Coolant Temp Gauge Pump Case Drain Filter Differential Press Charge Pump Filter Differential Press Motor Case Drain Filter Differential Press Accessory Circuits Wiper - Front (Park) Wiper - Front (Low) Wiper - Front (HI) Wiper - Rear (Park) Wiper - Rear (Low) Wiper - Rear (HI) Washer - Front Washer - Rear Radio Speaker - Left Radio Speaker - Left (Commom) Radio Speaker - Right Radio Speaker - Right (Common) Wire Number Wire Color 513 515 516 517 521 522 537 584 592 A513 A518 A519 A520 A522 A523 A524 A525 A526 A527 A528 A529 A530 A531 A532 A533 A534 A541 A552 A553 OR GY GN BU YL WH GN YL BU PK PU GN BU GN PU BR GN PK BU YL WH OR BR BR PK OR PU GN BU 602 604 605 606 608 609 610 611 614 619 639 640 650 WH OR YL GY GN YL OR PU PU GN WH GN OR 703 704 708 709 710 711 712 713 714 715 716 717 721 722 723 724 725 726 733 734 735 736 737 743 D774 E723 E737 E766 E767 E768 E769 E771 E772 G718 892 893 D834 D836 D837 D838 D996 D997 BU GY YL OR GN BR WH OR YL GN BU BR BR WH OR YL GN BU BR WH OR YL GN PU BU GN PU GN BU BU OR BU GN YL BR GN PU GN GY OR PU YL Harness And Wire Electrical Schematic Symbols Description Accessory Circuits Continued A/C Compressor/Refrigerant Pressure SW Blower Motor (HI) Blower Motor (Medium) Blower Motor (Low) A/C SW To Refrigerant SW A/C Clutch To Thermostat SW Turn Signal SW To Flasher Wiper SW Jumper DC/DC Converter Power Output DC/DC Converter Memory Output Throttle Lock (Off) Axle Suspension Sol Valve Relay To Axle Suspension Rocker SW Press SW To Ejector Detent Coil Temp Potentiometer Pos 1 Temp Potentiometer Pos 2 Temp Potentiometer Pos 3 Electronic Water Valve Actuator Electronic Water Valve Actuator Electronic Water Valve Actuator Electronic Water Valve Actuator Electronic Water Valve Actuator Throttle Lock (On) Fr Throttle Lock Sol To Control Fr Throttle Lock Sol To Control Tl Control To Brake SW (Sensor Supply) Flasher To Indicator Lights Bail SW To Bail Sol Bail Release To Bail SW Lighting Circuits Dome Lamp Stop Lamp Turn Lamp - Left Turn Lamp - Right Flood Lamp - Rear Flood Lamp - Side Head Lamp Basic Head Lamp Hi Park/Tail/Dash/Lamp Head Lamp Lo Left Hand Stop/Tail Lamp Right Hand Stop/Tail Lamp Rear Flood / Dash Lamps Control Circuits XMSN Up Sol XMSN Down Sol XMSN Hold SW Sensor Power Supply XMSN Speed Pickup Signal XMSN Lever Code 1 XMSN Lever Code 2 XMSN Lever Code 3 XMSN Lever Code 4 XMSN Lever Code 5 XMSN Lever Code 6 Bowl Apron Sol Float XMSN Gear Code 1 XMSN Gear Code 2 XMSN Gear Code 3 XMSN Gear Code 4 XMSN Gear Code 5 XMSN Gear Code 6 Switching Gear Code 1 Front Switching Gear Code 2 Front Switching Gear Code 3 Front Switching Gear Code 4 Front Switching Gear Code 5 Front Switching Neut/Run SW Rev Elev Detent Throttle Lock Press Sensor To Control Input Filter W/L To Temp SW Auger SW EPTCII Fwd Auger/Elev Sol Cushion Hitch RelayTo Diode Bail Relay To Diode Jumper Pin 1 To 7 - Auger Relay Jumper Pin 1 To 2 - Auger Relay Elevator Control Signal (EPTCII) VMIS Start Mod Right (-) Port/CAT Data Link (-) VMIS Start Mod Right (+) Port/CAT Data Link (+) Forward Auger SW To Rev Auger SW Forward Auger SW To Slip Limiter SW Slip Limiter Solenoid Auger Solenoid XMSN Cont Service Set XMSN Cont Service Clear A AA Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug 1 2 1 2 1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Pin or Socket Number Wire, Cable, or Harness Assembly Identification Component Part Number Single Wire Connector C A A 325-PK-14 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
RENR1497 April 1999 Component Location Schematic Location Machine Location Schematic Location Machine Location Actuator - Water Valve F-5 6 Air Dryer A-6 5 Solenoid - Air Conditioner Clutch A-9 2 Solenoid - ASBS A-15 Alarm - Action E-9 1 A Solenoid - Axle Suspension B-12 D Alarm - Backup Alternator C-15 32 Solenoid - FWD Horn C-9 24 A-8 2 Solenoid - Impl Valve Detent A-13 15 Batteries A-12 3 Solenoid - Start Aid A-5 25 Breaker - Alternator E-13 B Solenoid - Torque Converter C-13 10 Breaker - Blower Motor E-13 B Speedometer C-4 A Breaker - Dome, Stop, Turn Lamp E-13 B Switch - Air C-9 D Breaker - Head, Panel, Tail & Park Lamp E-13 B Switch - Air Pressure C-12 26 Breaker - Key E-13 B Switch - A/C F-1 2 Electronic Monitoring System (EMS) F-10 A Switch - Backup Alarm F-12 C Control Board Assembly F-6 6 Switch - Converter B-11 10 Flasher F-9 E Switch - Coolant B-9 30 Fuse Block F-12 B Switch - Coolant Flow B-14 22 Gauge - Air Pressure C-4 A Switch - Disconnect A-12 2 Gauge - Converter Temp B-5 A Switch - Dome Lamp F-10 E Gauge - Coolant Temp B-4 A Switch - Ejector Detent A-9 29 Gauge - Fuel C-4 A Switch - Ejector Detent Press A-13 15 Ground E-15 32 Switch - El Neu Start F-11 A Ground - Cab C-2 D Switch - EMS Test D-3 A Ground - Chassis C-2 D Switch - Engine Oil A-9 29 Ground - Compartment D-13 B Switch - Engine Oil Press A-9 29 Ground - Scraper Chassis D-15 32 Switch - Fan Speed F-2 A Component 14 3 5 25 34 4 2 29 13 28 30 22 24 18 17 19 27 10 23 11 8 26 15 A 7 31 16 E 12 9 20 21 B 7 9 31 E 5 A 13 25 34 8 2 6 26 C 29 30 22 18 D 24 1 C D 6 33 32 12 21 28 B 14 4 15 10 17 19 32 33 27 23 20 11 3 1 16 Lamp - EMS Action B-5 A Switch - Flood Lamp F-2 A Meter - Tach/HR C-5 A Switch - Forward Horn F-9 E Motor - Blower F-8 6 Switch - Front Wiper F-5 A Motor - Front Washer Pump A-2 6 Switch - Front/Rear Washer D-5 A Motor - Front Wiper F-8 7 Switch - Fuel B-9 22 Motor - Fuel Pump B-15 1 Switch - Fuel Pump D-2 A Motor - Rear Washer Pump A-3 34 Switch - Head Lamp Dimmer C-9 E Motor - Rear Wiper F-14 9 Switch - Headlamp F-3 A Motor - Starter A-11 10 Switch - Key E-1 A Receptacle - Aux Start A-10 2 Switch - Neutral F-11 A Relay - Fuel Pump D-11 12 Switch - Neutral Start F-11 A Relay - Head Lamp E-14 D Switch - Panel Dimmer E-6 A Relay - Main E-12 12 Switch - Parking Brake C-9 27 Relay - Start D-12 12 Switch - Rear Wiper D-5 A Relay - Suspension Axle D-13 B Switch - Refrigerant C-9 2 Resistor - Blower Motor E-8 6 Switch - Start Aid D-3 A Resistor - Diagnostic B-11 10 Switch - Start Aid Temp B-9 30 F-5 A Switch - Steering B-12 23 Sender - Converter B-11 10 Switch - Stop Lamp C-10 D Sender - Coolant B-9 13 Switch - Thermostat E-8 6 Sender - Fuel Level D-15 14 Switch - Torqe Converter F-12 E Sender - Tachometer B-11 15 Switch - Turn Signal F-8 E Sender - Trans Output Speed A-11 16 Resistor - Panel Dimmer E79930 Machine Harness Connector and Component Location Component Machine locations are repeated for components located close together. C = Located in operator's right hand console. A = Located in Tractor dash. D = Located under Tractor cab. B = Located in cab on relay panel. E = Located in Tractor cab. 611 Wheel Tractor-Scraper Electrical System 6SZ1-UP 7WZ1-UP Printed in U.S.A. © 1999 Caterpillar All Rights Reserved Wire Description Wire Number Connector Location¹ Machine Location CONN 1 E-14 32 CONN 2 C-14 23 CONN 3 D-14 B CONN 4 E-14 B CONN 5 F-14 B CONN 6 C-13 23 CONN 7 C-13 23 CONN 8 E-13 B CONN 9 E-13 B CONN 10 Diagnostic F-12 B CONN 11 B-12 23 CONN 12 B-12 23 CONN 13 C-12 10 CONN 14 C-12 11 CONN 15 C-11 11 CONN 16 C-11 11 CONN 17 E-11 B CONN 18 F-11 B CONN 19 F-11 B CONN 20 F-11 B CONN 21 C-10 11 CONN 22 E-9 E CONN 23 F-8 7 Part No. CONN 24 E-8 6 7N-9560 CONN 25 E-7 A CONN 26 A-6 18 CONN 27 A-6 18 CONN 28 C-6 A CONN 29 B-5 A CONN 30 C-3 D ¹The connectors shown in this chart are harness to harness and special use connectors. Connectors which join a harness to a component are generally located at on near the component. See the component location chart. Part No. Component Solenoid - Air Conditioner Clutch 17.6 ± 0.6 3E-7259 Sender - ConverterTemperature 6 3T-3123 Resistor - Panel Dimmer 6N-5926 Sender - Coolant Temperature 7N-9785 7X-1598 8N-1683 9X-3040 114-5334 Electronic Monitoring System SENR2945 Starter: 6V-5537 SENR3581 Converter/Retarder Oil Temp Gauge PK Fuel Level Gauge 103 RD Aux Ckt 449 BU Spdom Sender (Signal No. 1) 450 YL Tach Sender (+) 488 WH Air SW To Air SW Jumper 524-586 @ 115.6 C (240.1 F) 109 RD Alt Output (+) Term. B443 BR Bk Oil Press/Coolant Flow 5806-7264 @ 54.4 C (129.9 F) 112 PU Main Power Rly Output B445 GN Elec Speedo (-) Signal 150 ± 7.5 114 GN Warning Horn (Forward) 116 BR Aux Ckt 500 BR Wiper - Front (Park) 117 YL Aux Ckt 501 GN Wiper - Front (Low) 118 GY Aux Ckt 502 OR Wiper - Front (HI) 119 PK Aux Ckt 503 BR Wiper - Rear (Park) 120 YL Aux Ckt 504 YL Wiper - Rear (Low) Overall 2.0 ± 0.1; Tap 1.0 ± .05 121 RD Back Alarm To Lamp 505 BU Wiper - Rear (HI) 6 122 BU Aux Ckt 506 PU Washer - Front 108 ± 5.5 123 WH Aux Ckt 507 WH Washer - Rear 68 124 GN A/C 508 PU Radio Speaker - Left 125 OR Aux Ckt 509 WH Radio Speaker - Left (Commom) 141 PK Aux Ckt 511 BR Radio Speaker - Right 512 GN Radio Speaker - Right (Common) 74.0 ± 7.4 8C-9634 Solenoid - Ejector Detent 34 8T-8692 Solenoid - Axle Suspension 9G-1950 Resistor - Blower Motor Speed 9G-4365 Solenoid - Start Aid 9T-6590 Solenoid - Implement Valve Detent 9X-9482 Solenoid - ASBS 68 34.2 125-9352 134-6547 160-2445 Deactuate Contact Position 129.4 ± 2.8° C 118.3° C MIN Normally (265.0 ± 5.0° F) (245.0° F MIN) Closed 107.2 ± 2.8° C 93.0° C MIN Normally (225.0 ± 5.0° F) (200.0° F MIN) Closed Ejector Kickout Pressure 15200 ± 280 kPa 13800 kPa MIN Normally Closed pin 1-3 Hyd Pilot Filter Pressure (2200 ± 40 psi) (2000 psi MIN) Normally Open pin 1-2 37.8 ± 2.8° C 26.7° C MIN Normally (100.0 ± 5.0° F) (80.0° F MIN) Closed 362.0 ± 29.0 mN, 45.6 mm ID point 303 mN MIN Normally (1.3 ± 0.1 oz, 1.8 in ID point) (1.1 oz MIN) Open 517.0 ± 35.0 kPa 448.0 ± 35.0 kPa Normally (75.0 ± 5.0 psi) (65.0 ± 5.0 psi) Open 62.0 ± 21.0 kPa 38.0 ± 21.0 kPa Normally (9.0 ± 3.0 psi) (5.5 ± 3.0 psi) Open 93.0 ± 21.0 kPa 69.0 ± 21.0 kPa Normally (13.5 ± 3.0 psi) (10.0 ± 3.0 psi) Closed 275 to 1750 kpa¹ -- Normally ² (40 to 255 psi) -- Open 83.0 kPa MAX 48.0 ± 20.0 kPa MIN Normally (12.0 psi MAX) (7.0 ± 3.0 psi MIN) Open Coolant Temperature Start Aid Temperature Coolant Flow Air Pressure Engine Oil Pressure Fuel Pressure Refrigerant Pressure (AC) Stop Lamp Pressure Alternator: 100-5047 SENR2082 GN 447 Key Sw Solenoid - Forward Horn Related Electrical Service Manuals SENR4130 445 Hd Lmp Aux Ckt Off Machine Switch Specification 107-0616 Consist: 100-5046 Bat (+) RD YL Solenoid - Torque Converter Ejector Detent Pressure Consist: 100-5045 RD 102 Ground Circuits 107-0613 Form Number 101 Steering Flow Air Pressure 4.0 g MAX 1.5 g MIN Normally (0.14 oz MAX) (0.05 oz MIN) Open 517.0 ± 35.0 kPa 448.0 ± 35.0 kPa Normally (75.0 ± 5.0 psi) (65.0 ± 5.0 psi) Open ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). ² Contact position at the contacts of the harness connector. BK Main Chassis 513 OR A/C Compressor/Refrigerant Pressure SW 201 BK Operator Monitor Return 515 GY Blower Motor (HI) 203 BK Chassis Diagnostic 516 GN Blower Motor (Medium) 207 BK Starter Diagnostic 517 BU Blower Motor (Low) A292 BK Reversing fan option code 1 521 YL A/C SW To Refrigerant SW Basic Machine Circuits 522 WH A/C Clutch To Thermostat SW 301 BU Starter No. 1 Sol 537 GN Turn Signal SW To Flasher 302 OR Starter No. 1 Resistor To Diagnostic 584 YL Wiper SW Jumper 304 WH Starter Relay No. 1 Output A514 YL SW To Relay Coil 306 GN Starter Relay Coil To Neut Start SW Or Key SW A519 GN Axle Suspension Sol Valve 307 OR Key SW To Neutral Start SW A520 BU Relay To Axle Suspension Rocker SW 308 YL Main Power Relay Coil A521 WH SW To Sol Valve 2nd Imp Pump 310 PU Start Aid SW To Start Aid Sol A522 GN Press SW To Ejector Detent Coil 311 WH Start Aid Sol To Temp SW A523 PU Temp Potentiometer Pos 1 316 PK Cane To Elevator Neutral Start SW Jumper A524 BR Temp Potentiometer Pos 2 321 BR Backup Alarm A525 GN Temp Potentiometer Pos 3 322 GY Warning Horn (Forward) A526 PK Electronic Water Valve Actuator 323 WH Fuel Pump Power A527 BU Electronic Water Valve Actuator 324 BU Differential Lock Sol A528 YL Electronic Water Valve Actuator 326 PU Key SW "C" Term. A529 WH Electronic Water Valve Actuator A530 OR Electronic Water Valve Actuator 403 GN Alternator (R) Term. 405 GY Opr Mon Oil Press. (Low Setting) 600 BR Dash Lamp Basic 406 PU Opr Mon Coolant Temp 601 GY Dash Lamp HI 407 PK Opr Mon Converter/Retarder Oil Temp 602 WH Dome Lamp 408 WH Opr Mon System Air Press. 604 OR Stop Lamp 409 OR Opr Mon Neut 605 YL Turn Lamp - Left 410 WH Opr Mon Action Alarm 606 GY Turn Lamp - Right 411 PK Opr Mon Master 608 GN Flood Lamp - Rear 412 BU Opr Mon Cool Flow 610 OR Head Lamp Basic 413 BR Opr Mon Fuel Press. 611 PU Head Lamp Hi 415 GN Opr Mon Test SW 614 PU Park/Tail/Dash/Lamp 417 GY Primary Ster SW 619 GN Head Lamp Lo 419 YL Opr Mon Parking Brake 441 OR Eng Coolant Temp Gauge 444 BU Converter/Retarder Oil Temp Gauge Monitoring Circuits A AA Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. Receptacle Plug Lighting Circuits Control Circuits 763 BU XMSN Up Sol 1 2 1 2 1 Accessory Circuits 200 Electrical Schematic Symbols And Definitions Harness And Wire Electrical Schematic Symbols Monitoring Circuits Continued RD 7N-9719 Converter Temperature Description 105 7T-9074 Actuate Wire Color 104 Resistor - Starter/Diagnostic Function Wire Number 25.0 ± 0.3 ¹ At room temperature. 9X-3210 Title Resistance (Ohms)¹ 3E-1906 6T-2217 Description Power Distribution Circuits Resistor, Sender, and Solenoid Specifications Schematic Location Connector Number Wire Color 2 Typical representation of a Sure-Seal connector. The receptacle contain both pins and sockets. T Pressure Symbol Temperature Symbol Level Symbol Flow Symbol Pin or Socket Number Wire, Cable, or Harness Assembly Identification Component Part Number Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Single Wire Connector C A A 325-PK-14 Pin AA 1 9X-1123 325-PK-14 Wire Color Socket 2 Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Normally closed switch that will open with an increase of a specific condition. 200-BK-14 Circuit Number Identification Wire Gauge Electrical Schematic Symbols And Definitions Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. The circle indicates that the component has screw terminals and a wire can be disconnected from it. FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. T SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.
Component Identifiers (CID)¹ List Component Tractor Power Train Control (MID No. 027)² CID 0190 0248 0269 0444 0562 0590 0596 0700 0701 0702 0707 0708 0718 0967 1326 1429 1430 1431 1432 1433 1631 Wire Description Wire Number Engine RPM Sensor CAT Data Link Sensor Power Supply Starting Motor Relay Caterpillar Monitoring System Engine Electronic Control Module Machine Control Electronic Control Module Position Sensor (Transmission Gear) Position Sensor (Transmission Gear) Transmission Gear Lever Solenoid Valve (Upshift) Solenoid Valve (Downshift) Transmission System Machine Application Location Code Incorrect Pressor Sensor (Tractor Air) Pressor Sensor (Scraper Air) Pressure Sensor (Brake Air Supply) Solenoid Valve (Tractor Parking Brake) Solenoid Valve (Scraper Parking Brake) Solenoid Valve (Brake Air Supply) Level Sender (Fuel) Temperature Sensor (Transmission Oil) Data Link Sensor Power Supply Alarm (Action) Lamp (Action) Display Data Link Display Power Supply Implement Electronic Control (MID No. 039)² 0168 0248 0358 0600 0968 1275 1276 1277 1278 1279 1280 1281 1282 1283 1284 1285 1286 1287 1288 1289 1291 1292 1293 1294 1295 1296 1297 1299 1300 1322 1423 1424 Description Wire Number Electrical System Voltage Cat Data Link Solenoid Valve (Pilot Pressure Supply) Temperature Sensor (Hydraulic Oil) Lamp (Transmission Hold) Proportion Solenoid (Bowl Up) Proportion Solenoid (Bowl Down) Proportion Solenoid (Apron Raise) Proportion Solenoid (Apron Lower) Proportion Solenoid (Ejector Forward) Proportion Solenoid (Ejector Reverse) Position Sensor (Bowl Control) Position Sensor (Apron Control) Position Sensor (Ejector Control) Position Sensor (Elevator Control) Proportion Solenoid (Auger Forward) Proportion Solenoid (Auger Reverse) Proportion Solenoid (Elevator Speed) Solenoid Valve (Bail) Solenoid Valve (Cushion-Hitch) Trigger Switch (Bail) Push Switch (Transmission Hold) Push Switch (Cushion-Hitch) Lamp (Ejector Return) (Indicator) Lamp (Apron Float) (Indicator) Lamp (Tractor Mode) (Indicator) Lamp (Scraper Mode) (Indicator) Proportion Solenoid (Elevator Speed) Proportion Solenoid (Elevator Direction) Toggle Switch (Auger Reverse) Trigger Switch (Elevator Setpoint) Toggle Switch (Auger Forward) Component Machine Location 39 Alarm - Backup E - 15 1 Sensor (Sc) - Hydraulic Temp C-8 740 OR Scraper Xmsn Gear 3 Alternator (Tr) G-5 3 Sensor (Tr) - Converter Oil Temperature I-5 26 102 RD Unswitched Battery + 741 YL Scraper Xmsn Gear 4 Battery (Tr) - (2) F-6 5 Sensor (Tr) - Trans EOS I-5 23 103 RD Unswitched Battery + 742 GN Scraper Xmsn Gear 5 Battery (Tr) - Backup (2) F-6 5 Solenoid - A/C Compress H-4 3 105 RD Unswitched Battery + 743 PU Neutral Run SW Control - Engine ECM H-3 7 Solenoid - Apron Lower F-6 I 108 BU SW Battery + (Prelube Relay) 744 BU Scraper Xmsn Upshift Sol Control - Stop/Tail Lamp G-7 9 Solenoid - Apron Raise F-6 I 109 OR Unswitched Battery + 745 GY Scraper Xmsn Downshift Sol 35 Solenoid - Bowl Down F-6 I 110 RD Unswitched Battery + 746 PK Scraper Xmsn Sync Sol E-6 I 111 YL SW Battery + (Cigar_Lighter) A700 OR Digital Sensor Power +8V 112 PU SW Battery + A701 GY Injector 1 113 OR +Battery (Tractor Ems) A702 PU Injector 2 114 RD SW Battery + (Horn Relay Pwr) A703 BR Injector 3 115 PK SW Battery + (Spare) A704 GN Injector 4 116 BR SW Battery + (Diff Lock SW) A705 BU Injector 5 Control Circuits (Continued) 117 YL SW Battery + (Side Flood Lamp) A706 GY Injector 6 118 GY SW Battery + (Wipers) A707 PU Injector 7 Ground - Chassis G-5 Ground - Chassis (2) F-4 36 Ground - Engine (2) G-5 3 Solenoid - Cushion Hitch D-9 28 Ground - Engine (3) E-2 16 Solenoid - Ejector Forward E-6 I Horn - Fwd High D-1 10 Solenoid - Ejector Reverse E-6 I Horn - Fwd Low D-1 11 Solenoid - Forward Auger E-9 48 Injectors G-5 12 Solenoid - Pilot D-7 J Junction Block - Crank/Charge G-5 M Solenoid - Reverse Auger E-9 48 Lamp - Bowl Flood B-6 13 Solenoid (Sc) - Park Brake B-8 49 E-5 14 Solenoid (Tr) - Downshift D-7 J 29 YL SW Battery + (12V Converter) A708 BR Injector 8 122 BU SW Battery + (Air Dryer) A745 WH Fuel Pressure Module - A/C Protection H-4 37 Solenoid (Tr) - Start Aid C-1 123 WH SW Battery + (Bowl Flood Lamp) A746 PK Turbo Outlet Press Sensor Motor - Fuel Pump B-8 38 Solenoid (Tr) - Upshift D-7 J D-2 A Suppressor - Arc (Cushion Hitch) D-9 28 GN SW Battery + (A/C) A747 125 OR SW Battery + (Fuel Pump) 126 PK Battery + (24V) 128 PK 129 130 133 146 Motor - Front Washer GY Atmospheric Press Sensor A751 YL Fuel Temp Sensor Motor - Rear Washer C-2 A Switch - Motorcase Filter D-9 50 E707 GN Display Module Pwr Supply Motor (Tr) - Starter G-5 16 Switch - A/C Hi Pressure H-4 37 SW Battery + (Scraper) E708 PK Display Module Clock Receptacle (Tr) - AuxStart G-5 36 Switch - A/C Lo Pressure H-4 37 BU SW Battery + (Spare) E767 BU Aug Fwd Sol Resistor (Tr) - Starter/Diagnostic H-5 16 Switch - Auger Reverse D-9 51 GN SW Battery + (Spare) E790 PK Sol Ret Sender - Fuel Level B-8 20 Switch - Charge Pump Filter E-7 52 RD Unswitched Battery + E793 BU Ata Data Link - Sensor - Transmission Speed C-7 M Switch - Differential Pressure I-5 30 RD SW Battery + (Spare) E794 YL Ata Data Link + E-6 G 147 PU SW Battery + (Spare) E795 YL Engine Oil Temp M Switch - Ejector Kickout Press 148 WH Heat A/C Fan On E796 GN Rail Pressure E-7 53 150 RD Unswitched Battery + (Eng) E797 WH Rail Pressure Control Ret 165 RD SW Battery + (Spare) E798 PK Rail Pressure Control Ground Circuits E799 BR 3.5A Driver Return Main Chassis Ground F700 BU 3.5A Pwm Driver BK BK Ground (Tractor Ems) F701 BR 3.5A On/Off Driver Sensor - Atmosphere Pressure F-1 Sensor - Backup Cam S/T F-1 M Switch - Pump Case Drain Sensor - Coolant Temperature G-1 M Switch - Supl. Steer Flow C-8 31 Sensor - Engine Oil Pressure G-1 M Switch (Sc) - Park Brake B-8 19 Sensor - Fuel Temperature G-1 M Switch (Tc) - Ground Level Shutdown C-1 41 Sensor - Inlet Air Temperature G-1 M Switch (Tr) - Actual Gear C-7 42 Sensor - Turbo Inlet Pressure I-5 24 Switch (Tr) - Coolant Flow F-1 M Sensor - Turbo Outlet Pressure G-1 M Switch (Tr) - Disconnect F-5 36 Switch (Tr) - Engine Oil Fuel Pump Pres H-5 16 Switch (Tr) - Parking Brake C-7 J 202 BK -Battery (Gnd) F702 GN Throttle Sensor 203 BK Chassis Ground F703 GY Mic Spare Sensor - Primary Cam S/T F-1 M Sensor (Sc) - Air Pressure B-8 19 204 BK Ground (Scraper Ems) F704 OR Mic Spare 207 BK Starter Diagnostics Ground F705 PK Mic Spare 228 BK Fuel Level Sender Ret F706 PU Mic Spare 229 BK -Battery F707 WH Throttle Lock Lamp 231 BK Xmsn SW F708 YL Ether Start Valve Relay Engage 290 BK Service SW F709 BU Prelube Relay Engage 291 BK Clear SW F710 BR Mic Spare A234 BK Can Sheild F711 GN Can Data Link + A251 BK -Battery F712 GY Can Data Link - Basic Machine Circuits F713 OR Mic Spare BU Starter To Starter Resistor F714 PK Turbo Inlet Press Sensor 302 OR Starter Resistor To Diagnostic F715 PU Ground Level Shutdown (No) 304 WH Starter Relay To Starter F716 WH Ground Level Shutdown (Nc) 306 GN Scraper Start Relay/Prelube F717 YL Throttle Lock SW (Lock Off) 307 OR Ecm Keysw (Mac-14) F718 BU Throttle Lock SW (Lock On) 308 YL Ecm Keysw (Abl) F719 BR Mic Spare 310 PU Scraper Start Aid Sol Engage F720 GN Start Aid SW 311 WH Scraper Coolant Temp SW F721 GY Mic Spare 320 OR Horn Relay Coil To Horn SW F722 OR Mic Spare 322 GY Warning Horn (Forward) F723 PK Bottom S/T Sensor + 323 WH Fuel Pump Pwr F724 PU Top S/T Sensor + 324 BU Diff Lock Sol Pwr F725 WH Mic Spare 326 PU Scraper Eng Shutdown F726 YL Injector Common 1 327 PK Engine Shutdown Sol (Scraper) F727 BU Injector Common 2 A309 GY Fuel Pump Enable F728 BR Injector Common 5 Monitoring Circuits F729 GN Injector Common 6 Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Solenoid - Bowl Up 120 124 T Pressure Symbol Lamp - Cutting Edge Flood Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 621G Wheel Tractor-Scraper Electrical System Sender - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. ALP 1-UP (Machine) ANG1-UP (Scraper) Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols * Harness identification letter(s) and a serializing code. The "C" stands for connector and the number indicates which connector in the harness. Harness identification code This example indicates wire 135 in harness "AG". Machine locations are repeated for components located close together. F = Located around pilot manifold. Tr = Tractor G = Located under platform. Sc = Scraper I = Located on Implement Valve. A = Located inside of cab. J = Located around Top of XMSN. B = Located inside of right console. K = Located around Top of Scraper XMSN. C = Located inside of left console. L= Located in Cab Headliner. D = Located around relay panel. M =Located on Tractor Engine. E = Located around hydraulic oil tank. Wire, Cable, or Harness Assembly Identification Part Number For L-C12* AG-C4* Connector Assembly 3E-5179 111-7898 325-A135 PK-14 1 * * AG-C3 C-C4 130-6795 130-6795 325-A135 PK-14 Socket Pin Single Wire Connector Wire Gauge Wire Color Receptacle Fuse Plug Ground Circuit Connection Number Identification 2 200-L32 BK-14 Pin or Socket Number Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Volume 1 1 2 105-9344 Component Part Number Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Printed in U.S.A. © 2001 Caterpillar All Rights Reserved 403 GN Alternator (R) Terminal F732 PK Backup Camshaft Speed/Timing 405 GY Scraper Eng Oil Press SW F780 PK Operator Park Brake SW 410 WH Action Alarm (Tractor Ems) F789 YL Sol Ret 411 PK Action Lamp (Tractor Ems) F790 BR Sol Ret 412 BU Coolant Flow SW J764 BK SW And Sensor Gnd Ret 417 GY Supplemental Steering SW J766 PU Gnd For "SWitch To Gnd" 419 YL Tractor Park Brake Press SW J767 GY Sensor Ret 420 OR Fuel Filter Restrict K742 OR Top Drive Gear SW 3E-1906 Solenoid: Air Conditioner Clutch Ejector Fwd Sol 3E-6332 Solenoid: Tractor Start Aid 3E-7842 Resistors: Starter Motor 9G-1950 Resistor: Blower 9X-9482 Solenoid: Scraper Park Brake Brake Air Supply Differential Lock Tractor Park Brake 122-1134 Solenoid: Elevator Enable Pilot 144-6292 Solenoid: 144-9527 Solenoid: Downshift Upshift Auger Forward Auger Reverse 152-8339 Solenoid: Cushion Hitch 32.6 ± 1.6 156-2829 Solenoid: Bowl Down Bowl Up Ejector Rev Ejector Fwd Apron Lower Apron Raise 5.0 ± .3 162-8350 Sender: 191-3005 Solenoids: 421 BU Action Lamp (Scraper Ems) R713 OR 441 OR Scraper Eng Coolant Temp Sender R714 BU Ejector Rev Sol 444 BU Torque Converter Temp Sensor R715 GN Bowl Up Sol 445 GN Torque Converter Temp Sender R716 PK Bowl Down Sol 447 PK Fuel Level Sensor R717 BR Apron Raise Sol 450 YL Eng Speed Sensor + R720 GY Apron Lower Sol 451 BR Eng Speed Sensor - R721 YL Ejector Cylinder Press SW C413 YL Display Module Data R722 PU Pilot Sol C414 BU Output R732 BR Hydraulic Oil Temp Sensor C436 BU Auger Filter SW R733 GN Neutral Run SW Jumper Resistor, Sender and Solenoid Specifications Part No. 29 36 10 58 WH Pilot Air Press Sensor C465 OR Tractor Air Press Sensor R736 PK Scraper Park Brake Press SW E453 BU Motor Case Filter SW R737 YL Scraper Eng Start (Cab) R738 BU Scraper Eng Ether Aid (Cab) F 44 R739 GN Scraper Eng Shutdown (Cab) 501 GN Front Wiper (Lo) R741 GN Scraper Mode Select Lamp 502 OR Front Wiper (Hi) R742 YL Tractor Mode Select Lamp 503 BR Rear Wiper (Park) R745 OR Apron Float Lamp 504 YL Rear Wiper (Lo) R748 BR Ejector Return Lamp 505 BU Rear Wiper (Hi) R749 BU Apron/Elev Joystick Command 506 PU Front Washer R750 GN Ejector Joystick Command 507 WH Rear Washer R752 YL Bowl Joystick Command 508 PU Left Radio Speaker R756 WH Cushion Hitch SW (No) Schematic Location Machine Location 509 WH Left Radio Speaker Common R757 BR Cushion Hitch SW (Nc) 511 BR Right Radio Speaker R758 PK Gear Hold SW (No) CONN 1 CONN 2 CONN 3 CONN 4 CONN 5 I-7 H-7 F-4 E-4 C-4 E E E E G 512 GN Right Radio Speaker Common R759 BU Gear Hold SW (Nc) 515 GY Blower Motor (Hi) R760 GN Bail/Aug Fwd/Elev Set SW (No) 516 GN Blower Motor (Med) R761 YL Bail/Aug Fwd/Elev Set SW (Nc) 517 BU Blower Motor (Lo) R762 GY Tractor Mode Select SW CONN 13 E - 10 21 521 YL A/C SW To A/C Press SW R763 BU Scraper Mode Select SW CONN 15 D-8 55 522 WH A/C Compressor To Thermostat R764 WH Gear Hold Lamp CONN 17 E-7 48 CONN 18 D-7 J CONN 19 C-7 J CONN 20 B-7 56 CONN 21 B-6 54 CONN 22 B-6 56 CONN 23 C-6 42 CONN 24 D-6 14 CONN 25 E-6 31 CONN 26 B-5 E CONN 27 D-4 J CONN 28 I-3 M CONN 29 C-2 57 CONN 30 C-2 57 CONN 31 D-2 58 CONN 32 E-2 58 CONN 33 E-2 58 CONN 34 H-2 M CONN 35 H-2 M CONN 58 I-2 M The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. 537 GN Flasher Control R765 OR Aug Rev SW (Nc) 592 BU +12V Pwr R766 PU Aug Rev SW (No) 597 PU Hi Press SW To Lo Press SW R767 YL Service Brake Press SW Jumper A513 PK +12V Memory X796 PU Backup Alarm A519 GN Cushion Hitch Sol 892 BR Cat Data Link (-) A523 PU Temp Potentiometer Pos 1 893 GN Cat Data Link (+) A524 BR Temp Potentiometer Pos 2 F835 BU Operator SW A525 GN Temp Potentiometer Pos 3 H807 YL On/Off Driver Ret 1-4 (Abl) A526 PK Electronic Water Valve Actuator J807 BK Proportional Ret 1-4 (Abl) A527 BU Electronic Water Valve Actuator J808 BK Proportional Ret 5-8 (Abl) A528 YL Electronic Water Valve Actuator J809 BK Proportional Ret 9-12 (Abl) A529 WH Electronic Water Valve Actuator J813 BK Proportional Ret 13-16 (Abl) A530 OR Electronic Water Valve Actuator J814 BK Proportional Ret 17-20 (Abl) A535 GN Throttle Lock Sol 918 OR Eng Ovrspd Lamp And Alarm A572 PK Lo Press SW To Controller 919 GN Eng Ovrspd Test SW C558 BU Front Wiper SW Jumper 993 BR Analog Sensor Ret C559 GN Rear Wiper SW Jumper 994 GY Oil Pressure Sensor E554 PK Controller To A/C Clutch 995 BU Eng Coolant Temp Sensor 996 GN Eng Speed/Timing Sensor Pwr 601 GY Scraper Dash Lamp 997 OR Machine Analog Sensor Pwr +5V 602 WH Dome Lamp 998 BR Digital Sensor Ret 604 OR Stop Lamp Signal 999 WH Primary Cam S/T Sensor 605 YL Left Turn Lamp A958 WH Tractor Park Brake Sol 606 GY Right Turn Lamp C967 BU Inlet Air Temp Sensor 608 GN Bowl Flood Lamp C992 PU Service Brake Press SW 609 YL Side Flood Lamp E965 BU Top S/T Sensor - 610 OR High Beam Relay Engage E966 YL Top S/T Sensor + 611 PU High Beam Headlamp E973 GY Retarder Press SW 614 PU Park/Tail/Dash Lamp K901 WH Air Compressor Solenoid 619 GN Low Beam Headlamp K927 BU Sol Return (Mac-14) Lighting Circuits 639 640 WH GN Left Stop/Tail Lamp Right Stop/Tail Lamp K966 K968 PU GN Elev En/Aug Rev Sol Auger Slip Limit SW 661 GN Tachometer Back Light K969 GY Scraper Slip Limit Sol 662 YL Speedometer Back Light K970 OR Elevator Speed Sol 663 GY Quad Gage Back Light L983 WH Injector Common 1 L984 OR Injector Common 3 Control Circuits 703 BU Tractor Xmsn Upshift Sol L985 YL Injector Common 5 704 GY Tractor Xmsn Downshift Sol M904 OR Calibration Press SW (No) 709 OR +10V Sensor Power Supply M905 WH Calibration Press SW (Nc) 710 GN Xmsn Output Speed M997 PU Gear Selector 721 BR Tractor Xmsn Gear 1 N940 BU Engine Analog Sensor Pwr +5V 722 WH Tractor Xmsn Gear 2 N941 YL Engine Analog Sensor Ret 723 OR Tractor Xmsn Gear 3 N942 OR Mic Spare 724 YL Tractor Xmsn Gear 4 N943 BR SWitch 1 (Spare) 725 GN Tractor Xmsn Gear 5 N944 PU Tractor Eng Coolant Flow SW Ret 726 BU Xmsn Gear Ground Verify N948 GN Scraper Park Brake Sol 738 BR Scraper Xmsn Gear 1 P988 OR Bail/Elevator Direction Sol 739 WH Scraper Xmsn Gear 2 P991 PK Operator SW (Scraper_Ems) 16 27 11 41 31 28 35 48 51 6 23 1 K 13 19 9 22 34 14 I L 21 25 56 32 8 15 H 49 40 17 2 38 52 42 Component Description 33 53 43 B D 57 J 50 47 R734 Front Wiper (Park) 39 55 3 Scraper Air Press Sensor BR 26 12 M 37 BU 500 54 24 7 20 30 5 C457 Accessory Circuits Connector Number Schematic Location Unswitched Battery + 301 Connector Location for Vol 1. Machine Location RD 201 Engine Monitor System (MID No. 036)² Component Schematic Location 101 200 0001 Injector Cylinder 1 Solenoid 0002 Injector Cylinder 2 Solenoid 0003 Injector Cylinder 3 Solenoid 0004 Injector Cylinder 4 Solenoid 0005 Injector Cylinder 5 Solenoid 0006 Injector Cylinder 6 Solenoid 0091 Throttle Position signal 0100 Engine Oil Pressure 0110 Engine Coolant Temperature 0168 System Voltage High 0172 Intake Manifold Air Temp 0174 Fuel Temperature 0190 Loss of Engine Speed Signal 0248 CAT Data Link 0253 Personality Module mismatch 0254 Electronic Control Module 0261 Engine Timing Calibration required 0262 Volt Sensor Supply Short 0263 Digital Sensor Supply Short 0267 Incorrect Engine Shutdown Switch inputs 0268 Check Programmable Parameters 0273 Turbo Outlet Pressure 0274 Atmospheric Pressure 0275 Right Turbo Inlet Pressure 0342 Secondary Engine Speed Signal 0545 Ether Start Relay 0548 Throttle Lock Lamp 0549 Inncorrect Throttle Lock Switch inputs 0596 Unable to communicate with Machine ECM 0799 Need Service Tool update ¹ The CID is a diagnostic code that indicates which component is faulty. ² The MID is a diagnostic code that indicates which electronic control module diagnosed the fault. Description Electrical Schematic Symbols And Definitions RENR1514-01 June 2001 Component Location (Vol 1) Wire Color Power Circuits Tractor CAT Monitor System (MID No. 030)² 0096 0177 0248 0263 0271 0324 0819 0821 Wire Color G A E 45 4 C Resistance (Ohms)¹ 17.6 ± 0.6 6 150 ± 7.5 Overall 2 ± .1 Tap 1.0 ±. .05 42.4 ± 2.1 41.9 32.6 ± 1.6 32.6 ± 1.6 Empty: 92 to 98 Full: 0 to 3 1.06 ± .053 Fuel Level Injector ¹ At room temperature unless otherwise noted. Off Machine Switch Specification Part No. 13 43 L 56 A 28 8 F G B 37 29 30 24 7 12 3 C M 41 44 11 10 36 5 27 57 46 I 35 6 J 51 22 49 1 2 21 48 15 19 38 10000 kPa MIN (1450 psi MIN) 1-3 Normally Closed 1-2 Normally Open 517 ± 35 kPa (75.0 ± 5.1 psi) 448 ± 35 kPa (65.0 ± 5.1 psi) 1-3 Normally Closed 1-2 Normally Open Tractor Park Brake Scraper Park Brake 107-0612 Engine Oil Fuel Pump 93 ± 21 kPa (13.5 ± 3 psi) 70 ± 21 kPa (10.2 ± 3 psi) Normally Open 109-0260 Motor Case Filter Charge Pump Filter Pump Case Drain Filter 124 ± 14 kPa (18 ± 2 psi) 82 kPa MIN (12 psi MIN) Normally Closed 114-5333 AC High Pressure 119-7870 Supl Steering Flow 275 to 1750 kPa¹ (40 to 255 psi.) 4 grams MAX (0.1 oz MAX) At screw head 83 kPa MAX (12 psi.) 362 to 29 mN (1.30 to 0.10 oz) 137.9 ± 13.8 kPa (13.4 ± 3 psi) 103.4 ± 13.8 kPa (15 ± 2 psi.) --1.5 grams MIN (0.5 oz MIN) At screw head 48 ± 20 kPa (7 ± 2.9 psi) 125-9352 23 11700 ± 170 kPa (1696 ± 24.6 psi) 8T-9792 33 17 42 Normally Closed Ejector Kickout Pressure Stop Lamp Pressure 52 26 Contact Position 55 ± 20 kPa (8 ± 2.9 psi) 3E-7799 40 25 Deactuate 3E-2034 H 9 K 14 53 31 16 45 4 54 55 39 E 32 34 20 Actuate 80 kPa MAX (11.6 psi.) Tractor Service Brake Scraper Service Brake 50 47 Function 134-6054 Coolant Flow 144-5661 Differential Pressure 149-6371 A/C Lo Pressure 303 mN MIN (1.08 oz MIN) 70 ± 21 kPa (10 ± 3 psi) 34.5 ± 7 kPa (5 ± 1 psi.) Normally Open² Normally Open Normally Open Normally Open Normally Open Normally Open ¹ With increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). ² Contact Position at the contacts of the harness. Machine Harness Connector And Component Locations Failure Mode Identifiers (FMI)¹ FMI No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Failure Description Data valid but above normal operational range. Data valid but below normal operational range. Data erratic, intermittent, or incorrect. Voltage above normal or shorted high. Voltage below normal or shorted low. Current below normal or open circuit. Current above normal or grounded circuit. Mechanical system not responding properly. Abnormal frequency, pulse width, or period. Abnormal update. Abnormal rate of change. Failure mode not identifiable. Bad device or component. Out of calibration. Parameter failures. Parameter failures. Parameter not available. Module not responding. Sensor supply fault. Condition not met. Parameter failures. ¹The FMI is a diagnostic code that indicates what type of failure has occurred. Monitoring System Modes Mode of Operation Mode Number Operator 0 Machine Code 1 Parameter Display 2 Diagnostic Servicing 3 Digital Tattletale 4 Units 5 Related Electrical Service Manuals Title Alternator (Tractor): Machine Code Form Number 3E-7577 SENR 4100 Tractor Transmission Control: SENR 4097 Implement Control: SENR 4099 Engine Control: RENR 2318 Starting and Charging: Machine Code 621G 44 621G With Auger Attch. 42 SENR 7507 CAT Monitoring System: Starter Motor Tractor: SENR 2947 6V-0890 SENR 3860
Component Identifiers (CID)¹ List Component Tractor Power Train Control (MID No. 027)² CID 0190 0248 0269 0444 0562 0590 0596 0700 0701 0702 0707 0708 0718 0967 1326 1429 1430 1431 1432 1433 1631 Engine RPM Sensor CAT Data Link Sensor Power Supply Starting Motor Relay Caterpillar Monitoring System Engine Electronic Control Module Machine Control Electronic Control Module Position Sensor (Transmission Gear) Position Sensor (Transmission Gear) Transmission Gear Lever Solenoid Valve (Upshift) Solenoid Valve (Downshift) Transmission System Machine Application Location Code Incorrect Pressor Sensor (Tractor Air) Pressor Sensor (Scraper Air) Pressure Sensor (Brake Air Supply) Solenoid Valve (Tractor Parking Brake) Solenoid Valve (Scraper Parking Brake) Solenoid Valve (Brake Air Supply) Level Sender (Fuel) Temperature Sensor (Transmission Oil) Data Link Sensor Power Supply Alarm (Action) Lamp (Action) Display Data Link Display Power Supply Implement Electronic Control (MID No. 039)² 0168 0248 0358 0600 0968 1275 1276 1277 1278 1279 1280 1281 1282 1283 1284 1285 1286 1287 1288 1289 1291 1292 1293 1294 1295 1296 1297 1299 1300 1322 1423 1424 Wire Number Wire Color 101 RD 102 Electrical System Voltage Cat Data Link Solenoid Valve (Pilot Pressure Supply) Temperature Sensor (Hydraulic Oil) Lamp (Transmission Hold) Proportion Solenoid (Bowl Up) Proportion Solenoid (Bowl Down) Proportion Solenoid (Apron Raise) Proportion Solenoid (Apron Lower) Proportion Solenoid (Ejector Forward) Proportion Solenoid (Ejector Reverse) Position Sensor (Bowl Control) Position Sensor (Apron Control) Position Sensor (Ejector Control) Position Sensor (Elevator Control) Proportion Solenoid (Auger Forward) Proportion Solenoid (Auger Reverse) Proportion Solenoid (Elevator Speed) Solenoid Valve (Bail) Solenoid Valve (Cushion-Hitch) Trigger Switch (Bail) Push Switch (Transmission Hold) Push Switch (Cushion-Hitch) Lamp (Ejector Return) (Indicator) Lamp (Apron Float) (Indicator) Lamp (Tractor Mode) (Indicator) Lamp (Scraper Mode) (Indicator) Proportion Solenoid (Elevator Speed) Proportion Solenoid (Elevator Direction) Toggle Switch (Auger Reverse) Trigger Switch (Elevator Setpoint) Toggle Switch (Auger Forward) Unswitched Battery + 741 YL Scraper Xmsn Gear 4 103 RD Unswitched Battery + 742 GN Scraper Xmsn Gear 5 Battery (Tr) - Backup (2) 105 RD Unswitched Battery + 743 PU Neutral Run SW 108 BU SW Battery + (Prelube Relay) 744 BU Scraper Xmsn Upshift Sol 109 OR Unswitched Battery + 745 GY Scraper Xmsn Downshift Sol 110 RD Unswitched Battery + 746 PK Scraper Xmsn Sync Sol 111 YL SW Battery + (Cigar_Lighter) A700 OR Digital Sensor Power +8V 112 PU SW Battery + A701 GY Injector 1 113 OR +Battery (Tractor Ems) A702 PU Injector 2 114 RD SW Battery + (Horn Relay Pwr) A703 BR Injector 3 115 PK SW Battery + (Spare) A704 GN Injector 4 116 BR SW Battery + (Diff Lock SW) A705 BU Injector 5 Control Circuits (Continued) E E E E G CONN 13 E - 10 21 CONN 15 D-8 55 CONN 17 E-7 48 CONN 18 D-7 J CONN 19 C-7 J CONN 20 B-7 56 CONN 21 B-6 54 CONN 22 B-6 56 CONN 23 C-6 42 CONN 24 D-6 14 CONN 25 E-6 31 CONN 26 B-5 E CONN 27 D-4 J CONN 28 I-3 M CONN 29 C-2 57 CONN 30 C-2 57 CONN 31 D-2 58 CONN 32 E-2 58 CONN 33 E-2 58 CONN 34 H-2 M CONN 35 H-2 M CONN 58 I-2 M The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Battery (Tr) - (2) Schematic Location Machine Location Sensor - Turbo Outlet Pressure G-1 M Sensor - Primary Cam S/T H-1 M C-8 39 Component Sensor (Sc) - Hydraulic Temp F-6 5 Sensor (Tr) - Converter Oil Temperature I-5 26 Control - Engine ECM H-3 7 Control - Stop/Tail Lamp G-7 9 Sensor (Tr) - Trans EOS I-5 23 Solenoid - A/C Compress H-4 Control (Sc) - - CAT Monitoring System H-7 3 H Solenoid - Bowl Down F-6 I Ground - Chassis Ground - Chassis (2) G-5 35 Solenoid - Bowl Up E-6 I F-4 36 Solenoid - Cushion Hitch D-9 28 Ground - Engine (2) G-5 3 Solenoid - Ejector Forward E-6 I Ground - Engine (3) F-2 16 Solenoid - Ejector Reverse E-6 I Horn - Fwd High D-1 10 Solenoid - Elevator Direction E-9 J Horn - Fwd Low D-1 11 Solenoid - Elevator Enable E-9 J YL SW Battery + (Side Flood Lamp) A706 GY Injector 6 Injectors H-1 Solenoid - Elevator Speed E-9 118 GY SW Battery + (Wipers) A707 PU Injector 7 Junction Block - Crank/Charge G-5 M Solenoid - Forward Auger E-9 48 120 YL SW Battery + (12V Converter) A708 BR Injector 8 Lamp - Bowl Flood B-6 13 Solenoid - Pilot D-7 J 122 BU SW Battery + (Air Dryer) A745 WH Fuel Pressure Lamp - Cutting Edge Flood E-5 14 Solenoid (Sc) - Park Brake B-8 19 123 WH SW Battery + (Bowl Flood Lamp) A746 PK Turbo Outlet Press Sensor Module - A/C Protection H-4 37 Solenoid (Tr) - Downshift D-7 J 124 GN SW Battery + (A/C) A747 GY Atmospheric Press Sensor Motor - Front Washer D-2 A Solenoid (Tr) - Start Aid C-1 6 125 OR SW Battery + (Fuel Pump) A751 YL Fuel Temp Sensor Motor - Fuel Pump B-8 38 Solenoid (Tr) - Upshift D-7 K 126 PK Battery + (24V) E707 GN Display Module Pwr Supply Motor - Rear Washer C-2 A Suppressor - Arc (Cushion Hitch) D-9 28 128 PK SW Battery + (Scraper) E708 PK Display Module Clock Motor (Tr) - Starter G-5 16 Switch - A/C Hi Pressure H-4 37 129 BU SW Battery + (Spare) E767 BU Aug Fwd Sol Receptacle (Tr) - AuxStart G-5 36 Switch - A/C Lo Pressure H-4 37 130 GN SW Battery + (Spare) E790 PK Sol Ret Relay (Sc) - Main F - 14 6 Switch - Differential Pressure I-5 30 133 RD Unswitched Battery + E793 BU Ata Data Link - RD SW Battery + (Spare) E794 YL Ata Data Link + Resistor (Tr) - Starter/Diagnostic H-5 16 Switch - Ejector Kickout Press E-6 G 146 147 PU SW Battery + (Spare) E795 YL Engine Oil Temp C-8 31 148 WH Heat A/C Fan On E796 GN Rail Pressure 150 RD Unswitched Battery + (Eng) E797 WH Rail Pressure Control Ret 165 RD SW Battery + (Spare) E798 PK Rail Pressure Control E799 BR 3.5A Driver Return F700 BU 3.5A Pwm Driver BK BK BK Main Chassis Ground Ground (Tractor Ems) -Battery (Gnd) Chassis Ground F701 F702 F703 BR GN GY B-8 20 Switch - Supl. Steer Flow Sensor - Transmission Speed C-7 M Switch (Sc) - Park Brake B-8 19 Sensor - Atmosphere Pressure F-1 M Switch (Tc) - Ground Level Shutdown C-1 33 Sensor - Backup Cam S/T F-1 M Switch (Tr) - Actual Gear C-7 21 Sensor - Coolant Temperature G-1 M Switch (Tr) - Coolant Flow F-1 22 Sensor - Engine Oil Pressure G-1 M Switch (Tr) - Disconnect F-5 32 3.5A On/Off Driver Sensor - Fuel Temperature G-1 M Switch (Tr) - Engine Oil Fuel Pump Pres H-5 16 Throttle Sensor Sensor - Inlet Air Temperature G-1 M Switch (Tr) - Parking Brake C-7 J Mic Spare Sensor - Turbo Inlet Pressure I-5 24 204 BK Ground (Scraper Ems) F704 OR Mic Spare 207 BK Starter Diagnostics Ground F705 PK Mic Spare Tr = Tractor 228 BK Fuel Level Sender Ret F706 PU Mic Spare Sc = Scraper 229 BK -Battery F707 WH Throttle Lock Lamp A = Located inside of cab. G =Located under platform. 231 BK Xmsn SW F708 YL Ether Start Valve Relay Engage B = Located inside of right console. I = Located on implement valve 290 BK Service SW F709 BU Prelube Relay Engage C = Located inside of left console. J = Located on top of tractor XMSN 291 BK Clear SW F710 BR Mic Spare D = Located around relay panel. K = Located on Top of Scraper XMSN BK Can Sheild F711 GN Can Data Link + A251 BK -Battery F712 GY Can Data Link - E = Located around hydraulic oil tank. F = Located around pilot manifold. L = Located in cab headline M = Located on tractor engine Basic Machine Circuits F713 OR Mic Spare BU Starter To Starter Resistor F714 PK Turbo Inlet Press Sensor 302 OR Starter Resistor To Diagnostic F715 PU Ground Level Shutdown (No) 304 WH Starter Relay To Starter F716 WH Ground Level Shutdown (Nc) 306 GN Scraper Start Relay/Prelube F717 YL Throttle Lock SW (Lock Off) 307 OR Ecm Keysw (Mac-14) F718 BU Throttle Lock SW (Lock On) 308 YL Ecm Keysw (Abl) F719 BR Mic Spare 310 PU Scraper Start Aid Sol Engage F720 GN Start Aid SW 311 WH Scraper Coolant Temp SW F721 GY Mic Spare 320 OR Horn Relay Coil To Horn SW F722 OR Mic Spare 322 GY Warning Horn (Forward) F723 PK Bottom S/T Sensor + 323 WH Fuel Pump Pwr F724 PU Top S/T Sensor + 324 BU Diff Lock Sol Pwr F725 WH Mic Spare 326 PU Scraper Eng Shutdown F726 YL Injector Common 1 327 PK Engine Shutdown Sol (Scraper) F727 BU Injector Common 2 A309 GY Fuel Pump Enable F728 BR Injector Common 5 F729 GN Injector Common 6 PK Backup Camshaft Speed/Timing 405 GY Scraper Eng Oil Press SW F780 PK Operator Park Brake SW 410 WH Action Alarm (Tractor Ems) F789 YL Sol Ret 411 PK Action Lamp (Tractor Ems) F790 BR Sol Ret 412 BU Coolant Flow SW J764 BK SW And Sensor Gnd Ret 417 GY Supplemental Steering SW J766 PU Gnd For "SWitch To Gnd" 419 YL Tractor Park Brake Press SW J767 GY Sensor Ret 420 OR Fuel Filter Restrict K742 OR Top Drive Gear SW 421 BU Action Lamp (Scraper Ems) R713 OR Ejector Fwd Sol 441 OR Scraper Eng Coolant Temp Sender R714 BU Ejector Rev Sol 58 444 BU Torque Converter Temp Sensor R715 GN Bowl Up Sol 37 445 GN Torque Converter Temp Sender R716 PK Bowl Down Sol BR Apron Raise Sol 450 YL Eng Speed Sensor + R720 GY Apron Lower Sol 451 BR Eng Speed Sensor - R721 YL Ejector Cylinder Press SW C413 YL Display Module Data R722 PU Pilot Sol C414 BU Output R732 BR Hydraulic Oil Temp Sensor C436 BU Auger Filter SW R733 GN Neutral Run SW Jumper C457 BU Scraper Air Press Sensor R734 WH Pilot Air Press Sensor C465 OR Tractor Air Press Sensor R736 PK Scraper Park Brake Press SW E453 BU Motor Case Filter SW R737 YL Scraper Eng Start (Cab) R738 BU Scraper Eng Ether Aid (Cab) Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. ARW1-UP (Machine) AWB1-UP (Scraper) Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols * Harness identification letter(s) and a serializing code. The "C" stands for connector and the number indicates which connector in the harness. Wire, Cable, or Harness Assembly Identification Part Number For L-C12* AG-C4* Connector Assembly 3E-5179 111-7898 325-A135 PK-14 1 * * AG-C3 C-C4 130-6795 130-6795 325-A135 PK-14 Socket Pin Wire Gauge Wire Color Receptacle Fuse Plug Ground Circuit Connection Number Identification 2 200-L32 BK-14 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 1 2 105-9344 Component Part Number Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Printed in U.S.A. © 2001 Caterpillar All Rights Reserved F732 R717 T Volume 1 Alternator (R) Terminal Fuel Level Sensor 623G Wheel Tractor-Scraper Electrical System Sender - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. Pin or Socket Number GN PK This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Single Wire Connector 403 447 Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. Harness identification code This example indicates wire 135 in harness "AG". A234 Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Sender - Fuel Level Machine locations are repeated for components located close together. T Pressure Symbol This indicates that the component has a wire connected to it that is connected to ground. 117 BK Electrical Schematic Symbols And Definitions RENR1532-01 June 2001 Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. 23 Monitoring Circuits I-7 H-7 F-4 E-4 C-4 Component Description 12 301 CONN 1 CONN 2 CONN 3 CONN 4 CONN 5 F-6 5 RD 203 Machine Location 2 Scraper Xmsn Gear 3 202 Schematic Location 1 G-5 OR Accessory Circuits Connector Number E - 15 Alternator (Tr) 740 201 Connector Location for Vol 1. Alarm - Backup Unswitched Battery + 200 Engine Monitor System (MID No. 036)² Machine Location Wire Color Ground Circuits 0001 Injector Cylinder 1 Solenoid 0002 Injector Cylinder 2 Solenoid 0003 Injector Cylinder 3 Solenoid 0004 Injector Cylinder 4 Solenoid 0005 Injector Cylinder 5 Solenoid 0006 Injector Cylinder 6 Solenoid 0091 Throttle Position signal 0100 Engine Oil Pressure 0110 Engine Coolant Temperature 0168 System Voltage High 0172 Intake Manifold Air Temp 0174 Fuel Temperature 0190 Loss of Engine Speed Signal 0248 CAT Data Link 0253 Personality Module mismatch 0254 Electronic Control Module 0261 Engine Timing Calibration required 0262 Volt Sensor Supply Short 0263 Digital Sensor Supply Short 0267 Incorrect Engine Shutdown Switch inputs 0268 Check Programmable Parameters 0273 Turbo Outlet Pressure 0274 Atmospheric Pressure 0275 Right Turbo Inlet Pressure 0342 Secondary Engine Speed Signal 0545 Ether Start Relay 0548 Throttle Lock Lamp 0549 Inncorrect Throttle Lock Switch inputs 0596 Unable to communicate with Machine ECM 0799 Need Service Tool update ¹ The CID is a diagnostic code that indicates which component is faulty. ² The MID is a diagnostic code that indicates which electronic control module diagnosed the fault. Schematic Location Wire Number Description Power Circuits Tractor CAT Monitor System (MID No. 030)² 0096 0177 0248 0263 0271 0324 0819 0821 Component Location (Vol 1) Wire Description 29 36 10 26 39 16 27 3 28 35 41 6 32 8 15 H 49 Solenoid: Air Conditioner Clutch 3E-6332 Solenoid: Tractor Start Aid 3E-7842 Resistors: Starter Motor 9G-1950 Resistor: Blower 38 9X-9482 Solenoid: Scraper Park Brake Brake Air Supply Differential Lock Tractor Park Brake Throttle Lock Slip Limit 122-1134 Solenoid: Elevator Enable Pilot 144-6292 Solenoid: 144-9527 Solenoid: 52 42 G A 44 E 45 4 C Resistance (Ohms)¹ 17.6 ± 0.6 6 150 ± 7.5 17 2 40 Component Description 3E-1906 1 K 13 19 9 22 34 23 14 I L F 48 51 21 25 56 Part No. 33 53 43 B D 57 J 50 47 11 31 55 12 M Resistor, Sender and Solenoid Specifications 54 24 7 20 30 5 Overall 2 ± .1 Tap 1.0 ±. .05 42.4 ± 2.1 41.9 Downshift Upshift Auger Forward Auger Reverse 32.6 ± 1.6 32.6 ± 1.6 500 BR Front Wiper (Park) R739 GN Scraper Eng Shutdown (Cab) 152-8339 Solenoid: Cushion Hitch 32.6 ± 1.6 501 GN Front Wiper (Lo) R741 GN Scraper Mode Select Lamp 152-8340 Solenoid: 32.6 ± 1.6 502 OR Front Wiper (Hi) R742 YL Tractor Mode Select Lamp 503 BR Rear Wiper (Park) R745 OR Apron Float Lamp 156-2829 Solenoid: 504 YL Rear Wiper (Lo) R748 BR Ejector Return Lamp Elevator Enable Bowl Down Bowl Up Ejector Rev Ejector Fwd 505 BU Rear Wiper (Hi) R749 BU Apron/Elev Joystick Command 506 PU Front Washer R750 GN Ejector Joystick Command 162-8349 Sender: 507 WH Rear Washer R752 YL Bowl Joystick Command 191-3005 Solenoids: Injector 508 PU Left Radio Speaker R756 WH Cushion Hitch SW (No) 197-8811 Solenoids: Elevator Speed 509 WH Left Radio Speaker Common R757 BR Cushion Hitch SW (Nc) 511 BR Right Radio Speaker R758 PK Gear Hold SW (No) 512 GN Right Radio Speaker Common R759 BU Gear Hold SW (Nc) 515 GY Blower Motor (Hi) R760 GN Bail/Aug Fwd/Elev Set SW (No) 516 GN Blower Motor (Med) R761 YL Bail/Aug Fwd/Elev Set SW (Nc) 517 BU Blower Motor (Lo) R762 GY Tractor Mode Select SW 521 YL A/C SW To A/C Press SW 522 WH A/C Compressor To Thermostat R763 BU Scraper Mode Select SW R764 WH Gear Hold Lamp 537 GN Flasher Control R765 OR Aug Rev SW (Nc) 592 BU +12V Pwr R766 PU Aug Rev SW (No) 597 PU Hi Press SW To Lo Press SW R767 YL Service Brake Press SW Jumper A513 PK +12V Memory X796 PU Backup Alarm A519 GN Cushion Hitch Sol 892 BR Cat Data Link (-) A523 PU Temp Potentiometer Pos 1 893 GN Cat Data Link (+) A524 BR Temp Potentiometer Pos 2 F835 BU Operator SW A525 GN Temp Potentiometer Pos 3 H807 YL On/Off Driver Ret 1-4 (Abl) A526 PK Electronic Water Valve Actuator J807 BK Proportional Ret 1-4 (Abl) A527 BU Electronic Water Valve Actuator J808 BK Proportional Ret 5-8 (Abl) A528 YL Electronic Water Valve Actuator J809 BK Proportional Ret 9-12 (Abl) A529 WH Electronic Water Valve Actuator J813 BK Proportional Ret 13-16 (Abl) A530 OR Electronic Water Valve Actuator J814 BK Proportional Ret 17-20 (Abl) A535 GN Throttle Lock Sol 918 OR Eng Ovrspd Lamp And Alarm A572 PK Lo Press SW To Controller 919 GN Eng Ovrspd Test SW C558 BU Front Wiper SW Jumper 993 BR Analog Sensor Ret C559 GN Rear Wiper SW Jumper 994 GY Oil Pressure Sensor E554 PK Controller To A/C Clutch 995 BU Eng Coolant Temp Sensor 996 GN Eng Speed/Timing Sensor Pwr OR Machine Analog Sensor Pwr +5V Lighting Circuits 5.0 ± .3 Empty: 92 to 98 Full: 0 to 3 Fuel Level 1.06 ± .053 ¹ At room temperature unless otherwise noted. Off Machine Switch Specification 43 L Part No. 56 A 47 8 G B 7 29 3 12 C M 39 44 36 5 45 27 57 46 31 51 6 22 H 9 49 1 2 40 25 K 14 53 J 16 35 4 54 55 I E 32 34 20 30 24 41 11 10 3E-2026 28 50 F 37 13 21 48 15 33 52 17 26 42 19 23 Scraper Engine Oil Pressure Actuate Deactuate Contact Position 60 kPa MAX (8.7 psi.) 38 ± 20 kPa (5.5 ± 2.9 psi) Normally Open 80 kPa MAX (11.6 psi.) 55 ± 20 kPa (8 ± 2.9 psi) Normally Closed 38 ± 3 °C (100 ± 5°F) 11700 ± 170 kPa (1696 ± 24.6 psi) 27°C MIN (85° F) 10000 kPa MIN (1450 psi MIN) 1-3 Normally Closed 1-2 Normally Open 517 ± 35 kPa (75.0 ± 5.1 psi) 448 ± 35 kPa (65.0 ± 5.1 psi) 1-3 Normally Closed 1-2 Normally Open 3E-2034 Tractor Service Brake Scraper Service Brake 3E-6425 Scraper Coolant Temp 3E-7799 Ejector Kickout Pressure 8T-9792 Tractor Park Brake Scraper Park Brake 107-0612 Engine Oil Fuel Pump 93 ± 21 kPa (13.5 ± 3 psi) 70 ± 21 kPa (10.2 ± 3 psi) Normally Open 109-0260 Motor Case Filter Charge Pump Filter Pump Case Drain Filter 124 ± 14 kPa (18 ± 2 psi) 82 kPa MIN (12 psi MIN) Normally Closed 114-5333 AC High Pressure 119-7870 Supl Steering Flow 275 to 1750 kPa¹ (40 to 255 psi.) 4 grams MAX (0.1 oz MAX) At screw head 83 kPa MAX (12 psi.) 362 to 29 mN (1.30 to 0.10 oz) 137.9 ± 13.8 kPa (13.4 ± 3 psi) 103.4 ± 13.8 kPa (15 ± 2 psi.) --1.5 grams MIN (0.5 oz MIN) At screw head 48 ± 20 kPa (7 ± 2.9 psi) 38 Machine Harness Connector And Component Locations Function 125-9352 Stop Lamp Pressure 134-6054 Coolant Flow 144-5661 Differential Pressure 149-6371 A/C Lo Pressure 303 mN MIN (1.08 oz MIN) 70 ± 21 kPa (10 ± 3 psi) 34.5 ± 7 kPa (5 ± 1 psi.) Normally Closed Normally Open² Normally Open Normally Open Normally Open Normally Open Normally Open 601 GY Scraper Dash Lamp 997 602 WH Dome Lamp 998 BR Digital Sensor Ret 604 OR Stop Lamp Signal 999 WH Primary Cam S/T Sensor ¹ With increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). 605 YL Left Turn Lamp A958 WH Tractor Park Brake Sol ² Contact Position at the contacts of the harness. 606 GY Right Turn Lamp C967 BU Inlet Air Temp Sensor 608 GN Bowl Flood Lamp C992 PU Service Brake Press SW 609 YL Side Flood Lamp E965 BU Top S/T Sensor - 610 OR High Beam Relay Engage E966 YL Top S/T Sensor + 611 PU High Beam Headlamp E973 GY Retarder Press SW 614 PU Park/Tail/Dash Lamp K901 WH Air Compressor Solenoid 619 GN Low Beam Headlamp K927 BU Sol Return (Mac-14) 639 640 WH GN Left Stop/Tail Lamp Right Stop/Tail Lamp K966 K968 PU GN Elev En/Aug Rev Sol Auger Slip Limit SW 661 GN Tachometer Back Light K969 GY Scraper Slip Limit Sol 662 YL Speedometer Back Light K970 OR Elevator Speed Sol 663 GY Quad Gage Back Light L983 WH Injector Common 1 Control Circuits L984 OR Injector Common 3 703 BU Tractor Xmsn Upshift Sol L985 YL Injector Common 5 704 GY Tractor Xmsn Downshift Sol M904 OR Calibration Press SW (No) 709 OR +10V Sensor Power Supply M905 WH Calibration Press SW (Nc) 710 GN Xmsn Output Speed M997 PU Gear Selector 721 BR Tractor Xmsn Gear 1 N940 BU Engine Analog Sensor Pwr +5V 722 WH Tractor Xmsn Gear 2 N941 YL Engine Analog Sensor Ret 723 OR Tractor Xmsn Gear 3 N942 OR Mic Spare 724 YL Tractor Xmsn Gear 4 N943 BR SWitch 1 (Spare) 725 GN Tractor Xmsn Gear 5 N944 PU Tractor Eng Coolant Flow SW Ret 726 BU Xmsn Gear Ground Verify N948 GN Scraper Park Brake Sol 738 BR Scraper Xmsn Gear 1 P988 OR Bail/Elevator Direction Sol 739 WH Scraper Xmsn Gear 2 P991 PK Operator SW (Scraper_Ems) Failure Mode Identifiers (FMI)¹ FMI No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Failure Description Data valid but above normal operational range. Data valid but below normal operational range. Data erratic, intermittent, or incorrect. Voltage above normal or shorted high. Voltage below normal or shorted low. Current below normal or open circuit. Current above normal or grounded circuit. Mechanical system not responding properly. Abnormal frequency, pulse width, or period. Abnormal update. Abnormal rate of change. Failure mode not identifiable. Bad device or component. Out of calibration. Parameter failures. Parameter failures. Parameter not available. Module not responding. Sensor supply fault. Condition not met. Parameter failures. ¹The FMI is a diagnostic code that indicates what type of failure has occurred. Monitoring System Modes Mode of Operation Mode Number Related Electrical Service Manuals Operator 0 Machine Code 1 Parameter Display 2 Alternator (Tractor): Diagnostic Servicing 3 CAT Monitoring System: SENR 4100 Digital Tattletale 4 Tractor Transmission Control: SENR 4097 Units 5 Implement Control: SENR 4099 Engine Control: RENR 2318 Title Form Number 3E-7577 Starting and Charging: Starter Motor Tractor: Machine Code Machine Code 623G 41 SENR 7507 SENR 2947 6V-0890 SENR 3860
CID 0190 0248 0269 0444 0562 0590 0596 0700 0701 0702 0707 0708 0718 0967 1326 1429 1430 1431 1432 1433 1631 Component Identifiers (CID)¹ List Component Tractor Power Train Control (MID No. 027)² Wire Description Engine RPM Sensor CAT Data Link Sensor Power Supply Starting Motor Relay Caterpillar Monitoring System Engine Electronic Control Module Machine Control Electronic Control Module Position Sensor (Transmission Gear) Position Sensor (Transmission Gear) Transmission Gear Lever Solenoid Valve (Upshift) Solenoid Valve (Downshift) Transmission System Machine Application Location Code Incorrect Pressor Sensor (Tractor Air) Pressor Sensor (Scraper Air) Pressure Sensor (Brake Air Supply) Solenoid Valve (Tractor Parking Brake) Solenoid Valve (Scraper Parking Brake) Solenoid Valve (Brake Air Supply) Level Sender (Fuel) Temperature Sensor (Transmission Oil) Data Link Sensor Power Supply Alarm (Action) Lamp (Action) Display Data Link Display Power Supply Electrical System Voltage Cat Data Link Sensor Power Supply Power Train Electronic Control Module (Tractor) Solenoid Valve (Synchronizing) Magnetic Switch (Start Relay) Solenoid Valve (Throttle Lock) Caterpillar Monitoring System Engine Electronic Control Module Machine Control Electronic Control Module Position Sensor (Transmission Gear) Solenoid Valve (Upshift) Solenoid Valve (Downshift) Machine Application Solenoid Valve (Speed Limit) Location Code Incorrect RD Unswitched Battery + 740 OR Scraper Xmsn Gear 3 102 RD Unswitched Battery + 741 YL Scraper Xmsn Gear 4 103 RD Unswitched Battery + 742 GN Scraper Xmsn Gear 5 105 RD Unswitched Battery + 743 PU Neutral Run SW 108 BU SW Battery + (Prelube Relay) 744 BU Scraper Xmsn Upshift Sol 109 OR Unswitched Battery + 745 GY Scraper Xmsn Downshift Sol 110 RD Unswitched Battery + 746 PK Scraper Xmsn Sync Sol 111 YL SW Battery + (Cigar_Lighter) A700 OR Digital Sensor Power +8V 112 PU SW Battery + A701 GY Injector 1 113 OR +Battery (Tractor Ems) A702 PU Injector 2 114 RD SW Battery + (Horn Relay Pwr) A703 BR Injector 3 115 PK SW Battery + (Spare) A704 GN Injector 4 116 BR SW Battery + (Diff Lock SW) A705 BU Injector 5 Control Circuits (Continued) SW Battery + (Wipers) B-8 Sensor (Sc) - Engine Speed E - 14 25 Alternator (Tr) G-5 3 Sensor (Sc) - Hydraulic Temp C-8 39 H - 11 4 Sensor (Tr) - Converter Oil Temperature I-5 26 Injector 6 Injector 7 Batterery (SC) H - 11 4 Sensor (Tr) - Trans EOS I-5 23 Battery (Tr) - (2) F-6 5 Solenoid - A/C Compress H-4 3 Battery (Tr) - Backup (2) F-6 5 Solenoid - Apron Lower F-6 I Breaker (Sc) - Alternator H - 14 6 Solenoid - Apron Raise F-6 I Breaker (Sc) - Engine Shutoff G - 14 6 Solenoid - Bail C-2 28 Breaker (Sc) - Start G - 14 6 Solenoid - Bowl Down F-6 I Control - Engine ECM H-3 7 Solenoid - Bowl Up E-6 I Control - Stop/Tail Lamp G-7 9 Solenoid - Cushion Hitch D-9 28 Control (Sc) - - CAT Monitoring System H-7 H Solenoid - Ejector Forward E-6 I Control (Sc) - Engine Shutoff B - 12 8 Solenoid - Ejector Reverse E-6 I C - 13 34 Solenoid - Forward Auger E-9 48 Battery ( Sc) - Backup Control (Sc) - Transmission A708 BR Injector 8 Control (Tr) - Transmission B-10 Solenoid - Pilot D-7 J SW Battery + (Air Dryer) A745 WH Fuel Pressure Ground - Chassis G-5 35 Solenoid - Rail Press Ctrl F-1 M 123 WH SW Battery + (Bowl Flood Lamp) A746 PK Turbo Outlet Press Sensor Ground - Chassis (2) F-4 36 Solenoid - Reverse Auger E-9 48 124 GN SW Battery + (A/C) A747 GY Atmospheric Press Sensor Ground - Engine (2) G-5 3 Solenoid (Sc) - Downshift B - 12 K 125 OR SW Battery + (Fuel Pump) A751 YL Fuel Temp Sensor Ground - Engine (3) E-2 16 Solenoid (Sc) - Throttle Lock E - 11 40 126 PK Battery + (24V) E707 GN Display Module Pwr Supply Ground (Sc) - Engine F - 11 15 Solenoid (Sc) - Eng Shutoff E - 11 40 128 PK SW Battery + (Scraper) E708 PK Display Module Clock Ground (Sc) - Engine (2) G - 11 2 Solenoid (Sc) - Park Brake B-8 49 129 BU SW Battery + (Spare) E767 BU Aug Fwd Sol Horn - Fwd High D-1 10 Solenoid (Sc) - Slip Limit E - 11 49 130 GN SW Battery + (Spare) E790 PK Sol Ret Horn - Fwd Low D-1 11 Solenoid (Sc) - Start Aid E - 11 6 133 RD Unswitched Battery + E793 BU Ata Data Link - Injectors G-5 12 RD SW Battery + (Spare) E794 YL Ata Data Link + Solenoid (Sc) - Sync B - 12 K 146 PU SW Battery + (Spare) E795 YL Engine Oil Temp Solenoid (Sc) - Upshift B - 12 K 147 G-5 M 148 WH Heat A/C Fan On E796 GN Rail Pressure Lamp - Bowl Flood B-6 13 Solenoid (Tr) - Downshift D-7 J 150 RD Unswitched Battery + (Eng) E797 WH Rail Pressure Control Ret Lamp - Cutting Edge Flood E-5 14 Solenoid (Tr) - Start Aid C-1 29 165 RD SW Battery + (Spare) E798 PK Rail Pressure Control Lamp (Sc) - Master Action F - 15 H Solenoid (Tr) - Upshift D-7 J E799 BR 3.5A Driver Return Meter - (Sc) - Service E-7 H Suppressor - Arc (AC Clutch) B-2 37 F700 BU 3.5A Pwm Driver Module - A/C Protection H-4 37 Suppressor - Arc (Cushion Hitch) D-9 28 Motor - Fuel Pump B-8 38 Switch - Motorcase Filter D-9 50 Motor - Front Washer D-2 A Switch - A/C Hi Pressure H-4 37 Mic Spare Motor - Rear Washer C-2 A Switch - A/C Lo Pressure H-4 37 F - 11 15 Switch - Auger Reverse D-9 51 BK BK BK BK Main Chassis Ground Ground (Tractor Ems) -Battery (Gnd) Chassis Ground F701 F702 F703 BR GN GY 3.5A On/Off Driver Throttle Sensor Junction Block - Crank/Charge 204 BK Ground (Scraper Ems) F704 OR Mic Spare Motor (Sc) - Starter 207 BK Starter Diagnostics Ground F705 PK Mic Spare Motor (Tr) - Starter G-5 16 Switch - Charge Pump Filter E-7 52 228 BK Fuel Level Sender Ret F706 PU Mic Spare Receptacle (Sc) - AuxStart G - 12 17 Switch - Differential Pressure I-5 30 229 BK -Battery F707 WH Throttle Lock Lamp Receptacle (Tr) - AuxStart G-5 36 Switch - Ejector Kickout Press E-6 G 231 BK Xmsn SW F708 YL Ether Start Valve Relay Engage Relay (Sc) - Main F - 14 6 Switch - Instrument Panel Lamp F - 15 H 290 BK Service SW F709 BU Prelube Relay Engage Relay (Sc) - Start F - 14 6 Switch - Pump Case Drain E-7 53 291 BK Clear SW F710 BR Mic Spare Resistor (Sc) - Power G - 14 6 Switch - Supl. Steer Flow C-8 31 A234 BK Can Sheild F711 GN Can Data Link + Resistor (Sc) - Starter/Diagnostic F - 11 15 Switch (Sc) - Actual Gear A -12 21 A251 BK -Battery F712 GY Can Data Link - Resistor (Tr) - Starter/Diagnostic H-5 16 Switch (Sc) - Coolant Flow E - 14 22 Basic Machine Circuits F713 OR Mic Spare Sender - Fuel Level B-8 20 BU Starter To Starter Resistor F714 PK Turbo Inlet Press Sensor Switch (Sc) - Disconnect G - 11 32 302 OR Starter Resistor To Diagnostic F715 PU Ground Level Shutdown (No) Sender (Sc) - Conv. Oil Temp D - 14 21 Switch (Sc) - EMS Function G-7 H 304 WH Starter Relay To Starter F716 WH Ground Level Shutdown (Nc) Sender (Sc) - Eng. Coolant Temp F - 14 22 Switch (Sc) - Engine Coolant Temp EMS F - 14 22 306 GN Scraper Start Relay/Prelube F717 YL Throttle Lock SW (Lock Off) Sensor - Transmission Speed C-7 M Switch (Sc) - Engine Oil Pressure EMS E - 14 22 307 OR Ecm Keysw (Mac-14) F718 BU Throttle Lock SW (Lock On) Sensor - Atmosphere Pressure F-1 M Switch (Sc) - Engine Shutoff G-7 H 308 YL Ecm Keysw (Abl) F719 BR Mic Spare Sensor - Backup Cam S/T F-1 M Switch (Sc) - Engine Start F-7 H 310 PU Scraper Start Aid Sol Engage F720 GN Start Aid SW Sensor - Coolant Temperature G-1 M Switch (Sc) - Ether Aid F-7 H Sensor - Engine Oil Pressure H-1 M Switch (Sc) - Ground Level Shutdown F-7 33 311 WH Scraper Coolant Temp SW F721 GY Mic Spare 320 OR Horn Relay Coil To Horn SW F722 OR Mic Spare Sensor - Engine Oil Temp G-1 M Switch (Sc) - Park Brake B-8 19 Bottom S/T Sensor + Sensor - Fuel Temperature G-1 M Switch (Tc) - Ground Level Shutdown C-1 41 G-1 M Switch (Tr) - Actual Gear C-7 42 GY Warning Horn (Forward) F723 PK 323 WH Fuel Pump Pwr F724 PU Top S/T Sensor + Sensor - Inlet Air Temperature 324 BU Diff Lock Sol Pwr F725 WH Mic Spare Sensor - Turbo Inlet Pressure I-5 24 Switch (Tr) - Coolant Flow F-1 M 326 PU Scraper Eng Shutdown F726 YL Injector Common 1 Sensor - Turbo Outlet Pressure H-1 M Switch (Tr) - Disconnect F-5 36 327 PK Engine Shutdown Sol (Scraper) F727 BU Injector Common 2 Sensor - Primary Cam S/T H-1 M Switch (Tr) - Engine Oil Fuel Pump Pres H-5 16 A309 GY Fuel Pump Enable F728 BR Injector Common 5 Sensor - Rail Pressure I-5 M Switch (Tr) - Parking Brake C-7 J F729 GN Injector Common 6 Monitoring Circuits 403 GN Alternator (R) Terminal F732 PK Backup Camshaft Speed/Timing 405 GY Scraper Eng Oil Press SW F780 PK Operator Park Brake SW 410 WH Action Alarm (Tractor Ems) F789 YL Sol Ret 411 PK Action Lamp (Tractor Ems) F790 BR Sol Ret 412 417 BU GY Coolant Flow SW Supplemental Steering SW J764 J766 BK PU SW And Sensor Gnd Ret Gnd For "SWitch To Gnd" 419 YL Tractor Park Brake Press SW J767 GY Sensor Ret 420 OR Fuel Filter Restrict K742 OR Top Drive Gear SW 421 BU Action Lamp (Scraper Ems) R713 OR Ejector Fwd Sol 441 OR Scraper Eng Coolant Temp Sender R714 BU Ejector Rev Sol 444 BU Torque Converter Temp Sensor R715 GN Bowl Up Sol 445 GN Torque Converter Temp Sender R716 PK Bowl Down Sol 447 PK Fuel Level Sensor R717 BR Apron Raise Sol 450 YL Eng Speed Sensor + R720 GY Apron Lower Sol 451 BR Eng Speed Sensor - R721 YL Ejector Cylinder Press SW C413 YL Display Module Data R722 PU Pilot Sol C414 BU Output R732 BR Hydraulic Oil Temp Sensor C436 BU Auger Filter SW R733 GN BU Scraper Air Press Sensor R734 WH Pilot Air Press Sensor C465 OR Tractor Air Press Sensor R736 PK Scraper Park Brake Press SW E453 BU Motor Case Filter SW R737 YL Scraper Eng Start (Cab) T Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 627G Wheel Tractor-Scraper Electrical System Sender - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. AXF1-UP (Machine) AYK1-UP (Scraper) Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols * Harness identification letter(s) and a serializing code. The "C" stands for connector and the number indicates which connector in the harness. Harness identification code This example indicates wire 135 in harness "AG". Wire, Cable, or Harness Assembly Identification Part Number For L-C12* AG-C4* Connector Assembly 3E-5179 111-7898 325-A135 PK-14 1 * * AG-C3 C-C4 130-6795 130-6795 325-A135 PK-14 Socket Pin Single Wire Connector Wire Gauge Wire Color 29 36 10 Plug 2 58 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Volume 1 1 2 54 26 39 27 28 35 Printed in U.S.A. 44 51 Air Conditioner Clutch 3E-6332 Solenoid: Tractor Start Aid 3E-7842 Resistors: Starter Motor 4W-9972 Senders: Scraper Converter Oil Temp 13 32 8 15 H 49 40 Sync Resistor: Load Resisitor 9G-1950 Resistor: Blower 9X-9482 Solenoid: Scraper Park Brake Brake Air Supply Differential Lock Tractor Park Brake Throttle Lock Slip Limit 42.4 ± 2.1 110-6465 Solenoid: Eng. Shut Off 5.12 ± .26 122-1134 Solenoid: Elevator Enable Pilot 144-6292 Solenoid: 144-9527 Solenoid: Downshift Upshift Auger Forward Auger Reverse 152-8339 Solenoid: Cushion Hitch 32.6 ± 1.6 156-1114 Solenoid: 32.6 ± 1.6 156-2829 Solenoid: Bail Bowl Down Bowl Up Ejector Rev Ejector Fwd Apron Lower Apron Raise 17 2 38 G A BR Front Wiper (Park) R739 GN Scraper Eng Shutdown (Cab) GN Front Wiper (Lo) R741 GN Scraper Mode Select Lamp 502 OR Front Wiper (Hi) R742 YL Tractor Mode Select Lamp 503 BR Rear Wiper (Park) R745 OR Apron Float Lamp 504 YL Rear Wiper (Lo) R748 BR Ejector Return Lamp 505 BU Rear Wiper (Hi) R749 BU Apron/Elev Joystick Command 506 PU Front Washer R750 GN Ejector Joystick Command 507 WH Rear Washer R752 YL Bowl Joystick Command 162-8350 Sender: 508 PU Left Radio Speaker R756 WH Cushion Hitch SW (No) 191-3005 Solenoids: 509 WH Left Radio Speaker Common R757 BR Cushion Hitch SW (Nc) 511 BR Right Radio Speaker R758 PK Gear Hold SW (No) 512 GN Right Radio Speaker Common R759 BU Gear Hold SW (Nc) 515 GY Blower Motor (Hi) R760 GN Bail/Aug Fwd/Elev Set SW (No) 516 GN Blower Motor (Med) R761 YL Bail/Aug Fwd/Elev Set SW (Nc) 521 YL A/C SW To A/C Press SW 522 WH A/C Compressor To Thermostat R763 BU Scraper Mode Select SW R764 WH Gear Hold Lamp 537 GN Flasher Control R765 OR Aug Rev SW (Nc) 592 BU +12V Pwr R766 PU Aug Rev SW (No) 597 PU Hi Press SW To Lo Press SW R767 YL Service Brake Press SW Jumper A513 PK +12V Memory A519 GN Cushion Hitch Sol X796 PU Backup Alarm 892 BR Cat Data Link (-) A523 PU A524 BR Temp Potentiometer Pos 1 893 GN Cat Data Link (+) Temp Potentiometer Pos 2 F835 BU Operator SW A525 GN Temp Potentiometer Pos 3 H807 YL On/Off Driver Ret 1-4 (Abl) A526 PK Electronic Water Valve Actuator J807 BK Proportional Ret 1-4 (Abl) A527 BU Electronic Water Valve Actuator J808 BK Proportional Ret 5-8 (Abl) A528 YL Electronic Water Valve Actuator J809 BK Proportional Ret 9-12 (Abl) A529 WH Electronic Water Valve Actuator J813 BK Proportional Ret 13-16 (Abl) A530 OR Electronic Water Valve Actuator J814 BK Proportional Ret 17-20 (Abl) A535 GN Throttle Lock Sol 918 OR Eng Ovrspd Lamp And Alarm A572 PK Lo Press SW To Controller 919 GN Eng Ovrspd Test SW C558 BU Front Wiper SW Jumper 993 BR Analog Sensor Ret C559 GN Rear Wiper SW Jumper 994 GY Oil Pressure Sensor E554 PK Controller To A/C Clutch 995 BU Eng Coolant Temp Sensor 996 GN Eng Speed/Timing Sensor Pwr OR Machine Analog Sensor Pwr +5V Lighting Circuits 601 GY Scraper Dash Lamp 997 602 WH Dome Lamp 998 BR Digital Sensor Ret 604 OR Stop Lamp Signal 999 WH Primary Cam S/T Sensor 605 YL Left Turn Lamp A958 WH Tractor Park Brake Sol 606 GY Right Turn Lamp C967 BU Inlet Air Temp Sensor 608 GN Bowl Flood Lamp C992 PU Service Brake Press SW 609 YL Side Flood Lamp E965 BU Top S/T Sensor - 610 OR High Beam Relay Engage E966 YL Top S/T Sensor + 611 PU High Beam Headlamp E973 GY Retarder Press SW 614 PU Park/Tail/Dash Lamp K901 WH Air Compressor Solenoid 619 GN Low Beam Headlamp K927 BU Sol Return (Mac-14) 639 640 WH GN Left Stop/Tail Lamp Right Stop/Tail Lamp K966 K968 PU GN Elev En/Aug Rev Sol Auger Slip Limit SW 661 GN Tachometer Back Light K969 GY Scraper Slip Limit Sol 662 YL Speedometer Back Light K970 OR Elevator Speed Sol 663 GY Quad Gage Back Light L983 WH Injector Common 1 Control Circuits L984 OR Injector Common 3 703 BU Tractor Xmsn Upshift Sol L985 YL Injector Common 5 704 GY Tractor Xmsn Downshift Sol M904 OR Calibration Press SW (No) 709 OR +10V Sensor Power Supply M905 WH Calibration Press SW (Nc) 710 GN Xmsn Output Speed M997 PU Gear Selector 721 BR Tractor Xmsn Gear 1 N940 BU Engine Analog Sensor Pwr +5V 722 WH Tractor Xmsn Gear 2 N941 YL Engine Analog Sensor Ret 723 OR Tractor Xmsn Gear 3 N942 OR Mic Spare 724 YL Tractor Xmsn Gear 4 N943 BR SWitch 1 (Spare) 725 GN Tractor Xmsn Gear 5 N944 PU Tractor Eng Coolant Flow SW Ret 726 BU Xmsn Gear Ground Verify N948 GN Scraper Park Brake Sol 738 BR Scraper Xmsn Gear 1 P988 OR Bail/Elevator Direction Sol 739 WH Scraper Xmsn Gear 2 P991 PK Operator SW (Scraper_Ems) E 45 4 C 6 150 ± 7.5 54° C (130° F) 638 ± 78 110° C (230° F) 77 ± 5 26 ± 2 Solenoid: 52 42 17.6 ± 0.6 6T-9290 1 K Resistance (Ohms)¹ 7X- 6416 19 9 22 34 23 14 I L 56 48 6 Component Description Solenoid: 501 Tractor Mode Select SW Component Part Number Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. 3E-1906 33 21 25 53 43 B D 57 J 50 47 41 31 55 16 3 Scraper Eng Ether Aid (Cab) GY 105-9344 © 2001 Caterpillar All Rights Reserved 20 12 M 37 BU R762 200-L32 BK-14 Pin or Socket Number 30 24 7 R738 Blower Motor (Lo) Fuse Resistor, Sender and Solenoid Specifications F BU Receptacle Ground Circuit Connection Number Identification 500 517 Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Part No. 5 11 Electrical Schematic Symbols And Definitions Pressure Symbol Machine locations are repeated for components located close together. F = Located around pilot manifold. Tr = Tractor G = Located under platform. Sc = Scraper I = Located on Implement Valve. A = Located inside of cab. J = Located around Top of XMSN. B = Located inside of right console. K = Located around Top of Scraper XMSN. C = Located inside of left console. L= Located in Cab Headliner. D = Located around relay panel. M =Located on Tractor Engine. E = Located around hydraulic oil tank. Neutral Run SW Jumper C457 Accessory Circuits CONN 1 I-7 E CONN 2 H-7 E CONN 3 F-4 E CONN 4 E-4 E CONN 5 C-4 G CONN 6 D - 15 H CONN 7 Diagnostic Connector E - 15 H CONN 8 C - 12 25 CONN 9 A - 12 21 CONN 10 E - 11 49 CONN 11 E - 11 2 CONN 12 F - 10 1 CONN 13 E - 10 21 CONN 14 B - 10 54 CONN 15 D-8 55 CONN 16 I-9 H CONN 17 E-7 48 CONN 18 D-7 J CONN 19 C-7 J CONN 20 B-7 56 CONN 21 B-6 54 CONN 22 B-6 56 CONN 23 C-6 42 CONN 24 D-6 14 CONN 25 E-6 31 CONN 26 B-5 E CONN 27 D-4 J CONN 28 I - 30 M CONN 29 C-2 57 CONN 30 C-2 57 CONN 31 D-2 58 CONN 32 E-2 58 CONN 33 E-2 58 CONN 34 H-2 M CONN 35 H-2 M CONN 36 I-2 M The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Sensor (Sc) - Air Pressure 2 SW Battery + (12V Converter) 322 Machine Location 1 G - 11 YL 301 Connector Location for Vol 1. PU E - 15 Alternator (Sc) Component BU 203 0001 Injector Cylinder 1 Solenoid 0002 Injector Cylinder 2 Solenoid 0003 Injector Cylinder 3 Solenoid 0004 Injector Cylinder 4 Solenoid 0005 Injector Cylinder 5 Solenoid 0006 Injector Cylinder 6 Solenoid 0091 Throttle Position signal 0100 Engine Oil Pressure 0110 Engine Coolant Temperature 0168 System Voltage High 0172 Intake Manifold Air Temp 0174 Fuel Temperature 0190 Loss of Engine Speed Signal 0248 CAT Data Link 0253 Personality Module mismatch 0254 Electronic Control Module 0261 Engine Timing Calibration required 0262 Volt Sensor Supply Short 0263 Digital Sensor Supply Short 0267 Incorrect Engine Shutdown Switch inputs 0268 Check Programmable Parameters 0273 Turbo Outlet Pressure 0274 Atmospheric Pressure 0275 Right Turbo Inlet Pressure 0342 Secondary Engine Speed Signal 0545 Ether Start Relay 0548 Throttle Lock Lamp 0549 Inncorrect Throttle Lock Switch inputs 0596 Unable to communicate with Machine ECM 0799 Need Service Tool update ¹ The CID is a diagnostic code that indicates which component is faulty. ² The MID is a diagnostic code that indicates which electronic control module diagnosed the fault. A707 GY Alarm - Backup Machine Location 19 Component Schematic Location 122 202 Engine Monitor System (MID No. 036)² A706 Machine Location 120 201 Water Coolant Temperature Temperature Sensor (Transmission Oil) Data Link Sensor Power Supply Alarm (Action) Lamp (Action) Display Power Supply Connector Number GY SW Battery + (Side Flood Lamp) Schematic Location Description E 200 Electrical System Voltage Cat Data Link Solenoid Valve (Pilot Pressure Supply) Temperature Sensor (Hydraulic Oil) Lamp (Transmission Hold) Proportion Solenoid (Bowl Up) Proportion Solenoid (Bowl Down) Proportion Solenoid (Apron Raise) Proportion Solenoid (Apron Lower) Proportion Solenoid (Ejector Forward) Proportion Solenoid (Ejector Reverse) Position Sensor (Bowl Control) Position Sensor (Apron Control) Position Sensor (Ejector Control) Position Sensor (Elevator Control) Proportion Solenoid (Auger Forward) Proportion Solenoid (Auger Reverse) Proportion Solenoid (Elevator Speed) Solenoid Valve (Bail) Solenoid Valve (Cushion-Hitch) Trigger Switch (Bail) Push Switch (Transmission Hold) Push Switch (Cushion-Hitch) Lamp (Ejector Return) (Indicator) Lamp (Apron Float) (Indicator) Lamp (Tractor Mode) (Indicator) Lamp (Scraper Mode) (Indicator) Proportion Solenoid (Elevator Speed) Proportion Solenoid (Elevator Direction) Toggle Switch (Auger Reverse) Trigger Switch (Elevator Setpoint) Toggle Switch (Auger Forward) Schematic Location YL Ground Circuits Scraper CAT Monitor System (MID No. 054)² 0110 0177 0248 0263 0271 0324 0821 101 118 Implement Electronic Control (MID No. 039)² 0168 0248 0358 0600 0968 1275 1276 1277 1278 1279 1280 1281 1282 1283 1284 1285 1286 1287 1288 1289 1291 1292 1293 1294 1295 1296 1297 1299 1300 1322 1423 1424 Wire Color Description RENR1542-01 June 2001 Component Location (Vol 1) Wire Number 117 Scraper Power Train Control(MID No. 031)² 0168 0248 0269 0296 0349 0444 0561 0562 0590 0596 0700 0707 0708 0967 1323 1326 Wire Color Power Circuits Tractor CAT Monitor System (MID No. 030)² 0096 0177 0248 0263 0271 0324 0819 0821 Wire Number 50 ± 5 Overall 2 ± .1 Tap 1.0 ±. .05 41.9 32.6 ± 1.6 32.6 ± 1.6 5.0 ± .3 Empty: 92 to 98 Full: 0 to 3 1.06 ± .053 Fuel Level Injector ¹ At room temperature unless otherwise noted. Off Machine Switch Specification Part No. 3E-2026 L 56 A 28 8 F G B 37 29 12 3 C M 41 44 36 5 27 57 46 I 35 6 51 22 49 H 9 2 21 15 33 17 42 19 23 80 kPa MAX (11.6 psi.) 55 ± 20 kPa (8 ± 2.9 psi) Normally Closed 38 ± 3 °C (100 ± 5°F) 11700 ± 170 kPa (1696 ± 24.6 psi) 27°C MIN (85° F) 10000 kPa MIN (1450 psi MIN) 1-3 Normally Closed 1-2 Normally Open 517 ± 35 kPa (75.0 ± 5.1 psi) 448 ± 35 kPa (65.0 ± 5.1 psi) 1-3 Normally Closed 1-2 Normally Open 3E-7799 Ejector Kickout Pressure 8T-9792 Tractor Park Brake Scraper Park Brake 107-0612 Engine Oil Fuel Pump 93 ± 21 kPa (13.5 ± 3 psi) 70 ± 21 kPa (10.2 ± 3 psi) Normally Open 109-0260 Motor Case Filter Charge Pump Filter Pump Case Drain Filter 124 ± 14 kPa (18 ± 2 psi) 82 kPa MIN (12 psi MIN) Normally Closed 114-5333 AC High Pressure 119-7870 Supl Steering Flow 275 to 1750 kPa¹ (40 to 255 psi.) 4 grams MAX (0.1 oz MAX) At screw head 83 kPa MAX (12 psi.) 362 to 29 mN (1.30 to 0.10 oz) 137.9 ± 13.8 kPa (13.4 ± 3 psi) 103.4 ± 13.8 kPa (15 ± 2 psi.) --1.5 grams MIN (0.5 oz MIN) At screw head 48 ± 20 kPa (7 ± 2.9 psi) 52 26 Normally Open Scraper Coolant Temp K 48 Contact Position 38 ± 20 kPa (5.5 ± 2.9 psi) 3E-6425 1 40 25 14 53 J 31 16 45 4 54 55 39 E 11 10 20 30 24 7 32 34 Deactuate Tractor Service Brake Scraper Service Brake 50 47 Actuate 60 kPa MAX (8.7 psi.) Scraper Engine Oil Pressure 3E-2034 13 43 Function 38 125-9352 Stop Lamp Pressure 134-6054 Coolant Flow 144-5661 Differential Pressure 149-6371 A/C Lo Pressure 303 mN MIN (1.08 oz MIN) 70 ± 21 kPa (10 ± 3 psi) 34.5 ± 7 kPa (5 ± 1 psi.) ² Contact Position at the contacts of the harness. Failure Mode Identifiers (FMI)¹ 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Failure Description Data valid but above normal operational range. Data valid but below normal operational range. Data erratic, intermittent, or incorrect. Voltage above normal or shorted high. Voltage below normal or shorted low. Current below normal or open circuit. Current above normal or grounded circuit. Mechanical system not responding properly. Abnormal frequency, pulse width, or period. Abnormal update. Abnormal rate of change. Failure mode not identifiable. Bad device or component. Out of calibration. Parameter failures. Parameter failures. Parameter not available. Module not responding. Sensor supply fault. Condition not met. Parameter failures. ¹The FMI is a diagnostic code that indicates what type of failure has occurred. Monitoring System Modes Mode of Operation Mode Number Operator 0 Machine Code 1 Parameter Display 2 Diagnostic Servicing 3 Digital Tattletale 4 Units Normally Open² Normally Open Normally Open Normally Open Normally Open Normally Open ¹ With increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). Machine Harness Connector And Component Locations FMI No. Normally Closed 5 Related Electrical Service Manuals Title Alternator (Scraper): Alternator (Tractor): Form Number 6N-9294 3E-7577 CAT Monitoring System: SENR 4100 Tractor Transmission Control: Scraper Transmission Control: SENR 4097 SENR 4098 Implement Control: SENR 4099 Engine Control: RENR 2318 Starting and Charging: Starter Motor Tractor: Machine Code Machine Code 627G 38 627G With Bail Attch. 35 627G With Auger Attch. 37 SENR 4130 SENR 7507 Starter Motor Scraper: Consist No.: 6V-5537 (42MT) Consist No.: 6V-5538 (F8) Consist No.: 106-8552 (K8) SENR 2947 6V-0890 SENR 3860 (6V-5227) SENR 3581 SENR 3536 SENR 4975
CID 0190 0248 0269 0444 0562 0590 0596 0700 0701 0702 0707 0708 0718 0967 1326 1429 1430 1431 1432 1433 1631 0096 0177 0248 0263 0271 0324 0819 0821 0168 0248 0358 0600 0968 1275 1276 1277 1278 1279 1280 1281 1282 1283 1284 1285 1286 1287 1288 1289 1291 1292 1293 1294 1295 1296 1297 1299 1300 1322 1423 1424 0110 0177 0248 0263 0271 0324 0821 Component Identifiers (CID)¹ List Component Tractor Power Train Control (MID No. 027)² Wire Description Description Engine RPM Sensor CAT Data Link Sensor Power Supply Starting Motor Relay Caterpillar Monitoring System Engine Electronic Control Module Machine Control Electronic Control Module Position Sensor (Transmission Gear) Position Sensor (Transmission Gear) Transmission Gear Lever Solenoid Valve (Upshift) Solenoid Valve (Downshift) Transmission System Machine Application Location Code Incorrect Pressor Sensor (Tractor Air) Pressor Sensor (Scraper Air) Pressure Sensor (Brake Air Supply) Solenoid Valve (Tractor Parking Brake) Solenoid Valve (Scraper Parking Brake) Solenoid Valve (Brake Air Supply) Level Sender (Fuel) Temperature Sensor (Transmission Oil) Data Link Sensor Power Supply Alarm (Action) Lamp (Action) Display Data Link Display Power Supply Machine Electronic Control (MID No. 039)² Electrical System Voltage Cat Data Link Solenoid Valve (Pilot Pressure Supply) Temperature Sensor (Hydraulic Oil) Lamp (Transmission Hold) Proportion Solenoid (Bowl Up) Proportion Solenoid (Bowl Down) Proportion Solenoid (Apron Raise) Proportion Solenoid (Apron Lower) Proportion Solenoid (Ejector Forward) Proportion Solenoid (Ejector Reverse) Position Sensor (Bowl Control) Position Sensor (Apron Control) Position Sensor (Ejector Control) Position Sensor (Elevator Control) Proportion Solenoid (Auger Forward) Proportion Solenoid (Auger Reverse) Proportion Solenoid (Elevator Speed) Solenoid Valve (Bail) Solenoid Valve (Cushion-Hitch) Trigger Switch (Bail) Push Switch (Transmission Hold) Push Switch (Cushion-Hitch) Lamp (Ejector Return) (Indicator) Lamp (Apron Float) (Indicator) Lamp (Tractor Mode) (Indicator) Lamp (Scraper Mode) (Indicator) Proportion Solenoid (Elevator Speed) Proportion Solenoid (Elevator Direction) Toggle Switch (Auger Reverse) Trigger Switch (Elevator Setpoint) Toggle Switch (Auger Forward) Water Coolant Temperature Temperature Sensor (Transmission Oil) Data Link Sensor Power Supply Alarm (Action) Lamp (Action) Display Power Supply Engine Monitor System (MID No. 036)² 0001 Injector Cylinder 1 Solenoid 0002 Injector Cylinder 2 Solenoid 0003 Injector Cylinder 3 Solenoid 0004 Injector Cylinder 4 Solenoid 0005 Injector Cylinder 5 Solenoid 0006 Injector Cylinder 6 Solenoid 0091 Throttle Position signal 0100 Engine Oil Pressure 0110 Engine Coolant Temperature 0168 System Voltage High 0172 Intake Manifold Air Temp 0174 Fuel Temperature 0190 Loss of Engine Speed Signal 0248 CAT Data Link 0253 Personality Module mismatch 0254 Electronic Control Module 0261 Engine Timing Calibration required 0262 Volt Sensor Supply Short 0263 Digital Sensor Supply Short 0267 Incorrect Engine Shutdown Switch inputs 0268 Check Programmable Parameters 0273 Turbo Outlet Pressure 0274 Atmospheric Pressure 0275 Right Turbo Inlet Pressure 0342 Secondary Engine Speed Signal 0545 Ether Start Relay 0548 Throttle Lock Lamp 0549 Inncorrect Throttle Lock Switch inputs 0596 Unable to communicate with Machine ECM 0799 Need Service Tool update ¹ The CID is a diagnostic code that indicates which component is faulty. ² The MID is a diagnostic code that indicates which electronic control module diagnosed the fault. Connector Number CONN 1 CONN 2 CONN 3 CONN 4 CONN 5 CONN 13 CONN 15 CONN 17 CONN 18 CONN 19 CONN 20 CONN 21 CONN 22 CONN 23 CONN 24 Transmission Test Connector CONN 25 Calibr Press Sw Service Tool CONN 26 CONN 27 CONN 28 CONN 29 CONN 30 CONN 31 CONN 32 CONN 33 CONN 34 CONN 35 CONN 58 CONN 59 CONN 60 CONN 61 Schematic Location I-7 H-7 F-4 E-4 C-4 E - 10 D-8 E-7 D-7 C-7 B-7 B-6 B-6 C-6 D-6 E-6 B-5 D-4 I-3 C-2 C-2 D-2 E-2 E-2 F-1 F-1 I-2 I-2 I-2 I-2 Control Circuits (Continued) Machine Location E E E E E 21 55 48 J J 56 54 53 42 14 31 E J M 57 57 58 58 58 M M M M M M The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. Machine Location E - 15 1 G-5 3 Alarm - Backup Alternator (Tr) Schematic Location Machine Location Sensor (Tr) - Converter Oil Temperature I-5 26 Sensor (Tr) - Trans EOS I-5 23 Solenoid - A/C Compress H-4 3 Component 101 RD Unswitched Battery + 740 OR Scraper Xmsn Gear 3 102 BU Unswitched Battery + 741 YL Scraper Xmsn Gear 4 Battery (Tr) - (2) F-6 5 103 YL Unswitched Battery + 742 GN Scraper Xmsn Gear 5 Battery (Tr) - Backup (2) F-6 5 Solenoid - Apron Lower F-6 I Control - Engine ECM H-3 7 Solenoid - Apron Raise F-6 I Control - Stop/Tail Lamp G-7 9 Solenoid - Bowl Down F-6 I Ground - Chassis G-5 35 Solenoid - Bowl Up E-6 I Ground - Chassis (2) F-4 36 Solenoid - Cushion Hitch D-9 28 G-5 3 Solenoid - Ejector Forward E-6 I 105 BR Unswitched Battery + 743 PU Neutral Run SW 108 BU SW Battery + (Prelube Relay) 744 BU Scraper Xmsn Upshift Sol 109 OR Unswitched Battery + 745 GY Scraper Xmsn Downshift Sol 110 GN Unswitched Battery + 746 PK Scraper Xmsn Sync Sol 111 YL SW Battery + (Cigar_Lighter) A700 OR Digital Sensor Power +8V 112 PU SW Battery + A701 GY Injector 1 Ground - Engine (2) 113 OR +Battery (Tractor Ems) A702 PU Injector 2 Ground - Engine (3) E-3 16 Solenoid - Ejector Reverse E-6 I 114 GN SW Battery + (Horn Relay Pwr) A703 BR Injector 3 Horn - Fwd High D-1 10 Solenoid - Forward Auger E-9 48 115 PK SW Battery + (Spare) A704 GN Injector 4 Horn - Fwd Low D-1 11 Solenoid - Pilot D-7 J 116 BR SW Battery + (Diff Lock SW) A705 BU Injector 5 SW Battery + (Side Flood Lamp) A706 GY Injector 6 I-1 Solenoid - Rail Press Ctrl F-1 M YL Injectors M 117 118 GY SW Battery + (Wipers) A707 PU Injector 7 Lamp - Bowl Flood B-6 13 Solenoid - Reverse Auger E-9 48 120 YL SW Battery + (12V Converter) A708 BR Injector 8 Lamp - Cutting Edge Flood E-5 14 Solenoid (Sc) - Park Brake B-8 19 122 BU SW Battery + (Air Dryer) A745 WH Fuel Pressure Module - A/C Protection H-5 37 Solenoid (Tr) - Downshift D-7 J 123 WH SW Battery + (Bowl Flood Lamp) A746 PK Turbo Outlet Press Sensor Motor - Front Washer D-2 A Solenoid (Tr) - Start Aid C-1 29 124 GN SW Battery + (A/C) A747 GY Atmospheric Press Sensor Motor - Fuel Pump B-8 38 Solenoid (Tr) - Upshift D-7 J 125 OR SW Battery + (Fuel Pump) A751 YL Fuel Temp Sensor Motor - Rear Washer C-2 A Suppressor - Arc (Cushion Hitch) D-9 28 126 PK Battery + (24V) E707 GN Display Module Pwr Supply Motor (Tr) - Starter G-5 16 Switch - Motorcase Filter D-9 50 128 PK SW Battery + (Scraper) E708 PK Display Module Clock Receptacle (Tr) - AuxStart G-5 36 Switch - A/C Hi Pressure H-4 37 129 BU SW Battery + (Spare) E767 BU Aug Fwd Sol Resistor (Tr) - Starter/Diagnostic H-5 16 Switch - A/C Lo Pressure H-4 37 130 GN SW Battery + (Spare) E790 PK Sol Ret 133 OR Unswitched Battery + E793 BU Ata Data Link - Sender - Fuel Level B-8 20 Switch - Auger Reverse D-9 51 146 GY SW Battery + (Spare) E794 YL Ata Data Link + Sensor - Transmission Speed C-7 23 Switch - Charge Pump Filter E-7 52 147 PU SW Battery + (Spare) E795 YL Engine Oil Temp Sensor - Atmosphere Pressure H-1 M Switch - Differential Pressure I-5 30 148 WH Heat A/C Fan On E796 GN Rail Pressure Sensor - Backup Cam S/T G-1 M Switch - Ejector Kickout Press E-6 G 150 OR Unswitched Battery + (Eng) E797 WH Rail Pressure Control Ret Sensor - Coolant Temperature G-1 M Switch - Pump Case Drain E-7 53 165 YL SW Battery + (Spare) E798 PK Rail Pressure Control Sensor - Engine Oil Pressure H-1 M Switch - Supl. Steer Flow C-8 31 E799 BR 3.5A Driver Return Sensor - Engine Oil Temp G-1 M Switch (Sc) - Park Brake B-8 19 BU 3.5A Pwm Driver Sensor - Fuel Temperature G-1 M Switch (Tc) - Ground Level Shutdown C-1 41 42 Ground Circuits Scraper CAT Monitor System (MID No. 054)² Component Description Power Circuits Tractor CAT Monitor System (MID No. 030)² Connector Location for Vol 1. Component Location (Vol 1) Schematic Location 200 BK Main Chassis Ground F700 201 BK Ground (Tractor Ems) F701 BR 3.5A On/Off Driver Sensor - Inlet Air Temperature G-1 M Switch (Tr) - Actual Gear C-7 202 BK -Battery (Gnd) F702 GN Throttle Sensor 203 BK Chassis Ground F703 GY Mic Spare Sensor - Turbo Inlet Pressure I-5 24 Switch (Tr) - Coolant Flow F-1 M 204 BK Ground (Scraper Ems) F704 OR Mic Spare Sensor - Turbo Outlet Pressure H-1 M Switch (Tr) - Disconnect F-5 36 207 BK Starter Diagnostics Ground F705 PK Mic Spare Sensor - Primary Cam S/T H-1 M Switch (Tr) - Engine Oil Fuel Pump Pres H-5 16 228 BK Fuel Level Sender Ret F706 PU Mic Spare Sensor - Rail Pressure H-1 M Switch (Tr) - Parking Brake C-7 J 229 BK -Battery F707 WH Throttle Lock Lamp Sensor (Sc) - Air Pressure B-8 19 231 BK Xmsn SW F708 YL Ether Start Valve Relay Engage Machine locations are repeated for components located close together. 290 BK Service SW F709 BU Prelube Relay Engage 291 BK Clear SW F710 BR Mic Spare A234 BK Can Sheild F711 GN Can Data Link + A251 BK -Battery F712 GY Can Data Link - Tr = Tractor Sc = Scraper A = Located inside of cab. B = Located inside of right console. Basic Machine Circuits F713 OR Mic Spare 301 BU Starter To Starter Resistor F714 PK Turbo Inlet Press Sensor 302 OR Starter Resistor To Diagnostic F715 PU Ground Level Shutdown (No) 304 WH Starter Relay To Starter F716 WH Ground Level Shutdown (Nc) 306 GN Scraper Start Relay/Prelube F717 YL Throttle Lock SW (Lock Off) 307 OR Ecm Keysw (Mac-14) F718 BU Throttle Lock SW (Lock On) 308 YL Ecm Keysw (Abl) F719 BR Mic Spare 310 PU Scraper Start Aid Sol Engage F720 GN Start Aid SW 311 WH Scraper Coolant Temp SW F721 GY Mic Spare 320 OR Horn Relay Coil To Horn SW F722 OR Mic Spare 322 GY Warning Horn (Forward) F723 PK Bottom S/T Sensor + 323 WH Fuel Pump Pwr F724 PU Top S/T Sensor + 324 BU Diff Lock Sol Pwr F725 WH Mic Spare 326 PU Scraper Eng Shutdown F726 YL Injector Common 1 327 PK Engine Shutdown Sol (Scraper) F727 BU Injector Common 2 A309 GY Fuel Pump Enable F728 BR Injector Common 5 F729 GN Injector Common 6 Monitoring Circuits 403 GN Alternator (R) Terminal F732 PK Backup Camshaft Speed/Timing 405 GY Scraper Eng Oil Press SW F780 PK Operator Park Brake SW 410 WH Action Alarm (Tractor Ems) F789 YL Sol Ret 411 PK Action Lamp (Tractor Ems) F790 BR Sol Ret 412 BU Coolant Flow SW J764 BR SW And Sensor Gnd Ret 417 GY Supplemental Steering SW J766 PU Gnd For "SWitch To Gnd" 419 YL Tractor Park Brake Press SW J767 GY Sensor Ret 420 OR Fuel Filter Restrict K742 OR Top Drive Gear SW 421 BU Action Lamp (Scraper Ems) R713 OR Ejector Fwd Sol 441 OR Scraper Eng Coolant Temp Sender R714 BU Ejector Rev Sol 444 BU Torque Converter Temp Sensor R715 GN Bowl Up Sol 445 GN Torque Converter Temp Sender R716 PK Bowl Down Sol 447 PK Fuel Level Sensor R717 BR Apron Raise Sol 450 YL Eng Speed Sensor + R720 GY Apron Lower Sol 451 BR Eng Speed Sensor - R721 YL Ejector Cylinder Press SW C413 YL Display Module Data R722 PU Pilot Sol C414 BU Output R732 BR Hydraulic Oil Temp Sensor C436 BU Auger Filter SW R733 GN Neutral Run SW Jumper C457 BU Scraper Air Press Sensor R734 WH Pilot Air Press Sensor C465 OR Tractor Air Press Sensor R736 PK Scraper Park Brake Press SW E453 WH Motor Case Filter SW R737 YL Scraper Eng Start (Cab) R738 BU Scraper Eng Ether Aid (Cab) R739 GN Scraper Eng Shutdown (Cab) R741 YL Scraper Mode Select Lamp E485 Accessory Circuits 500 BR Front Wiper (Park) 501 GN Front Wiper (Lo) R742 YL Tractor Mode Select Lamp 502 OR Front Wiper (Hi) R745 OR Apron Float Lamp 503 BR Rear Wiper (Park) R748 BR Ejector Return Lamp 504 YL Rear Wiper (Lo) R749 BU Apron/Elev Joystick Command 505 BU Rear Wiper (Hi) R750 GN Ejector Joystick Command 506 PU Front Washer R752 YL Bowl Joystick Command 507 WH Rear Washer R756 WH Cushion Hitch SW (No) 508 PU Left Radio Speaker R757 BR Cushion Hitch SW (Nc) 509 WH Left Radio Speaker Common R758 PK Gear Hold SW (No) 511 BR Right Radio Speaker R759 BU Gear Hold SW (Nc) 512 GN Right Radio Speaker Common R760 GN Bail/Aug Fwd/Elev Set SW (No) 515 GY Blower Motor (Hi) R761 YL Bail/Aug Fwd/Elev Set SW (Nc) 516 GN Blower Motor (Med) R762 GY Tractor Mode Select SW 517 BU Blower Motor (Lo) R763 BU Scraper Mode Select SW 521 YL A/C SW To A/C Press SW R764 WH Gear Hold Lamp 522 WH A/C Compressor To Thermostat R765 OP Aug Rev SW (Nc) 537 GN Flasher Control R766 PU Aug Rev SW (No) 592 BU +12V Pwr R767 YL Service Brake Press SW Jumper 597 PU Hi Press SW To Lo Press SW X796 PU Backup Alarm A513 PK +12V Memory 892 BR Cat Data Link (-) A519 GN Cushion Hitch Sol 893 GN Cat Data Link (+) A523 PU Temp Potentiometer Pos 1 F835 BU Operator SW A524 BR Temp Potentiometer Pos 2 H807 YL On/Off Driver Ret 1-4 (Abl) A525 GN Temp Potentiometer Pos 3 J807 BK Proportional Ret 1-4 (Abl) A526 PK Electronic Water Valve Actuator J808 BK Proportional Ret 5-8 (Abl) A527 BU Electronic Water Valve Actuator J809 BK Proportional Ret 9-12 (Abl) A528 YL Electronic Water Valve Actuator J813 BK Proportional Ret 13-16 (Abl) A529 WH Electronic Water Valve Actuator J814 BK Proportional Ret 17-20 (Abl) A530 OR Electronic Water Valve Actuator 918 OR Eng Ovrspd Lamp And Alarm A535 GN Throttle Lock Sol 919 GN Eng Ovrspd Test SW A572 PK Lo Press SW To Controller 993 BR Analog Sensor Ret C558 BU Front Wiper SW Jumper 994 GY Oil Pressure Sensor C559 GN Rear Wiper SW Jumper 995 BU Eng Coolant Temp Sensor E554 PK Controller To A/C Clutch Lighting Circuits 996 GN Eng Speed/Timing Sensor Pwr 997 OR Machine Analog Sensor Pwr +5V 601 GY Scraper Dash Lamp 998 BR Digital Sensor Ret 602 WH Dome Lamp 999 WH Primary Cam S/T Sensor 604 OR Stop Lamp Signal A958 WH Tractor Park Brake Sol 605 YL Left Turn Lamp C967 BU Inlet Air Temp Sensor 606 GY Right Turn Lamp C992 PU Service Brake Press SW 608 GN Bowl Flood Lamp E965 BU Top S/T Sensor - 609 YL Side Flood Lamp E966 YL Top S/T Sensor + 610 OR High Beam Relay Engage E973 GY Retarder Press SW 611 PU High Beam Headlamp K901 WH Air Compressor Solenoid 614 PU Park/Tail/Dash Lamp K927 BU Sol Return (Mac-14) 619 GN Low Beam Headlamp K966 PU Elev En/Aug Rev Sol 639 WH Left Stop/Tail Lamp K968 GN Auger Slip Limit SW 640 GN Right Stop/Tail Lamp K969 GY Scraper Slip Limit Sol 661 GN Tachometer Back Light K970 OR Elevator Speed Sol 662 YL Speedometer Back Light L983 WH Injector Common 1 663 GY Quad Gage Back Light L984 OR Injector Common 3 Control Circuits L985 YL Injector Common 5 M904 OR Calibration Press SW (No) 703 BU Tractor Xmsn Upshift Sol 704 GY Tractor Xmsn Downshift Sol M905 WH Calibration Press SW (Nc) 709 OR +10V Sensor Power Supply M997 PU Gear Selector 710 GN Xmsn Output Speed N940 BU Engine Analog Sensor Pwr +5V 721 BR Tractor Xmsn Gear 1 N941 YL Engine Analog Sensor Ret 722 WH Tractor Xmsn Gear 2 N942 OR Mic Spare 723 OR Tractor Xmsn Gear 3 N943 BR SWitch 1 (Spare) 724 YL Tractor Xmsn Gear 4 N944 PU Tractor Eng Coolant Flow SW Ret 725 GN Tractor Xmsn Gear 5 N948 GN Scraper Park Brake Sol 726 BU Xmsn Gear Ground Verify P988 OR Bail/Elevator Direction Sol 738 BR Scraper Xmsn Gear 1 P991 PK Operator SW (Scraper_Ems) 739 WH Scraper Xmsn Gear 2 T Pressure Symbol Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. 631G Wheel Tractor-Scraper Electrical System Sender - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. AWK1-UP (Machine) AXZ1-UP (Scraper) Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols * Harness identification letter(s) and a serializing code. The "C" stands for connector and the number indicates which connector in the harness. Harness identification code This example indicates wire 135 in harness "AG". Wire, Cable, or Harness Assembly Identification Part Number For L-C12* AG-C4* Connector Assembly 3E-5179 111-7898 325-A135 PK-14 1 * * AG-C3 C-C4 130-6795 130-6795 325-A135 PK-14 Socket Pin Single Wire Connector Wire Gauge Wire Color Receptacle Plug Ground Circuit Connection Number Identification 2 200-L32 BK-14 20 30 29 36 7 10 24 54 26 39 M 58 28 16 37 47 11 41 B D 57 J 50 35 3 31 53 55 51 56 I G H 13 38 52 42 19 1 23 14 43 L 48 9 21 1 2 Resistor, Sender and Solenoid Specifications Component Description 44 E 45 46 C Component Part Number Resistance (Ohms)¹ 3E-1906 3E-6333 3E-7842 Solenoid: Solenoid: Resistors: 9G-1950 Resistor: 9X-9482 Solenoid: 107-0677 122-1134 Solenoid: Solenoid: 144-6292 Solenoid: Downshift Upshift 32.6 ± 1.6 144-9527 Solenoid: Auger Forward Auger Reverse 32.6 ± 1.6 152-8339 Solenoid: Cushion Hitch 32.6 ± 1.6 156-2829 Solenoid: Bowl Down Bowl Up Ejector Rev Ejector Fwd Apron Lower Apron Raise 5.0 ± .3 162-8350 Sender: 184-7687 Solenoid: A F 105-9344 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Volume 1 Part No. Fuse Pin or Socket Number Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 5 Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. H = Located in scraper engine control panel. I = Located on implement valve. J = Located around top of XMSN. K = Located around top of scraper XSMN. L = Located in cab headliner. M = Located on tractor engine. C = Located inside of left console. D = Located around relay panel. E = Located around hydraulic oil tank. F = Located around pilot manifold. G =Located under platform. Electrical Schematic Symbols And Definitions RENR1597 April 2001 Air Conditioner Compressor Tractor Start Aid Starter Motor 17.6 ± 0.6 6 150 ± 7.5 Overall 2 ± .1 Tap 1.0 ±. .05 Blower Scraper Park Brake Brake Air Supply Differential Lock Tractor Park Brake Rail Press Ctrl Pilot 42.4 ± 2.1 10.1 @ 20°C 41.9 Empty: 92 to 98 Full: 0 to 3 Fuel Level Injectors 2.1 ± .2 ¹ At room temperature unless otherwise noted. 13 50 A D F 29 28 47 7 37 B 24 3 41 5 44 57 36 30 9 G C M 10 11 56 43 L Part No. 20 I 53 E 45 46 35 51 J 16 31 26 21 48 52 23 42 Deactuate Contact Position 80 kPa (11.6 psi.) 55 ± 20 kPa (8 ± 2.9 psi.) Normally Closed 3E-2034 3E-7799 Ejector Kickout Pressure 11700 ± 170 kPa (1696 ± 24.6 psi) 10000 kPa MIN (1450 psi MIN) 1-3 Normally Closed 1-2 Normally Open 8T-9792 Tractor Park Brake Scraper Park Brake 517 ± 35 kPa (75.0 ± 5.1 psi) 448 ± 35 kPa (65.0 ± 5.1 psi) 1-3 Normally Closed 1-2 Normally Open 107-0612 Engine Oil Fuel Pump 93 ± 21 kPa (13.4 ± 3 psi) 70 ± 21 kPa (10 ± 3 psi) Normally Open 114-5333 A/C Hi Pressure 275 to 1750 kPa¹ (40 to 255 psi.) --- Normally Open² 117-7773 Motor Case Filter Change Pump Filter Pump Case Drain Filter 138 ± 28 kPa (20 ± 4.1 psi.) 69 kPa (10 psi.) Normally Closed 119-7870 Supl Steering Flow 4 grams MAX (0.1 oz MAX) 1.5 grams MIN (0.5 oz MIN) Normally Open 125-9352 Stop Lamp 83 kPa (12 psi) 48 ± 20 kPa (7 ± 2.9 psi) Normally Open 144-5661 Differential Pressure 137.9 ± 13.8 kPa (13.4 ± 3 psi) 70 ± 21 kPa (10 ± 3 psi) Normally Open 149-6371 A/C Lo Pressure 103.4 ± 13.8 kPa (15 ± 2 psi.) 34.5 ± 7 kPa (5 ± 1 psi.) Normally Open 171-8780 Coolant Flow 362 ± 29 mN (1.30 ± 0.10 oz) 303 mN MIN (1.08 oz MIN) Normally Open ¹ With increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). Machine Harness Connector And Component Locations 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 38 Actuate Retarder Pressure Tractor Service Brake Scraper Service Brake 14 19 FMI No. Off Machine Switch Specification 1 54 55 Function ² Contact Position at the contacts of the harness. Failure Mode Identifiers (FMI)¹ Failure Description Data valid but above normal operational range. Data valid but below normal operational range. Data erratic, intermittent, or incorrect. Voltage above normal or shorted high. Voltage below normal or shorted low. Current below normal or open circuit. Current above normal or grounded circuit. Mechanical system not responding properly. Abnormal frequency, pulse width, or period. Abnormal update. Abnormal rate of change. Failure mode not identifiable. Bad device or component. Out of calibration. Parameter failures. Parameter failures. Parameter not available. Module not responding. Sensor supply fault. Condition not met. Parameter failures. ¹The FMI is a diagnostic code that indicates what type of failure has occurred. Monitoring System Modes Mode of Operation Mode Number Operator 0 Machine Code 1 Parameter Display 2 Diagnostic Servicing 3 Digital Tattletale 4 Units 5 Machine Machine Code Related Electrical Service Manuals Title Form Number Alternator (Tractor): 3E-7577 SENR 7507 CAT Monitoring System Tractor SENR 4100 Tractor Transmission Control SENR 4097 Implement Control SENR 4099 Engine Control Code 631G 54 631G with Auger Attached 52 Starter Motor Tractor: SENR1037 6V-0890 (50MT) SENR 3860
Wire Description Wire Number Wire Color AA1 AA2 AC200 AE200 CA281 CA282 CA283 CA312 CA313 CM6 CM9 CM11 CM18 CM20 CM31 CM39 CM42 CM76 CM78 CM89 CM94 CM101 CM102 CM108 CM109 CM114 CM123 CM124 CM139 CM144 CM155 CM169 CM171 CM174 CM175 CM186 CM187 CM189 CM191 CM197 CM204 CM217 CM218 CM219 CM221 CM225 CM231 CM234 CM235 CM236 CM241 CM243 CM249 CM260 CM264 CM271 CM272 CM275 CR131 CR132 CR139 CR140 CR195 CR196 CR197 CR198 FM4 FM10 FM14 FM15 FM16 FM17 FM176 FM177 FM181 FM186 FM187 FM188 FM240 FM72 FM8 GG3 HH4 JJ5 RH11 RH13 RH15 RH17 RH21 RH26 RH27 RH29 RH30 RH76 RH77 RH78 RH79 RH80 RH219 RH220 RH262 RM4 RM67 RM68 RM69 RM70 RM71 RM73 RM74 RM75 RM91 RM93 RM98 RM99 RM100 RM101 RM102 RM108 RM109 RM112 RM113 RM120 RM121 RM122 RM123 RM124 RM125 RM204 RM249 RM317 SS100 SS103 SS106 SS249 BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK AE617 CM3 CM3 CM23 CM23 CM24 CM24 CM25 CM28 CM28 CM32 CM33 CM33 CM34 CM37 CM43 CM44 CM45 CM46 CM47 CM47 CM49 CM104 CM207 CA284 CA285 CA286 CA287 CA288 CA289 CA290 CA291 CA301 CA302 CA304 CA305 CA310 CA311 CM72 CM81 CM87 BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR BR Description Ground Circuits Battery (Neg) Battery (Neg) Trailer Jumper Trailer Jumper PP1 Relay Ground Trailer Acc 1 Relay Ground Power Plug Relay Ground Ground Aux 1 Ground Aux 2 Battery - (Ground) Cold Start Relay Alarm Horn / Shutdown Overrde Sw Fuel Sol Pull - In Relay Shutdown Override Sw Aux #1 Relay Inching Clutch Pot / Sensor V- (Gnd) Battery - (Ground) PTO Relay Brake Lamp Relay Ground XSMN Dir Interrupt Relay XSMN Pwr Relay Battery - (Ground) Creeper Sw RH Dome Lamp Dome Lamp LH & RH Hazard Sw Converter Module Ground Flasher Module Ground Lamp GP Ground Lamp GP Ground Beacon Lamp SW Console / Dome Lamp RH & LH RH Console Lamp Ground Rear Lower Flood Lamp Ground Rear Lower Flood Lamp Ground Front / Mid Floods Relay Lower Cab Rear Floods Relay Upper Cab Rear Floods Relay Upper Cab Front Floods Relay Cigarette Lighter DAM Connector Rear Washer Motor Ground Front Washer Motor Ground Rear Wiper Ground Aux #2 Relay Accessory Socket Ground Upper Height Limit SW Radio LH Speaker Radio Ground Radio RH Speaker Accessory Relay HVAC Unit - Ground Implement Socket Relay Ground CAN Serial Data DAM Connector Implement Socket Ground Front Wiper Motor CAN Data Left Turn Lamp Ground Left Turn Signal Right Turn Lamp Right Turn Lamp Ground Front Upper Flood Lamp Front Upper Flood Lamp Rear Upper Flood Lamp Ground Rear Upper Flood Lamp Ground Start Relay Fuel Shutoff Sol Eng Oil Press Sensor Start Relay Coolant Temp Sensor Aftercooler Temp Sensor LH Lamp Assy - Ground LH Lamp Assy - Ground LH Lamp Assy/ Horn- Ground Front Mid Lower Flood Lamp Front Mid Lower Flood Lamp Inlet Air Heater Relay A/C Clutch Fuel Level Sender Start Aid Solenoid Starter Ground Engine Ground AIH Relay Sensivity Pot Ground Drop Rate Pot Ground Height Limit Pot Ground Cold Start Selay Quandrant Lever Pot Ground 3 Point Hitch Ind Lamp Ground 3 Point Hitch Ind Lamp Ground PTO Ind Lamp Ground Gear Shift Sw - Battery - (Ground) Sensor VBattery - (Ground) Battery - (Ground) Battery - (Ground) Console Control Sw Ground Console Control Sw Ground Console Control Sw Ground CAN Data Trailer Socket Ground Battery - (Ground) Radar Gun L Draft Pin Sensor Ground RH Draft Pin Sensor Ground Rockshaft Pot Ground XSMN Temp Sender Ground XSMN Speed Sensor Ground Engine RPM Sensor PTO Sol Valve Gnd Steering Reverse Sol Ground EDC Raise Return 3 Pt Raise Sol Valve Ground 3 Pt / EDC Lower XSMN Sol MC1 Ground XSMN Sol MC 2 Ground XSMN Sol C Ground XSMN Sol Creeper Ground XSMN Sol A Ground XSMN Sol B Ground XSMN Sol F1 Ground XSMN Sol F2 Ground XSMN Sol Rev Ground XSMN Sol #1 Ground XSMN Sol #2 Ground XSMN Sol #3 Ground Center Rear Lower Flood Lamp Gnd Suppl Steer Ground Splice to Splice Sec Steer Sec Steer Sec Steer Sec Steer Keyed Power Circuits Trailer Jumper Air Inlet Heater Sw Shutdown Override Sw Shutdown Override Sw Key Sw - Starter / Run Aux #1 Relay Key Sw - Starter / Run XSMN Pwr Relay Aux #2 Relay XSMN Pwr Relay Aux #1 Relay V Pwr Fuse - F23 Battery + (Switched) V Pwr Fuse - F23 Inching Clutch Pot / Sensor V+ Front Console Fuse - F23 LH 3 Point Hitch Sw Power RH 3 Point Hitch Sw Power LH Brake Sw - Not Used LH Brake Sw - Not Used RH Brake Sw Creeper Sw / RH Brake Sw Switch / Radar Fuse - F20 Front Wiper Fuse - F3 PP1 Sw Relay Output PP2 Sw Relay Output Trailer Acc1 Output Trailer Acc2 Output PP1 Sw Relay Enable PP2 Sw Relay Enable Trailer Acc1 Relay Enable Machine Run Signal Trailer Acc1 Fuse Trailer Acc2 Fuse Power Trailer Acc2 (Fuse) Power Trailer Acc2 (Fuse) Power Aux2 Sw (Fuse) Power Aux1 Sw (Fuse) Battery + Switched RH Console Fuse - F21 XSMN Dir Interrupt Relay Wire Number CM87 CM88 CM92 CM95 CM96 CM96 CM97 CM208 CM210 CM213 CM215 CM222 CM226 CM232 CM239 CM245 CM248 FM6 FM18 FM64 RH3 RH4 RM5 RM6 RH7 RH8 RH9 RH40 RH41 RH42 RH43 RH44 RH45 RH71 RH73 RH221 RH222 RM50 RM60 RM61 RM62 RM63 RM64 RM87 RM88 RM245 SS105 SS110 SS111 SS248 CM41 CM51 CM51 CM52 CM53 CM54 CM56 CM107 CM110 CM111 CM115 CM116 CM117 CM118 CM119 CM120 CM121 CM122 CM125 CM126 CM127 CM130 CM132 CM133 CM134 CM138 CM140 CM142 CM143 CM150 CM151 CM153 CM156 CM157 CM158 CM159 CM160 CM161 CM163 CM164 CM166 CM166 CM167 CM168 CM170 CM178 CM180 CM182 CM184 CM185 CM188 CM190 CM192 CM193 CM201 CM202 CM203 CR129 CR130 CR137 CR138 CR189 CR191 CR193 CR194 FM167 FM170 FM182 FM183 FM184 RM55 RM131 RM135 RM141 RM159 RM162 RM203 SS107 CM2 CM7 CM12 CM27 FM3 FM7 FM11 FM12 RH2 RH60 RH61 RM12 RM280 RM299 RM304 RM305 AE A571 CM10 CM19 CM19 CM21 CM40 CM68 CM70 FM13 FM77 FM84 FM85 RH23 RH24 RH35 RH36 RH37 RH38 RH39 RH49 RH50 RH69 RM11 RM13 RM77 RM78 RM79 RM80 RM85 Wire Description Color Keyed Power Circuits Cont BR PTO Relay BR XSMN Shift Sol (2) Fuse - F19 BR XSMN Pwr Relay BR XSMN Shift Sol (1) Fuse - F18 BR XSMN Dir Interrupt Relay BR PTO Sol Fuse - F20 BR XSMN Dir Interrupt Relay BR Rear Wiper Fuse - F3 BR Front Wiper Motor BR Aux #2 Relay BR Rear Wiper BR Movable Console Fuse - f15 BR Accessory Socket Fuse - F1 BR Radio Fuse - F17 BR Accessory Relay BR A/C Control Fuse - f2 BR Implement Socket BR Alternator R-Terminal BR Air Filter Vacuum Sw BR Eng Oil Press Sensor BR Sensor V+ BR Quandrant Lever Pot BR XSMN Oil Sw BR Alternator R-Terminal BR Height Limit Pot BR Drop Rate Pot BR Sensivity Pot BR PTO Start / Stop Sw BR Gear Shift Sw - Batt + Switched BR Autoshift Sw BR Raise / Work Sw Power BR Not Used BR Program Shift Sw BR Battery + Switched BR Battery + Switched BR Console Control Sw BR Console Control Sw BR Radar Gun BR Sensor V+ BR Sensor V+ BR L Draft Pin Sensor VS BR RH Draft Pin Sensor VS BR Rockshaft Pot VS BR Steering Filter Sw BR Hydraulic Filter Sw BR RH Track Sw BR Sec Steer BR Sec Steer BR Sec Steer BR Sec Steer Power Lighting Circuits BU Park Lamp Sense BU Not Used BU RH Brake Sw BU Brake Lamp Relay BU Lamp GP BU Lamp GP BU RH Brake Sw / Brake Lamp Relay BU RH Dome Lamp BU LH Dome Lamp BU Dome Lamp LH & RH BU Hazard Sw / Converter Module LH BU Hazard Sw / Flasher Module Out BU Hazard Sw / Flasher Module Batt+ BU Flasher Module Trlr Ind 2 BU Flasher Module Trlr Ind 1 BU Hazard / Turn / Horn / Hi Beam Sw BU Hazard Sw / Converter Module RH BU Flasher / Converter Module Batt + BU RH Turn / Horn / Hi Beam Sw BU LH Turn / Horn / Hi Beam Sw BU Converter Module LH Signal Out BU Lamp GP BU Left Turn Signal BU Right Turn Signal BU Converter Module RH Signal out BU Lamp GP BU Turn / Horn / Hi Beam Sw BU Roadlamps Low Beam Fuse - F29 BU Lamp GP BU Rotary Light Sw BU Rotary Light Sw BU Rotary Light Sw BU Turn / Horn / Hi Beam / Rotary Sw BU LH Park Lamp Fuse - F9 / Rotary BU Park Lamps Fuse - F8 / F9 BU RH Park Lamp Fuse - F8 BU RH Park Lamp Fuse - F8 BU LH Park Lamp Fuse - F9 BU Lamp GP BU RH Console Lamp BU Hi Beam Fuse - F28 BU Turn / Horn / Hi Beam Sw BU Roadlamps Hi Beam Fuse - F28 BU LH Console & Dome Lamp BU Roadlamps Low Beam Fuse - F29 BU Work Lamp 1 Enable - Ft / Mid BU Work Lamp 2 Enable - Low RR BU Work Lamp 3 Enable - Up RR BU Work Lamp 4 Enable - Up Ft Relay BU Front / Mid Floods Relay BU Lower Cab Rear Floods Relay BU Upper Cab Rear Floods Relay BU Upper Cab Front Floods Relay BU Hi Beam Indicator Fuse - F28 BU Rear Lower Flood Lamp BU Rear Lower Flood Lamp BU Center Rear Lower Flood Lamp BU Left Turn Signal BU Left Turn lamp BU Right Turn Lamp BU Right Turn Lamp BU Rear Upper Flood Lamp BU Rear Upper Flood Lamp BU Front Upper Flood Lamp BU Front Upper Flood Lamp BU LH Lamp Assy - Hi Beam BU LH Lamp Assy - Lo Beam BU Front Mid Lower Flood Lamp BU Front Mid Lower Flood Lamp BU LH Lamp Assy - Front Lower Flood BU Trailer Socket Stop BU Trailer Socket RH Turn BU Trailer Socket LH Turn BU Trailer Socket Work Lamp BU Trailer Socket LH Tail BU Trailer Socket RH Tail BU Center Rear Lower Flood Lamp BU Sec Steer Starting Circuits OR Key Sw - Start OR Cold Start Relay OR Fuel Sol Pull-In Relay OR Shutdown Override Sw OR Start Relay OR Start Aid Solenoid OR Inlet Air Heater Relay OR Fuel Shutoff Sol OR Gear Shift Sw - Key Switch OR Neutral Start Signal OR Gear Shift Sw - Neutral Start OR VIMS Display Data OR Power Suppl Steer (Conn) OR Power Trailer Acc1 OR Power Trailer Acc1 (Fuse) OR Power Trailer Acc2 (Fuse) Module Signal Out Circuits PU Trailer Jumper PU Cold Start Enable / Relay PU Fuel Sol Pull - In Relay PU Fuel Pull - In Relay PU Audible Alarm Control PU Imp Status Sw PU VPP / In Signal PU DAM Connector PU Fuel Shutoff Sol PU Fuel Level Sender PU Artercooler Temp Sensor PU Coolant Temp Sensor PU SLP Status Ind Lamp PU 3 Point Hitch / EDC Ind Lamp PU Downshift Signal PU Upshift Signal PU Reverse Signal PU Forward Signal PU Pto Status Ind Lamp PU Spare PU Diff Lock Pilot Ind Lamp PU VPP / In Signal PU Inlet Air Relay PU Fuel Hold-In Sol PU Fuel Level Sender PU XSMN Temp Sender PU XSMN Speed Sensor PU Engine RPM Sensor PU Coolant Temp Signal Wire Number FM86 CM90 CM98 CM99 CM100 CM254 CM256 CM270 RH135 RH136 RH137 RH138 RM92 RM94 RM97 RM99 RM105 RM106 RM107 RM110 RM111 RM114 RM115 RM116 RM117 RM118 RM119 FM2 CA300 CA303 CA306 CA307 CA308 CA309 CC6 CC7 CC8 CM8 CM14 CM15 CM26 CM35 CM36 CM48 CM50 CM57 CM75 CM77 CM91 CM93 CM105 CM106 CM112 CM113 CM145 CM146 CM147 CM148 CM149 CM176 CM177 CM179 CM181 CM183 CM205 CM205 CM227 CM228 CM240 CM240 CM246 CM247 CM252 CM258 CM259 CM263 EE9 FF10 FM5 KK11 RH261 RH74 SS480 CM29 CM165 CM206 CM209 CM211 CM212 CM214 CM216 CM223 CM224 CM229 CM233 CM237 CM244 CM245 CM273 CR152 CR153 FM165 FM244 RH223 RH224 RM244 AC618 AE605 CM13 CM22 CM38 CM58 CM59 CM60 CM61 CM62 CM63 CM64 CM65 CM66 CM67 CM82 CM83 CM84 CM85 CM86 CM103 CM253 CM255 CM269 FM59 FM81 RH10 RH12 RH14 RH16 RH20 RH25 RH31 RH47 RH48 RH49 RH51 RH52 RH54 RH55 RH56 RH57 RH58 RH59 RH62 RH85 RM51 RM52 RM53 RM54 RM56 RM57 RM59 RM81 RM83 RM89 RM90 RM246 RM247 RM251 SS60 SS101 SS102 SS104 SS109 Wire Description Color Module Signal Out Circuits Cont PU Coolant Level Sender PU DAM Connector PU DAM Connector PU DAM Connector PU Vpp / In Signal PU DAM Connector PU DAM Connector PU DAM Connector PU Gear Shift Sw - Down-Shift PU Gear Shift Sw - Up-Shift PU Gear Shift Sw - Reverse PU Gear Shift Sw - Forward PU PTO Sol Signal PU Steering Reverse Sol PU 3 Pt / EDC Raise Sol PU 3 Pt / EDC Lower Sol PU XSMN Sol MC1 PU XSMN Sol Creeper PU XSMN Sol C PU XSMN Sol B PU XSMN Sol A PU XSMN Sol #3 PU XSMN Sol #2 PU XSMN Sol #1 PU XSMN Sol Rev PU XSMN Sol F2 PU XSMN Sol F1 Battery Unswitched Circuits RD Start Relay RD Aux2 Sw Fuse RD Aux1 Sw Fuse RD Aux1 Unsw Fuse RD Aux2 Unsw Fuse RD Power Aux2 Unsw (Fuse) RD Power Aux1 Unsw (Fuse) RD Battery (Pos) RD Battery (Pos) RD Battery (Pos) RD Cold Start Fuse - F27 / Relay RD Fuel Sol Pull-In Relay RD Main Power #1 Fuse - MF2 RD Key Switch Fuse - F26 RD KAM Fuse - F25 (Batt+ Unswitched) RD KAM Fuse - F25 RD Park Brake Sw RD Brake Lamp Relay Fuse - F14 RD Brake Lamp Fuse - F12 / Relay RD Radio B+ Mem RD DAM Connector / Fuse - F27 RD Main XSMN Pwr Fuse - MF3 / Relay RD Battery + Unswitched RD Dome Lamp LH & RH RD Dome Lamp Fuse - F14 / RH Dome Lamp RD Turn Signals Fuse - F24 / Hazard Sw RD Hazard Fuse - F13 / Hazard Sw RD Main Road Lamp Fuse - MF4 RD Main Work Lamps Fuse - F10 / Rot Sw RD Cigarette Lighter Fuse - F11 RD Horn / Beacon Fuse - F11 / Switch RD Turn / Horn / Hi Beam / Beacon RD Main Work Lamp Fuse - MF5 RD Front / Mid Floods Fuse - F4 / Relay RD Low Cab RR Floods Fuse - F5 / Relay RD Up Cab RR Floods Fuse - F6 / Relay RD Up Cab FT Floods Fuse- F7 / Relay RD Main Acc Power (Fuse) RD Main Acc Fuse - MF6 / Aux #2 Relay RD Seat Fuse - F16 / Height Adjust Sw RD Operator Presence Sw RD Main Power 2 (Fuse) RD Mn Power #2 Fuse - MF7 / Acc Relay RD Implement Monitor (Fuse) RD Imp Monitor Fuse - F30 / Imp Socket RD Main Implement Socket Fuse - MF8 RD Implement Socket Relay RD CAN Serial Data + RD DAM Connector RD Maxi Fuse Power RD Alternator Ground RD Starter / Alternator RD Starter Power Stud RD CAN Data + RD Battery + Unswitched RD Sec Steer Accessories Circuits WH Key Sw - (Acc / Run) / Acc Relay WH Turn / Horn / Hi Beam Sw - Horn Out WH Rear Wiper WH Front Washer Motor WH Front Wiper Motor WH Front Wiper Motor WH Rear Washer Motor WH Rear Wiper WH Console Motor WH Console Motor WH Seat Switch WH Radio LH Speaker + WH Radio RH Speaker + WH HVAC Unit - Compressor Relay WH HVAC Unit - Switched Power WH Front Wiper Motor WH Beacon WH Beacon WH Forward Warning Horn WH A/C Clutch WH Console Control Sw WH Console Control Sw WH AC Control Power Module Signal In Circuits YL Trailer Jumper YL Trailer Jumper YL Air Inlet Heater Sw YL Shutdown Override Sw YL Inching Clutch Pot YL RH Brake Sw YL LH Brake Sw - Not Used YL Park Brake Sw YL Creeper Ind Lamp / Switch YL RH 3 Point Hitch Sw Signal YL RH 3 Point Hitch Sw Signal YL LH 3 Point Hitch Sw Signal YL LH 3 Point Hitch Sw Signal YL HPL External Lower Signal YL HPL External Lower Signal YL Clutch Sw YL XSMN Dir Int Relay / Clutch Sw YL PTO Relay YL PTO Relay YL PTO Relay / Solenoid YL Creeper Sw YL DAM Connector YL DAM Connector YL DAM Connector YL Eng Oil Press Sensor YL Air Filter Vacuum Sw YL Draft Mix / Sensitiviy Pot YL Drop Rate Pot YL Draft Height Limit Pot YL Draft Slip Limit YL Quandrant Lever Pot YL PTO Start / Stop Sw YL PTO Start / Stop Enable YL Raise / Work Sw YL Raise / Work Sw YL Not Used YL Not Used YL Not Used YL Program Shift Sw YL Program Shift Sw YL Autoshift Sw YL Gear Shift Sw - XSMN Enable Signal YL XSMN Enable YL Not Used YL PTO Start / Stop Sw Signal YL PTO Start / Stop Sw Signal YL XSMN Oil Press Sender YL Radar Gun YL Radar Signal YL LH Draft Pin Sensor YL RH Draft Pin Sensor YL Rockshaft Pot YL Engine Oil Press Sender Signal YL Air Filter Clog Signal YL Hyd Filter Sw / XSMN Filter Sw YL Steering Filter Sw YL XSMN Filter Press Sw YL LH Track Tension Sw YL RH Track Tension Sw YL Sec Steer Relay YL Sec Steer YL Sec Steer YL Sec Steer YL Sec Steer YL Sec Steer Fault Codes 3-Point Hitch Function and Electronic Draft Function F001, Transient reset F002, CCM internal error - channel lockup F003, True ground speed greater than transmission speed F004, Transmission speed greater than maximum speed F008, Raise/Work switch failed high F009, Fender three-point switches - both activated F010, Height limit pot failed low F011, Height limit pot failed high F012, Drop rate pot failed low F013, Drop rate pot failed high F014, Right draft pin failed low F015, Right draft pin failed high F016, Left draft pin failed low F017, Left draft pin failed high F018, Both draft pins disconnected/failed F019, 8 Volt draft pin supply failed low F020, 8 Volt draft pin supply failed high F021, Sensitivity pot failed low F022, Sensitivity pot failed high F024, Perform hitch calibration (Mode 11) F025, Three-point lever position pot failed low F026, Three-point lever position pot failed high F027, Rockshaft pot failed low F028, Rockshaft pot failed high F029, Both three-point solenoid valves - low current F030, All three-point pots signal failed high F057, Both three-point solenoid valves on w/o command F058, Draft pin and rockshaft signal failed high F059, Raise/Work switch - failed low F063, Three-point lower solenoid - low current F064, Three-point raise solenoid - low current F098, Rockshaft signal noise F099, Three-point pots signal noise Right Hand Controls (RHC) F100, RHC sensor 5 volt supply failed low F101, RHC sensor 5 volt supply failed high F102, Up shift switch failed high F103, Up shift switch failed low F104, Down shift switch failed high F105, Down shift switch failed low F106, Reverse shift switch failed high F107, Reverse shift switch failed low F108, Forward shift switch failed high F109, Forward shift switch failed low Electronic Monitoring Center (EMC) F200, EMC 5 volt supply failed low F201, EMC output circuit short F202, CAN error between EMC and RHC F203, CAN error between EMC and draft control circuits of CCM F204, CAN error between EMC and transmission control circuits of CCM F205, Features disagree F207, Brakes engaged while moving F208, EMC sensor 5 volt supply failed high F209, Air inlet heater switch stuck on Transmission Control Function F300, Transmission solenoid 1 - high current F301, Transmission solenoid 2 - high current F302, Transmission solenoid 3 - high current F303, Transmission solenoid A - high current F304, Transmission solenoid B - high current F305, Transmission solenoid C - high current F306, Transmission solenoid F1 - high current F307, Transmission solenoid F2 - high current F308, Transmission solenoid MC1 - high current F309, Transmission solenoid MC2 - high current F310, Transmission solenoid REV - high current F311, Transmission solenoid CREEPER - high current F312, Air inlet heater relay - high current F313, Fuel hold-in solenoid - high current F314, PTO solenoid - high current F315, Steering reverse solenoid - high current F316, Fuel pull-in relay - high current F317, Connector C003 - open F318, Connector C002 - open F319, Connector C001 - open F320, Transmission solenoid 1 - low current F321, Transmission solenoid 2 - low current F322, Transmission solenoid 3 - low current F323, Transmission solenoid A - low current F324, Transmission solenoid B - low current F325, Transmission solenoid C - low current F326, Transmission solenoid F1 - low current F327, Transmission solenoid F2 - low current F328, Transmission solenoid MC1 - low current F329, Transmission solenoid MC2 - low current F330, Transmission solenoid REV - low current F331, Transmission solenoid CREEPER - low current F332, Air inlet heater relay - low current F333, Fuel hold-in solenoid - low current F334, PTO solenoid - low current F335, Steering reverse solenoid - low current F336, Fuel pull-in relay - low current F338, CCM sensor 5 volt supply failed low F339, CCM sensor 5 volt supply failed high F340, Transmission speed sensor failed high F341, Transmission speed sensor failed low F342, Engine RPM sensor failed high F343, Engine RPM sensor failed low F344, Engine RPM sensor failure F345, Transmission speed sensor failure F346, Inching pedal pot failed low F347, Inching pedal pot failed high F348, Inching pedal pot - low calibration error F349, Inching pedal pot - high calibration error Component Location Machine Component Component Location Alternator 1 Sender - Fuel Level Batteries 2 Sender - XMSN in Speed Cigar Lighter D Sender - XMSN Speed Control - Chassis F-16,G-16,H-16 5 Sensor - Eng Oil Press Fuses - Relay Block F-8,13 A,3 Sensor - LH Draft Pin Heater - Air Intake J-3 4 Sensor - RH Draft Pin Horn - Action_Alarm D-4 B Sensor - XMSN Oil Temp Horn - Forward Horn E-1 5 Solenoid - A/C Clutch Lamp - EDC Indicator B-10 C Solenoid - Air Release (Seat) Lamp - PTO Indicator B-10 C Solenoid - Creeper Module - Elect Instrument F-5 B Solenoid - Fuel Shutoff Module - Flasher F-11 A Solenoid - Implement Lower Module - Naso ISO Convtr F-12 A Solenoid - Implement Raise Module - RH Control D-13 C Solenoid - PTO Motor - Blower I-5 D Solenoid - Rev Steering Motor - Compressor (Seat) I-13 7 Solenoids - XMSN Motor - RH Console C-8 C Switch - A/C Motor - Starter H-3 9 Switch - A/C Hi/Low Press Motor - Washer Front H-17 2 Switch - A/C Low Press Motor - Washer Rear H-17 2 Switch - Air Filter Vac Motor - Wiper Front E-4 D Switch - Auto Shift Motor - Wiper Rear I-15 8 Switch - Beacon Potentiometer - Drop Rate D-9 C Switch - Blower Potentiometer - Height Limit D-9 C Switch - Clutch Potentiometer - Inching Clutch I-6 B Switch - Console Control Potentiometer - Quadrant Lever D-9 C Switch - Creeper Potentiometer - Rockshaft A-16 10 Switch - Hazard Potentiometer - Sensitivity D-9 C Switch - Height Adjust Potentiometer - Slip Limit E-9 C Switch - Key Start Radar A-8 11 Switch - LH 3 Point Hitch Radio H-11 D Switch - LH Brake Relay - A/C Compressor I-5 D Switch - LH Track Tension Relay - Accessory G-10 A Switch - Lower Height Limit Relay - Air Inlet Heater K-2 4 Switch - Main Light Relay - Aux 1 G-11 A Switch - Operator Presence Relay - Aux 2 F-10 A Switch - Park Brake Relay - Brake Lamp G-10 A Switch - Program Shift Relay - Flood Front Lower G-8 A Switch - PTO Start/Stop Relay - Flood Front Upper G-9 A Switch - Raise/Work (3-Point) Relay - Flood Rear Lower G-8 A Switch - RH 3 Point Hitch Relay - Flood Rear Upper G-8 A Switch - RH Brake Relay - Fuel Solenoid G-13 A Switch - RH Track Tension Relay - Implement Socket G-13 A Switch - Shutdn Override Relay - PP1 SW C-13 C Switch - Start Aid Relay - PP2 SW C-13 C Switch - Steering Filter Relay - PTO G-9 A Switch - Thermostat Relay - Start E-1 12 Switch - Turn/Horn/Hi-Lo Beam Relay - Start Aid G-10 A Switch - Upper Height Limit Relay - Trail Acc1 B-13 C Switch - Wiper Front Relay - Trail Acc2 B-13 C Switch - Wiper Rear Relay - XMSN G-9 A Switch - XMSN Filter Relay - XMSN Power G-11 A Switch - XMSN Gear Shift Resistor - Blower Speed I-5 D Switch - XMSN Oil Press Sender - Aftercooler Temp K-1 17 Switch - Charge Pump Press Sender - Coolant Level L-2 13 Switch - Park Brake Sender - Coolant Temp L-1 1 Machine locations are repeated for components located close together. A = Components in Main Distribution Panel (MDP). B = Component in dash area. C = Component in right console area. D = Component in cab headliner. Schematic Location K-2 D-16 C-6 Electrical Schematic Symbols And Definitions RENR1782-01 October 2000 T Pressure Symbol Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Challenger 35, Challenger 45 and Challenger 55 Agricultural Tractors Electrical System 35: 8RD1-UP ADK1-UP 45: ABF1-UP 3BK1-UP Sender - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. 55: 6NN1-UP AEN1-UP Harness And Wire Symbols * Harness identification letter(s) and a serializing code. The "C" stands for connector and the number indicates which connector in the harness. Harness identification code This example indicates wire 135 in harness "AG". Wire, Cable, or Harness Assembly Identification Part Number For L-C12* AG-C4* Connector Assembly 3E-5179 111-7898 325-A135 PK-14 1 * * AG-C3 C-C4 130-6795 130-6795 325-A135 PK-14 Socket Pin Single Wire Connector 7 1 2 Wire Color Wire Gauge Ground Circuit Connection Number Identification Receptacle Plug Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 2 Fuse 200-L32 BK-14 Pin or Socket Number 1 2 105-9344 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Part No. 111-8490 31 36 A 35 1 5 26 13 4 17 39 14 16 24 25 B D 45 11 15 38 23 18 12 3 C 40 34 6 7 43 9 37 33 32 27 21 30 10 20 2 22 8 44 Solenoid - PTO 112-8927 114-9484 Potentiometer - Inching Clutch Quadrant Lever Potentiometer - Drop Rate Height Limit Sensitivity Slip Limit Sender - XMNS Temperature Sender - XMNS Speed Solenoids - Creeper Reverse Steer XMSN Solenoid - Implement Raise Solenoid - A/C Clutch 117-6850 Resistor - Blower Speed 154-9953 Sender - Fuel Level Full: Empty: 114-5930 19 46 42 41 112-8723 113-8869 113-8872 114-5913 29 28 ¹ Rating Color 1 10A Red Accessory socket 2 25A Clear Heating and air conditioning control 7.6 ± 0.4 4000 3 15A Blue Wiper/Washer 4 20A Yellow Front work lights and middle work lights 1200 5 20A Yellow Lower cab mounted rear work lights 6 15A Blue Upper cab mounted rear work lights 7 15A Blue Upper cab mounted front work lights 8 7.5A Brown Right side parking light 9 7.5A Brown Left side parking light 10 25A Clear Main work light 11 15A Blue Cigar lighter, horn and rotating beacon 12 15A Blue Brake lights 13 15A Blue Hazard lights 14 5A Tan Interior lights 15 7.5A Brown Movable console 16 20A Yellow Seat 17 7.5A Brown Power for the radio 18 20A Yellow Transmission shift 1 control solenoid 19 20A Yellow Transmission shift 2 control solenoid 20 15A Blue Transmission relay and PTO 21 5A Tan Right side console 22 5A Tan Front console 23 10A Red Control module switch power (VPWR) 24 15A Blue Turn signal Unswitch battery power (KAPWR) Pull-In 0.29 ± 0.03 Hold-In 12 ± 1.2 Solenoid - Fuel Shutoff 112-8929 Number Resistance (Ohms)¹ Component 2300 to 2650 2550 1.7 2.4 3.5 ± 0.15 Terminals 1 to 3, 0.50 Terminals 1 to 2, 1.50 22 462 At room temperature. 41 3935 D A 8 Part No. 3E-6450 B 15 38 26 5 13 23 43 4 3 17 40 1 37 14 12 18 C 24 25 9 11 45 33 32 16 27 31 36 7 6 42 34 2 30 28 22 Function Pump Pressure 113-8870 XMSN Oil Pressure 116-9846 XMSN Filter Pressure 117-7773 Steering Filter Pressure 119-9640 Actuate 1200 kPa MAX (175 psi MAX) 1055 ± 50 kPa (153.0 ± 7.0 psi) 276 ± 28 kPa (40 ± 4.0 psi) 138 ± 28 kPa (20.0 ± 4.0 psi) Closes on Risiing Pressure 241 ± 35 kPa (35.0 ± 5.0 psi) 276 kPa to 2241 kPa1 (40 psi to 325 psi) AC Low Pressure 44 10 119-9637 46 AC High / Low Pressure ¹ 29 21 20 19 Deactuate 700 ± 100 kPa (100 ± 15 psi) 875 ± 50 kPa (127 ± 7 psi) 179 kPa MIN (26 psi MIN) 69 kPa MIN (10 psi MIN) Opens On Decending Pressure 103 ± 35 kPa (15 ± 5 psi) _ 5A Tan 26 10A Red Key start switch and diagnostic connector Contact Position 27 15A Blue Air inlet heater and D.A.M. connector A-B Normally Closed A-C Normally Open Normally Closed 28 15A Blue High beam roading light 29 15A Blue Low beam roading light 30 15A Blue Implement monitor Number Rating Color 1 50A 2 40A Red 3 50A Orange Transmission 4 50A Red Roading lights 5 50A Red Work lights 6 40A Orange Main Fuse II 7 40A Orange Accessory 8 40A Orange Implement socket Contact position at the contacts of the harness connector. Related Electrical Service Manuals Title Alternator: Machine Harness Connector and Component Locations Normally Closed Normally Closed Normally Open Normally Closed2 A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 3740 kPa (542.4 psi), with decreasing pressure the condition can be maintained down to 166 kPa (24.1 psi). 2 Electric Starting Motor: System Operation Testing and Adjusting: Form Number 125-9597 SENR4757 6V-4238 SENR3581 SENR1781 Description 25 Off Machine Switch Specifications Component Part Number Printed in U.S.A. Fuses Resistor, Sender And Solenoid Specifications Engine Control Function F400, Coolant temperature too high (shutdown) F401, Engine oil pressure too low (shutdown) F403, Aftercooler temperature too high F404, Fuel level sensor failed low F405, Fuel level sensor failed high F406, Coolant temperature sensor failed low F407, Coolant temperature sensor failed high F408, Engine oil pressure sensor failed low F411, Aftercooler temperature sensor failed low F412, Aftercooler temperature sensor failed high F413, Radar sense fault F414, Radar signal fault F415, Coolant level sensor failed low F416, Coolant level sensor failed high F417, Air filter status F418, Coolant level status F419, Alternator not charging F420, Alternator overcharging F421, Low battery voltage at EMC F422, Connector C008 - open Machine Location 15 14 16 18 19 20 21 23 7 24 18 22 22 22 25 24 D D D 26 C B D B C B B 7 B 28 B 29 7 B 7 7 C C C 30 B 31 B B 32 D B 7 D D 33 C 33 © 2000 Caterpillar All Rights Reserved F350, Clutch switch and inching pedal pot disagree - pedal depressed F351, Clutch switch and inching pedal pot disagree - pedal released F360, Transmission F1 calibration error F361, Transmission F2 calibration error F362, Transmission REV calibration error F363, CCM internal error - shuttle constant F365, CCM internal error - F1/F2 shift constant F366, CCM internal error - F2/F1 shift constant F377, CCM internal error - transmission configuration byte 1 F378, CCM internal error - transmission configuration byte 2 F379, CCM internal error - transmission configuration byte 3 F380, CCM internal error - prototype hardware revision F381, CCM internal error - production hardware revision F382, CCM internal error - upshift constant F383, CCM internal error - downshift constant F386, Transmission oil temperature too high (shutdown) F387, Transmission oil pressure too low (shutdown) F388, Transmission oil pressure switch failed low F389, Transmission oil temperature sensor failed low F390, Transmission oil temperature sensor failed high F392, Transmission filter bypass occurring F393, Directional input and gearshift disagree F394, Steering/Implement filter bypass occurring (shutdown) F395, Track tension status F399, Transient reset of modules Schematic Location G-2 B-8 A-10 D-2 L-15 A-16 A-16 D-1 I-13 A-8 C-1 A-17 L-15 A-17 A-8 A-7 I-5 I-5 I-5 L-1 D-11 G-4 I-5 H-6 C-11 D-5 H-5 I-13 C-5 I-17 G-5 L-10 I-13 H-4 I-13 I-8 C-9 C-11 C-9 C-17 E-5 B-10 D-5 A-5 A-10 I-5 G-4 I-13 D-6 D-6 A-10 E-10 A-9 L-7 K-7 Main Fuse Panel Description Spare Main Fuse I Right Hand Console Fuses Rating 10A 10A 30A 30A 10A 10A Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Color Red Red Green Green Red Red Description Accessory socket I Accessory socket II Accessory socket I Accessory socket II Trailer accessory I Trailer accessory II Relays Description Lower front work lights and side work lights Lower cab mounted rear work lights Upper cab mounted rear work lights Upper cab mounted front work lights Power take-off Transmission directional interrupt Brakes Cold Start Accessory power Auxiliary power 2 Power for the transmission Auxiliary power 1 Flasher module NASO/ISO Turn signal,flasher converter module NASO/ISO Turn signal,flasher converter module Fuel pull-in solenoid Implement power Connector Location Schematic Machine Location Location CONN 1 B-15 34 CONN 2 C-6, L-4 35 CONN 3 E-14 36 CONN 4 J-3 37 CONN 5 Roading F-2, K-10, K-8 38 CONN 6 HVAC I-5 39 CONN 7 Dam Connector I-16 40 CONN 8 D-17 35 CONN 9 Air Ride Seat I-13 42 CONN 10 Secondary Steering A-8, L-7 14 CONN 11 Trailer Connector E-18, L-17, L-16 44 CONN 12 Secondary Steering L-7, L-10 46 CONN 13 B-15 34 CONN 14 Power Plug C-12 C CONN 15 Power Plug C-12 C Connector Number The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart.
Component Alarm - Travel Schematic Location C-7 Component Location Machine Location 1 Component Sensor - Fuel Temperature Schematic Location B-10 Machine Location 21 Alternator E-12 2 Sensor - Intake Manifold Air Temperature B-10 17 Alternator (Artic Pkg) B-10 2 Sensor - O.W.D B-2 8 Assembly - Buzzer H-5 35 Sensor - Oil Pressure B-10 18 Assembly - Terminal Block E-9 D Sensor - Pump Discharge Press B-7 19 Batteries - 12VDC G-11 3 Sensor - Speed/Timing B-10 18 Breaker - Alternator G-9 D Solenoid - A/C Clutch E-11 22 Breaker - Main G-8 D Solenoid - AC1 I-8 14 Breaker - Fuel Heater H-12 3 Solenoid - AC2 I-8 14 Braeker - Warming Windshield G-11 3 Solenoid - Eng/Pump Control A-7 4 Control - Aux Hyd I-9 4 Solenoid - Flow Control I-8 14 Control - Engine A-12 5 Solenoid - Hammer 2 I-6 14 Control - Engine/Pump F-2 C Solenoid - High Pressure (A2) B-2 32 Control - O.W.D. H-5 A Solenoid - High Pressure (A3) B-2 32 Controller - Wiper/Washer D-1 E Solenoid - Hydraulic Lock H-1 F Converter - Voltage B-6 A Solenoid - Level Finish A-7 4 Diode - Main Relay F-8 D Solenoid - Low Pressure (A1) B-2 32 Diode - Refueling A-2 6 Solenoid - Pedal ON/OFF H-1 F Fuses I-4,5 B Solenoid - R1/R2 I-7 14 Ground - Cab B-5 7 Solenoid - Start Aid F-12 23 Ground - Cab E-1 E Solenoid - Swing Brake B-7 14 Ground - Chassis B-3 8 Solenoid - Travel Speed A-7 4 Ground - Chassis D-12 9 Solenoid - Trenching A-7 4 Ground - Chassis I-10 D Solenoids - Injector A-11 24 Ground - Engine Control C-11 5 Switch - Air Cleaner Flow F-12 25 Ground - Platform H-1 F Switch - Aux D-3 C Ground - Platform H-2 F Switch - Aux D-3 C Ground - Relay Panel D-8 D Switch - Aux Pressure I-7 B Ground Strap - Chassis to Platform G-6 10 Switch - Backup D-2 C Horn A-2 8 Switch - Backup EPR Valve D-5 C Indicator C-5 A Switch - Backup THRT D-6 C Lighter E-1 E Switch - Boom Raise Pressure C-7 C Meter - Service F-1 E Switch - Coolant Level F-12 23 Monitor F-1 E Switch - Disconnect G-9 D Motor - Lower Wiper G-1 11 Switch - Engine Oil Level D-11 26 Motor - Starter D-12 9 Switch - Horn H-5 B Motor - Starter (Artic Pkg) A-10 9 Switch - Hyd Tank Press A-5 27 Motor - Upper Wiper B-6 12 Switch - Hydraulic Control D-4 C Motor - Washer H-12 D Switch - Hydraulic Oil Filter A-5 15 Pump - Auto Lube F-12 13 Switch - Hydraulic Oil Level A-5 15 Pump - BIO F-12 14 Switch - Implement Pressure C-7 14 Pump - Refueling A-3 6 Switch - Key E-2 C Radio - 12VDC I-3 A Switch - LH Foot Pedal I-5 A Relay - Boom Lamp F-7 D Switch - Neutral Start Limit H-5 B Relay - Cab/Chassis Lamp E-7 D Switch - O.W.D. D-5 C Relay - Fuel Heater H-12 3 Switch - Off Heater H-12 3 Relay - Horn G-7 D Switch - On Heater H-12 3 Relay - Hydraulic Lock Solenoid F-7 D Switch - On/Off Fuel Heater H-11 3 Relay - Main F-8 D Switch - One Touch Low Idle F-2 C Relay - Neutral Start E-7 D Switch - Pressure I-7 14 Relay - Refueling Power A-3 6 Switch - Proximity I-7 14 Relay - Refueling Start A-2 6 Switch - Refrigerant Low Press E-11 23 Relay - Refueling Stop A-2 6 Switch - Refueling Level A-4 28 Relay - Start F-8 D Switch - Refueling Pump(NC) A-4 6 Relay - Start Disable H-11 3 Switch - Refueling Pump(NO) A-3 6 Relay - Start Heater H-11 3 Switch - RH Foot Pedal I-5 A Relay - Timer D-7 D Switch - Rotary H-3 31 Relay - Warming Windshield G-11 3 Switch - Seat Heater D-4 C Resistor - Backup G-8 D Switch - Start Aid D-5 C Sender - Hydraulic Oil Temp A-5 15 Switch - Start Aid Coolant Temp E-11 18 15 Sensor - A/C Photo F-1 E Switch - Suction Line Shutoff Limit A-7 Sensor - ATM Pressure B-10 16 Switch - Throttle Position E-2 C Sensor - Boost Pressure B-10 17 Switch - Travel Pressure C-7 14 Sensor - Coolant Temperature B-10 18 Switch Panel F-2 C Sensor - Engine Speed Pickup D-11 19 Unit - A/C H-3 29 Sensor - Fuel Level A-4 20 Machine locations are repeated for components located close together. D = Located around relay panel. A = Located inside of cab. E = Located around hydraulic oil tank. B = Located inside of right console. F = Located around pilot manifold. C = Located inside of left console. Connector Location Connector Number Schematic Location Machine Location CONN 1 A-11 16 CONN 2 B-11 26 CONN 3 C-11 26 CONN 4 C-11 26 CONN 5 C-11 26 CONN 6 C-11 26 CONN 7 F-10 D CONN 8 F-10 D CONN 9 F-10 D CONN 10 G-10 D CONN 11 G-10 D CONN 12 D-9 D CONN 13 E-9 D CONN 14 E-9 D CONN 15 E-8 D CONN 16 F-9 D CONN 17 Service G-8 D CONN 18 I-7 14 CONN 19 C-6 7 CONN 20 C-6 7 CONN 21 C-5 7 CONN 22 C-5 7 CONN 23 C-5 F CONN 24 C-4 F CONN 25 C-4 F CONN 26 F-5 C CONN 27 F-5 C CONN 28 F-5 C CONN 29 F-5 C CONN 30 F-5 C CONN 31 F-4 C CONN 32 F-4 C CONN 33 H-6 F CONN 34 H-6 F CONN 35 H-6 F CONN 36 H-6 F CONN 37 H-6 14 CONN 38 H-6 14 CONN 39 H-6 14 CONN 40 H-6 14 CONN 41 H-6 14 CONN 42 H-5 B CONN 43 H-4 B CONN 44 H-4 B CONN 45 H-4 B CONN 46 H-4 B CONN 47 H-3 B CONN 48 H-3 B CONN 49 H-3 B CONN 50 H-3 B CONN 51 I-5 E CONN 52 I-5 E CONN 53 A-3 6 CONN 54 B-2 14 CONN 55 B-2 30 CONN 56 C-2 F CONN 57 C-2 F CONN 58 C-2 F CONN 59 D-2 D CONN 60 A-3, B-3 33 CONN 61 A-4 28 CONN 62 A-4 20 CONN 63 A-3 20 CONN 64 I-12 34 CONN 65 Factory Adjustment D-2 F The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart. G =Located under platform. E96828 Wire Number Wire Color 101 103 105 109 110 111 112 113 114 115 118 120 124 129 135 139 140 147 149 150 151 152 154 168 175 176 177 180 185 189 191 196 RD RD RD RD RD RD PU OR GN PK GY YL GN BU BU OR BU PU PU RD GN BU RD RD PK YL RD GN YL RD WH BU 201 210 235 BK BK BK 304 306 307 308 310 311 320 321 322 323 325 329 330 365 386 WH GN OR YL PU WH RD BR GY WH PK YL YL YL PK 403 412 430 439 491 492 495 496 499 A424 A425 A499 C468 E455 F400 GN BU BU YL PK GY GN WH GY WH YL BU BU BR GY 500 501 506 508 509 511 512 513 521 524 546 547 548 549 575 576 578 586 590 A537 A586 A587 A588 A587 A588 BN GN PU PU WH BR GN OR YL BU BU OR GY PK YL PK BU BR GY PK OR YL GN YL GN Wire Description Description Power Circuits Bat (+) (Not Application Specific) Aux Ckt Key Start Sw Alt Output (+) Term. Aux Ckt Aux Ckt Main Power Rly Output Opr Mon Panel B (+) Switched Warning Horn (Forward) Cab Chassis Lamp Relay Washer/Wiper Converter A/C Cigar Lighter Converter/ Atch AM-FM Radio Converter/ Atch AM-FM Radio Lubricator Aux Ckt Boom Lamp Bat (+) Neutral Start Sw to Hyd Lock Sol Rly Aux Ckt Neutral Start Sw to Neutral Start Rly Refueling Pump Aux Ckt Aux Ckt Main Brkr Bio Pump Backup EPR Valve Sw Timer Rly Aux Ckt Insp Lamp Ground Circuits Operator Monitor Return Radio Electronic Pump Ctrl Gnd Basic Machine Circuits Starter Relay No. 1 Output Starter Relay Coil To Neut Start SW Or Key Start SW To Neutral Start SW Or Main Power Relay Coil Start Aid SW To Start Aid Sol Start Aid Sol To Temp SW Horn Relay Coil To Sw Backup Alarm Lamp Travel Alarm Warning Horn (Forward) Fuel Pump Power Fuel Pump Relay Fuel Pump To Sw Neutral Start Relay Coil Fuel Pump Relay To Sw Air Shutoff Solenoid Enable Monitoring Circuits Alternator (R) Term. Operator Monitor Cool Flow Operator Monitor Air Filter Lamp Indicator Hydraulic Oil Temp Sensor Coolant Temp Sensor Fuel Level Operator Monitor Panel Hyd Oil Level Operator Monitor Implement Oil Filter Overload Warning Device Overload Warning Device Operator Monitor Hydraulic Oil Press Engine oil Level Hydraulic Oil Filter Low Oil Pressure Accessory Circuits Windshield Sw to Wiper Control Wiper - Front (Low) Washer - Front Radio Speaker - Left Radio Speaker - Left (Common) Radio Speaker - Right Radio Speaker - Right (Common) A/C Compressor/ Refrigerant Press Sw A/C SW To Refrigerant SW Wiper Motors Aux Hyd - Rotate CW Aux Hyd - Rotate CCW Aux Hyd - Open Aux Hyd - Closed Wiper - Aux Wiper - Aux Washer - Aux Aux Hydraulic - Close Wiper Sw To Intermittent Module Seat Heater Wiper SW To Wiper Cont Power Window Cont To Safety Sol Relay Safety Sol Relay To Sol Power Window Cont to Safety Sol Relay Safety Sol Relay to Sol Electrical Schematic Symbols And Definitions Wire Number Wire Color C537 C538 GN OR 607 615 616 633 638 PK YL BU BU WH 763 786 788 791 A701 A702 A703 A704 A705 A706 A746 A747 A751 A755 A756 A756 A757 A757 A758 A762 A768 A769 A770 A771 D789 D790 D791 E793 E794 F717 F718 892 893 A847 A848 A849 A850 F846 950 951 952 954 955 961 993 994 995 996 997 998 999 C912 C967 K904 K905 K906 K907 K909 K911 K912 K915 K973 K974 K975 K976 K997 L908 L909 L968 L969 L970 L971 L972 L973 L974 L976 L977 L978 N919 N920 N921 N922 N923 N924 8630 BU RD YL PK GY PU BR GN BU GY PK GY YL PK BU PU GY WH BR PU BU GY PK PU WH OR YL BU YL YL BU BR GN YL PK OR WH PU BR PK OR GN BU BR BR GY BU GN OR BR WH GN BU GN RD GN BU BU PK GN GN BR PU WH OR BU OR BU OR WH GY GN BU GN GN GN YL GY GN BU YL OR GY WH BU Accessory Circuits (Continued) A/C Photo Sensor + Sig A/C Photo Sensor - Sig Lighting Circuits Flood Lamps - Front Cab Flood Lamp/Rops Boom Flood Lamp DC/DC Converter Rotating Beacon Control Circuits Torque Converter Sw Engine Speed Cont Engine Speed (+) Engine Speed Cont Injector #1 Injector #2 Injector #3 Injector #4 Injector #5 Injector #6 Turbo Outlet Pressure Atmospheric Pressure After Cooler Temp Throttle Sw #1 Throttle Sw #2 Throttle Sw #2 Throttle Sw #3 Throttle Sw #3 Throttle Sw #4 Elec Pump Cont Eng Speed Ground Pump Control Valve #1 (+) Pump Control Valve #2 (-) Elec Pump Cont Bypass Sw Float Sw Injector Common 1 & 2 Injector Common 3 & 4 Injector Common 5 & 6 ATA Data Link (-) ATA Data Link (+) Sw 4 Sw 5 CAT Data Link (-) CAT Data Link (+) Aux Hyd Controller Aux Hyd Controller Aux Hyd Controller Aux Hyd Controller LED Driver 1 Hammer Sw C Hammer Sol C Aux Hyd Controller Hammer Sw A Hammer Sw A Aux Hyd Controller Analog Sensor Common Oil Pressure (Filtered) Coolant Temperature Engine Speed/Timing Sensor Power Analog Sensor Power (+5V) Digital Sensor Return Primary Camshaft Speed/Timing Throttle Position Inlet Air Temperature Pump Discharge - Signal Pump Discharge - +B Swing Brake Sol - Signal Swing Brake Sol - +B Backup SW - +B E/P Controller - RS485 (+) E/P Controller - RS485 (-) Fine Swing Sw - E/P Controller Aux Hyd Controller Aux Hyd Controller Aux Hyd Controller Aux Hyd Controller (+) V Sensor Controller RS-232C TX Controller RS-232C RX Electronic Pump Control Ps Valve (-) Electronic Pump Control Ps Valve (+) Elec Pump Cont To Sw Common Ret Elec Pump Cont To Travel Press Sw Low Idle SW Fine Swing Cont Relay To Sol Valve Elec Pump Ctrl Boom Raise Press SW Excavator Fuel Pump Switch Trenching Sol Level Finish Sol HEX Backup Engine Speed Control 1 HEX Backup Engine Speed Control 2 HEX Backup Engine Speed Control 3 HEX Backup Engine Speed Control 4 Backup Mode Sw 1 Backup Mode Sw 2 Rotating Beacon 12 7 A 18 24 16 13 27 17 5 26 9 25 2 22 19 23 30 28 31 29 21 D 15 35 B 34 3 10 20 1 11 Part No. 6 32 8 E C 33 Resistor, Sender and Solenoid Specifications Component Description 3E-6332 4I-5394 102-8017 107-7056 111-9916 121-1490 F Solenoid: Sender: Resistor: Solenoid: Solenoid: Solenoid: 121-1491 Solenoid: RENR1913-01 April 2000 Description Valve - Start Aid Hydraulic Oil Temp Backup Atch Fine Swing Engine Pump Control Level Finish Trenching AC1 AC2 Hydraulic Lock Swing Brake Travel Speed Resistance (Ohms)¹ 6.0 6130 to 7500 52.0 ± 2.6 34.0 ± 0.5 11.7 ± 1.2 32.0 ± 3.2 T Pressure Symbol Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally closed switch that will open with an increase of a specific condition. No circle indicates that the wire cannot be disconnected from the component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Harness And Wire Symbols Pin 25 3 D 29 A 7 F 12 11 10 23 18 C 35 E 2 22 1 21 24 16 5 14 17 7 32 30 9 20 27 26 19 33 15 6 28 4 Machine Harness Connector And Component Locations Part No. 3E-6425 Function Coolant Temperature (Start Aid) Off Machine Switch Specification Actuate Deactuate Contact Position 38 ± 3° C 27° C Min. Normally Closed (100 ± 5° F) (80.6° F) 106-0179 Implement Pressure 1520 ± 98 kPa 1127 kPa MIN Normally Open Travel Pressure (224.4 ± 14.21 psi) (163.5 psi MIN) 106-0180 Boom RaisePressure 2646.00 ± 196.00 kPa 2156.00 ± 196.00 kPa Normally Open (383.77 ± 28.43 psi) (312.70 ± 28.43 psi) 106-0181 Aux Hydraulic Pressure 490 ± 49 kPa MAX 290 kPa MIN Normally Open ATCH HammerPressure (71 ± 7 psi MAX) (42 psi MIN) 107-0615 Hydraulic Tank Pressure 48 ± 14 kPa 24 kPa MIN Normally Closed (7.0 ± 2.0 psi) (3.5 psi MIN) 114-5333 Refrigerant Pressure (AC) 275 to 1750 kPa¹ -Normally Open² (40 to 255 psi) -131-9203 Aux Hydraulic Pressure 3500 kPa MAX 3000 ± 150 kPa A-B Normally Open (507.6 psi) (435.1 ±21.8 psi) A-C Normally Closed ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure the closed position can be maintained down to 170 kPa (25 psi). ² Contact position at the contacts of the harness connector. Socket Wire Color Circuit Number Identification 105-9344 1 Receptacle Wire Gauge Plug Ground Connection Fuse AA 325-PK-14 Single Wire Connector Component Part Number Wire, Cable, or Harness Assembly Identification A 2 200-BK-14 Pin or Socket Number 1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Printed in U.S.A. ©2000 Caterpillar All Rights Reserved Component identifiers (CID¹) and Module Identifier (MID²) CID Component Real Time Error Codes Engine Control Real Time Error Codes Code Description of Problems Description of Problems 1301 Engine oil pressure is too low. 1302 Engine coolant temperature is too high. 1303 Hydraulic oil temperature is too high. 1304 Air filter is clogged. 1305 Battery voltage is not normal. 2201 Governor actuator feedback sensor circuit is open or shorted to battery voltage. 0001 Cylinder 1 0002 Cylinder 2 b102 Cylinder 1 short. 0003 Cylinder 3 0004 Cylinder 4 b103 Cylinder 2 open circuit. 0005 Cylinder 5 b104 Cylinder 2 short. 0006 Cylinder 6 b105 Cylinder 3 open circuit. 0100 Oil Pressure Signal b106 Cylinder 3 short. 2202 Governor actuator feedback sensor circuit is shorted to body ground. 0110 Coolant Temperature Signal b107 Cylinder 4 open circuit. 2301 Governor actuator feedback signal is not stable. 0168 Electrical System Voltage b108 Cylinder 4 short. 2302 Governor actuator feedback signal deviates. 0172 Inlet Air Temperature Signal b109 Cylinder 5 open circuit. 2303 Governor actuator does not move. 0174 Fuel Temperature Signal Engine RPM Signal Cylinder 5 short. Calibration data error. 0190 b10A 2304 Personality Mode Cylinder 6 open circuit. Monitor RAM is not normal. 0253 b10b 3201 Timing Calibration Cylinder 6 short. Electric power supply to the controller is too much (43 volts). 0261 b10C 4101 4102 Over-current in proportional reducing valve. 0262 Analog Sensor Supply b10d Throttle switch inputs are incorrect. 4103 Proportional reducing valve circuit is open. 0268 Programmable Parameters b10E Oil pressure open/short to + battery. 4104 Monitor power supply (digital output) over current. 0273 Boost Pressure Signal b10F Oil pressure short to ground. 4105 Over-current in digital output (trenching solenoid). 0274 Atmospheric Pressure Signal b110 Oil pressure calibration required. 4106 Over-current in digital output (fine control solenoid). b111 Coolant temperature open/short to + battery. 4107 Over-current in digital output (travel speed change solenoid). b112 Coolant temperature short to ground. 4108 Over-current in digital output (travel alarm). 4109 Spare solenoid 1 (digital output) over current. b113 Battery voltage above normal. 410A Over-current in digital output (swing brake solenoid). b114 Battery voltage below normal. 410B Spare solenoid 2 (digital output) over current. b115 Loss of engine rpm signal. 4201 Engine speed is not normal. b116 Analog sensor supply short to + battery. 4202 Engine coolant temperature sensor is shorted to body ground. b117 Analog sensor supply short to ground. 4203 Hydraulic oil temperature sensor is shorted to body ground. b118 Digital sensor supply short to + battery. 4204 PWM sensor of pump delivery pressure is shorted to body ground. 4205 Spare PWM sensor 1 is shorted to body ground. b119 Digital sensor supply short to ground. 4206 Spare PWM sensor 2 is shorted to body ground. b11A Shutdown inputs are incorrect. 4207 PWM sensor of pump delivery pressure is open in circuit. b11b Turbo out pressure open/short to + battery. 420A Fuel sensor is shorted to body ground b11C Turbo out pressure short to ground. 420B Fuel sensor is open or shorted to battery voltage. b11d Turbo out pressure calibration required. 420C Electric power supply is to low (below 23 volts). b11E Atmospheric pressure open/short to + battery. 420D Electric power supply is to high (above 32 volts). b11F Atmospheric pressure short to ground. 420E Engine speed dial is not in one of the 10 specified positions. 4301 Data mismatch 1 between alternator and speed sensor (alternator is abnormal). Atmospheric pressure calibration. 4302 Data mismatch 2 between alternator and speed sensor (speed sensor is abnormal). 4303 Engine stalls. A201 Monitor communication is not normal. A202 Monitor takes too much time to respond to controller's signal. A203 Communication is abnormal in controller. A20D ADEM communication disconnect. 0286 Oil Lamp ¹ The CID is a diagnostic code that indicates which component is faulty. ² The MID is a diagnostic code that indicates which electronic control module diagnosed the fault. Failure Mode Identifiers (FMI)¹ Failure Description Cylinder 1 open circuit. Code b101 32.0 ± 3.2 B 34 Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. 7KS1-UP 2SW1-UP BFG1-UP FMI No. 13 Sender- A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. T 345B Excavator Electrical System ¹ At room temperature unless otherwise noted. 31 Circuit Breaker Symbol Flow Symbol Level Symbol Temperature Symbol 0 Data valid but above normal operational range. 1 Data valid but below normal operational range. b120 2 Data erratic, intermittent, or incorrect. b121 Check programmable parameters. 3 Voltage above normal or shorted high. 4 Voltage below normal or shorted low. b122 Timing calibration required. 5 Current below normal or open circuit. b123 Hydraulic oil temperature open/short to + battery. 6 Current above normal or grounded circuit. b124 Hydraulic oil temperature signal short to ground. 7 Mechanical system not responding properly. b200 ADEM unknown eror. 8 Abnormal frequency, pulse width, or period. 9 Abnormal update. 10 Abnormal rate of change. 11 Failure mode not identifiable. 12 Bad device or component. 13 Out of calibration. 14 Parameter failures. 15 Parameter failures. 16 Parameter not available. 17 Module not responding. 18 Sensor supply fault. 19 Condition not met. 20 Parameter failures. ¹The FMI is a diagnostic code that indicates what type of failure has occurred. Related Electrical Service Manuals Title Form Number Alternator: 100-5047 SENR2082 Alternator Artic Package: 132-2156 SENR4757 Electric Starting Motor: 106-8553 Engine Control: SENR3581 RENR1235 Engine/Pump Control: 126-2973 RENR1999 Starting and Charging: SENR1936