WireDescription

ComponentLocation Electrical Schematic Symbols And Definitions

Wire Wire Wire Wire
Number  Color 
Description
Number  Color 
Description
Component
Schematic Machine
Component
Schematic Machine SENR9258-02
Location Location Location Location
Power Distribution C ircuits Lighting C ircuits
November 1999
 Actuator-EngineGov A-9 1 Sender-HydraulicOilTemp A-5 E
101 R D Ba t(t( +) (N
(N o
t Ap
Ap p
l ci at oi nS p
e cif ci ) 5 7
8 B U Wa sher - Au x T
 AirInletHeater C-8 2 Sensor-A/CPhoto F-1 A
103 RD D ome Lamp C kt
Do 586 BR A ux H yd - Close
Au Pressure Temperature Level Flow CircuitBreaker 
 Alarm - ATCH Travel G-9 3 Sensor-AirInletHeaterCoolantTemp C-9 21
105 RD Key S
t art Sw 590 GY Wiper SW To Intermittent Module
Symbol Symbol
 Alternator B-8 4 Sensor-FuelLevel A-5 23 Symbol Symbol Symbol
107 RD Eng Shut -D
-Down Fire Suppr 592 BU D C/DC Co
Converter Power Output
 Antenna ATCH C-6 5 Sensor-PumpDischargePress B-8 24
109 RD Alt Output (+) Term.
Al A513 R D D C/DC Co
Converter Memory Output
 Assembly -Terminal Block F-8 D Socket12V H-6 A Normally open switch that will close with an increase of a specific condition (temp-press-etc.).
111 R D En g
i n
eP u
m pC on rt o
l C kt A 5
3 7 P K S e
a tH
tH eat er ( Res si it e
v El
Ele m
e n
t In
In Cu shio n
)
112 PU Main Power Rly Output A579 OR Wiper Motor + Batteries - 12VDC I-8,H-8 6 Solenoid - A/C Clutch C-9 26 The circle indicates that the component has screw terminals and a wire can be disconnected from it.
113 OR Opr Mon Panel VMIS B+ Sw tc
i hed A580 BR Wiper Motor - Breaker - Alternator I-8 D Solenoid - ATCH Crush D-8 31
Breaker - Main I-8 D Solenoid - ATCH Flow Control D-7 29
Normally closed switch that will open with an increase of a specific condition.
114 RD Warning Horn F
( orward) A581 GN Wiper Motor Raise
Cable - ATCH Antenna G-6, I-3 5 Solenoid - Fine Swing E-7 28
No circle indicates that the wire cannot be disconnected from the component.
115 PK Cab / Chassis Ckt A582 PU Wiper Motor Stop
118 GY Washer /Wiper Ckt A583 YL Power Window Int erlock To Wiper Cont Control - ATCH Power Window C-6 15 Solenoid -H
-Hydraulic Lock I-1 G
120 YL Converter Ckt A584 BU F ront Window Limit SW To Wiper C ont Control - Engine/Pump F-2 7 Solenoid - Level Finish A-7 F This indicates that the component has a wire connected to it that is connected to ground.
124 GN A/ C / Heater Ckt A586 OR Wiper SW To Wiper Cont Controller - Wiper/Washer E-1 A Solenoid -S
-Swing Brake E-7 32
129 BU Cigar Light er Ckt A587 YL Pow er Window Cont To Safety Sol Relay Converter - Voltage H-6 9 Solenoid - Travel Speed A-7 F
135 BU 12V 5A Output Ckt A588 GN Saf ety Sol Relay To S
ol Converter ATCH I-3 8 Solenoid - Trenching A-7 F This indicates that the component does not have a wire connected to ground. It is
140 BU L ubricator C kt A589 OR Power Window Up Dial - Engine Speed E-3 B Switch - A/C Panel H-5 C grounded by being fastened to the machine.
147 PU Fine Swing /F
Fi /Flow Co
Control Ck
Ckt A590 BU Pow e
Po r Window Do
Down Diode A-3 18 Switch - Air Cleaner Flow H-9 35
149 PU Boom Lamp Ckt A591 PU R ear Window Limit SW
Diode - Main Relay H-7 D Switch - ATCH Refueling Start A-4 42
150 RD Bat (+) C468 BU Engine Oil Level
Fuses I-4,5,6 C Switch - ATCH Refueling Stop A-4 44
Reed Switch - A switch whose contacts are controll ed by a magnet. A magnet closes the
151 GN Hyd Lock /N
/N e
utral St a
rt Ck
Ckt C537 GN Turn Signal SW To Flasher  
Heater -A
-ATCH Seat with Seat Heater F-4 43 Switch -A
-ATCH Fine Swing Control D-4 B
contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.
152 BU Lower Washer / Wiper Ckt C538 OR H azard n
I dicator  
Horn A-2 10 Switch - ATCH Hammer H-1 G
154 RD Neutral Start / Neutral Start Ck
Ckt 607 PK F lo
lood Lamp -F
-Front
Lamp - Cab G-1 12 Switch - ATCH Heater Panel H-5 C Sender- A component that is used with a temperature or pressure gauge. The sender
168 RD R efueling Pump C kt 615 YL C ab Flood L
amp/ Rops
Lamp - Chassis A-2 13 Switch - ATCH Lower Washer D-3 B
172 RD E ngine Governor 616 BU B uc
ucket Fl
Flood Lamp/Boom Flood Lamp measures the temperature or pressure. Its resistance changes to give an indication to
Lighter E-1 A Switch - ATCH Lower Wiper D-3 B T
17
5 RD F a nC kt ControlCircuits the gauge of the temperature or pressure.
176
177
YL
RD
Aux Ckt
Main Brkr
763
786
BU
GN
Torque Converter SW
Eng Speed Cont - Hi Press SW
Meter - Service
Monitor
F-1
F-1
A
A
Switch - ATCH Power Window limit
Switch - ATCH Refueling
B-6
A-4
A
41 320B Excavators Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity.
Motor - ATCH Lower Washer I-9 D Switch - ATCH Seat Heater D-4 B

Electrical Systems
180 GN Aux Ckt 788 YL Eng Speed (+)
Motor -ATCH Lower Wiper H-1 G Switch - Aux Hydraulic Pressure H-1 G It has a coil that makes an electromagnet when current flows through it. The
185 YL Backup Ckt 791 PK Eng Speed C ont - Lo Sol
189 RD H yd Lock Ckt A718 PU Start Aid Coolant Sensor Signal Motor - Starter A-9 14 Switch - Boom Raise Pressure D-8,D-7 34 electromagnet can open or close the switch part of the relay.
191 WH Power Window C kt A755 PK T hrot tle SW #1  M otor - Washer I-9 D Switch - Control Pressure H-1 G
196 BU Insp. Lamp Ckt
In A756 BU T hrot tle SW #2
Th Motor - Wiper E-1 A Switch - Coolant Level H-9 36 320B:
Solenoid - A solenoid is an electrical component that is activated by electricity. It has a
GroundCircuits  A757 GY Throttle SW #3 Pickup - Engine Speed B-9 29 Switch - Crush Pressure #1 H-1 G
AED1-UP coil that makes an electromagnet when current flows through it. The electromagnet
200 BK Main Chassis
Ma A758 BR T hrot tle SW #4 Pump - ATCH Au
Auto Lubrication H-9 16 Switch -Crush Pressure #2 G-1 G
201 B K O p
er at o
r Mo
Moni ot r Re
Ret urn A 7
6 1 PU E el c rt o
n ci Pu
Pum pC on tT
tT h
r ot lt eG or u n
d Pump -A
-ATCH Refueling A-2 17 Switch -E
-Engine Oil Press B-9 38 3MR1-UP can open or close a valve or move a piece of metal that can do work.
235 B K El e
c rt oni cP
cPu m
p Ct
Ct lr Gn
Gnd A 7
6 2 PU E el c rt o
n ci Pu
Pum pC ont En
En gS p
e e
d Gr
Gr o
un d Radio -A
-ATCH 12VDC I-3 C Switch -F
-Flow Control Pressure H-1 G 4MR1-UP
BasicMachineCircuits  A768 BU PumpControlValve#1 (+) Relay - ATCH Flow Control E-7 D Switch - Horn I-1 C
304 WH St a
rter Re
Relay No. 1O
1Output A769 GY Pump Control Valve #2 (-) 4NR1-UP Harness And Wire Symbols
Relay - ATCH Refueling Power A-3 18 Switch - Hydraulic Control D-4 C
Component
3 06 GN S ta tr er R el ay C oi lT oN eu t St ar t SW O r A 77 0 PK Ee
l ct ro ni cP um pC on tr ol B yp as sS WT o Re si st or   Relay -ATCH Refueling Start A-3 19 Switch -Hydraulic Oil Filter A-5 E 5BR1-UP Wire, Cable, or Harness Part Number 
3 07 OR K ey S ta tr S WT oN eu tr al S ta tr S WO r A 77 1 PU Fo
l at S W Relay -ATCH Refueling Stop A-3 20 Switch -Hydraulic Oil Level A-5 E
308 YL Main Power Relay Coil 877 YL Glow Plug Magnet ic SW To Glow Plug
Relay - Boom Lamp I-7 D Switch - Implement Pressure D-8 39
6CR1-UP P i n S o ck e t Wire Color   Assembly Identification
Fuse
309
310
GY
P U
Al et nr a
t or Re
Re g
ul a
t or Te
Ter m.
S at r tA di S WT oS at r tAi dSo l
9 5
0
9 5
1
B R
P K
R gi h
t Co
R gi h
Con o
t Co
s el Co m
Con tH
p a
c ot rS
tH and el S WT
rSW To
To Re al y/ Di o
WT oR el a
yD/ oi d e
d e
Relay - Cab/Chassis Lamp I-7 D Switch - Key F-2 B 9KR1-UP  A AA 105-9344
Relay - Demolition E-8 D Switch - Neutral Start Limit I-1 C
320 OR Horn Relay Coil To SW 954 GN R gi ht Co
Console En
Eng Th
Throt le
t SW
SW To Re
Relay/Diode
Relay - Fan I-8 D Switch - One Touch Low Idle F-2 B
1CS1-UP 325-PK-14 1
321 BR Backup Alarm Lamp Travel Alarm F771 OR Backup SW
322 GY Warning Horn (Forward) F772 WH Backup SW
Relay - Heater F-7 D Switch - Power Window Limit D-3 A 8ES1-UP
Relay - Horn I-7 D Switch - Travel Pressure D-8 45
323 WH Fuel Pump Power F773 OR Governor Accel 9CS1-UP Single Wire
Connector 
CircuitNumber Wire Gauge Receptacle
325 PK Fuel Pump Relay Cut-Out F774 WH Governor Decel
Relay - Hydraulic Lock Solenoid I-7 D Switch -Window Limit D-1 A Identification
326 P U K e
y S at r tSW " C" T er m
. G9 7
3 O R B oom R ais ePr ess S Wt oC ur sh P er s sS W
Relay - Main G-7 D Switch Panel F-2 B 4XW1-UP Plug
Ground 2
330 YL Neutral Start Re
Relay Coil G974 WH C ur sh Sol to Demolition Relay
Relay - Neutral Start F-7 D Switch- Refrigerants Low Pressure I-9 40
5GW1-UP Connection 200-BK-14
329 YL Fuel Pump To SW G975 YL C rush Press SW to Demolition Relay Relay - Start F-8 D Unit - A/C, Heater H-6 21

365 Y L F u
e P
l u
m pR
pR e
l a
y To
To Sw ti ch J 7
0 3 P K A tl Pu
Pul e
s Si
Sig To
To An i-t St a
r tR
tR e
l a
y (w
(w as D7
D7 4
6 PK ) Relay - Start Cont E-8 D Unit - ATCH Heater H-5 46 2WZ1-UP Pin or Socket
MonitoringCircuits K 90 4 GN P um p Di sc ha rg e - Si gn al Relay - Timer E-7 D Unit - Heater Control I-7 D Number 
403 GN Alternat or (R) Term. K905 RD Pump Discharge - +B Resistor - Backup I-7 D Valve Proportional Reducing A-7 F
405 GY Opr Mon Oil Press. (Low Setting) K906 GN SW To SW (Generic) S en de r-
r- Co
Co ol an tT
tT em pe ar u
t er B 8- , B- 9 22 1 Typical representation of a Deutsch 1 Typical representation of a Sure-Seal
4 12 BU O p r Mo n C oo l F ol w D
/ s 2 Ap p S pe c () Pni 2 6 H
) E UI - AD E MI K 9 07 BU X M SN C o n t Fw d S W T o G n
d Machinelocationsarerepeatedforcomponentslocatedclosetogether.
2 connector. The plug contains all 2 connector. The plug and receptacle
 A Locatedinthecab.
430 BU Opr Mon A
ir Filter K909 BU XMSN Cont Rev SW To Gnd
B Locatedinthelefthandconsole. sockets and the receptacle contains contain both pins and sockets.
487 OR Hyd Oil Flow SW K911 PK XMSN Cont Speed 2 SW To Gnd C Locatedintherighthandconsole. all pins.
491 PK VMIS Hyd Oil Temp Sensor K912 GN XMSN Co
Cont Speed 3S
3SW To Gnd D Locatedonornearrelaypanel.
492 GY VM S
I Co
Co o
l a
n tT
tT e
m pS ens o
r Si
Sig n
al K 9
1 5 G N X MSN Co
Co n
t Sp
Spe e
d 4 SW To
To Gn
Gnd
E Locatedonornearhydraulicoiltank.
F Locatedonornearpilotmanifold.
495 GN VMIS Fuel Level Signal K997 BU XMSN Cont Neut SW To Gnd
G Locatedonornearbottomplatform.
© 1999Caterpillar  Printed in U.S.A.
496 W H O p
r Mo
Mon Pa n
el Hy
Hy dO
dO l i Le e
v l L9 0
8 O R X MSN C ont Pk B kr Le e
v rS WT oG nd  All Rights Reserved
AccessoryCircuits L909 BU ImplContSW To GndN.O.
501 GN Wiper -F
-Front L( ow) L968 OR I mpl C ont SW To Gnd N.C .
506 PU W asher - Front L969 WH XMSN Cont Speed 1SW To Gnd
XM
508 PU R adio Speaker -L
-Left L970 GY I njector Diode To n
I jector 14
509 W H R adio Sp
Spe a
k e
r - Lef t(
t(C om m
o n
) L9 7
1 G N I mp C
l ont Li
Li tf Pr
Pr o
p o
r io
t n
a S
l o
l
511 BR R adio Speaker -R
-R giht L972 BU I mpl Cont Low e
r Proportional Sol
512 GN Radio Speaker -R
-Right (Common) L973 GN I m
pl Cont Sol Return
51
3 OR AC
/ C om pr es so /r Re rf gi er an t Pr es su er SW
SW L 97 4 GN I mp lC on t Pi ol tP
tP e
r s So
l
51
9 PK T he m
r os a
t t To R ef ir ge ar nt P er s . SW L 97 5 OK S er ai lD at a T( a
r ns mi )t
530 OR Washer Right L976 GN Serial Data (R eceive)
575 YL Wiper - Aux (Park) L977 YL XMSN S
hif t Sol No. 5or 4
576 PK Turn Signal SW To Flasher L978 GY XMSN Shif t Sol No. 6
12
RealTimeErrorCodes
ConnectorLocation
33 Code DescriptionOfProblems
Schematic Machine
ConnectorNumber  1301 Engineoilpressuretoolow
15 Location Location
 A 3102 Enginecoolanttemperatureistoohigh
11 CONN 1 A-9 1
5
CONN 2 F-9 D 1303 Hydraulicoil temperatureistoohigh
2 50 CONN 3 F-9 14 1304  Airfilterisclogged
22
21 9
24 35 41
CONN 4 G-9 D 1305 Batteryvoltageisnotnormal
25
39 28
4 38 31 D 8 43 2201 Governoractuatorfeedbacksensorcircuitisopenor
ksensorcircuitisopenor shortedbatteryvoltage
yvoltage
45
CONN 5 G-9 D
26 14 E 32 46 44 42
CONN 6 H-8 D 2202 Governoractuatorfeedbacksensorisshortedtobodyground
ksensorisshortedtobodyground
34 23
36 10 20 2301 Governoractuatorfeedbacksignalis notstable
37 48 19
CONN 7 G-8 A
1 29 47 7
B C 18 CONN 8 G-8 A 2302 Governoractuatorfeedbacksignaldeviates
40 3 16 49 27
F 6 30 13 G 2303 Governoractuatordoesnotmove
17 CONN 9 G-9 A
CONN 10 G-6 G 2304 Calibrationdataerror 
Resistor,Sender andSolenoid Specifications
CONN 11 C-6 A 3201 MonitorRAMisnotnormal
Part No. Component Des cription Resistanc e O
( hm s)¹
CONN 12 C-6
C- A 4101 Electricpowersupplytothecontrolleristoomuch(43volts)
102-801 6 Res ist or: Bac ku p 47 .0 ± 2 .35
CONN 13 C-5
C- A 4102 Over-currentinproportionalreducingvalve
107-705 6 Sol enoi d: Fi ne Swi ng 34 .0 ± 0.5
4103 Proportionalreducingvalvecircuitisopen
111-991 6 Sol enoi d: Eng ine/ Pu mp Con trol 1 1.7 ± 1.2 CONN 14 C-5
C- A
CONN 15 F-5 A 4105 Over-currentindigitaloutput(trenchingsolenoid)
LevelFinish
121-149 0 Sol enoi d: 32±3.2 4106 Over-currentindigitaloutput(finecontrolsolenoid)
Trenching CONN 16 F-5 G
HydraulicLock CONN 17 F-5 A 4107 Over-currentindigitaloutput(Travelspeedchangesolenoid)
121-149 1 Sol enoi d: SwingBrake 32±3.2 4108 Over-currentindigitaloutput(travelalarm)
CONN 18 F-5
F- G
TravelSpeed 410A Over-currentindigitaloutput(swingbrakesolenoid)
CONN 19 F-4 G
122-445 9 Sol enoi d: Fl ow Con trol 34 .3 ± 1.7 4201 Enginespeedisnotnormal
CONN 20 F-4 G
¹ Atroomtemperature.
e. 4202 Enginecoolanttemperaturesensorisshortedtobody ground
CONN 21 H-5 G
CONN 22 H-5 G 4203 Hydraulicoil temperaturesensorisshortedtobodyground
33
C 12 4204 PWMsensorofpumpdeliverypressureis
eis openincircuit
CONN 23 H-4 G
6 9
CONN 24 H-4 G 4207 PWMsensorofpumpdeliverypressureis
eis openincircuit
8
35 D
46  A 43 CONN 25 H-4 G 420A Fuelsensorisshortedtoground
16 G
25
36 40 33 420B Fuelsensorisopenorshortedtobatteryvoltage
CONN 26 H-4 G
Off Machine Switch Specification 49 7 420C
26 3 B CONN 27 B-4 23 Electricpowersupplyistoolow(below23volts)
15
Part No. Function Actuate Dea ctuate Contact Pos ition 5 12
21 CONN 28 A-4 42 420D Electricpowersupplyistoohigh(above32volts)
TravelPressure 1520 ± 98 kPa 1127kPaMin 34
106-0179 NormallyOpen 4 22
11
CONN 29 A-4 20 420E Enginespeeddialisnotoneof thespecified10
ImplementP ressure 220.5±14psi 163.5psi
2646 ± 196 kPa 2156 ± 196 kPa 10
CONN 30 B-3 47 4301 Datamismatch1betweenalternatorandspeedsensor(altern
natorandspeedsensor(alternatorisabnormal)
106-0180 BoomRaisePressu
e ssure NormallyOpen 29
383.8±28.4psi 312±28.4psi 50
4302
38 2 28 CONN 31 B-3 48 Datamismatch2betweenalternatorandspeedsensor(speedsens
natorandspeedsensor(speedsensorisabnormal)
orisabnormal)
FlowControlPressure 31 45 32 10
490 ± 49 kPa 290 kPa 4303
 106-0181  Aux.HydraulicPressure NormallyOpen CONN 32 C-2 49 Enginestalls
71±7.1psi 42psi 37 39
HammerPress ure 23 48 11
CONN 33 C-2 G  A201 Monitorcommunicationisnotnormal
E
196 ± 1340 kPa - 44 42
113-344 RefrigerantHig
a ntHigh/LowPressure NormallyOpen 1 13  A202 Monitortakestomuchtimetorespondtocontroller'ssignal
28.4±455.4psi - 47 20 CONN 34 C-2 G
14 19
CONN 35 C-2 G  A203 Communicationisabnormalincontroller 
27
18
24 F 30 17 CONN 36 B-2
B- D
CONN 37 E-8
E- D
41
CONN 38 E-8
E- D
Theconnectorsshowninthischartareforharnessto harness
connectors. Connectors that join a harnessto a component RelatedElectrical Service Manuals
Machine Harness Connector And Component Locations aregenerallylocatedat ornearthecomponent. Seethe
ComponentLocationChart.
Tit le Form Numb er  
Engi ne/Pum p Co
Contro l SENR929 1
StartingandCharging RENR1007