Cat 416C 426C 428C 436C & 438C Backhoe Loaders with European Cab Electrical System Schematic Manual

Page 1

FMI No.

Wire Number

Failure Mode Identifiers (FMI)

Wire Description

Wire Color

Description

Wire Number

Wire Color

Power Circuits

Failure Description

Description

SENR1275-03 December 2000

Accessory Circuits (cont'd)

0

Data valid but above normal operational range.

101

RD

Bat (+)

522

WH

A/C Clutch To Thermostat SW

1

Data valid but below normal operational range.

102

RD

Running Lamp Pwr

536

WH

Hazard SW To Turn SW

2

Data erratic, intermittent, or incorrect.

104

YL

Acc Rly Output

537

GN

Turn Signal SW To Flasher

3

Voltage above normal or shorted high.

4

Voltage below normal or shorted low.

105

RD

Key Sw Pwr

552

WH

Four Wheel Drive Sol

5

Current below normal or open circuit.

110

RD

Horn Pwr

568

GN

Park Brake Alarm Sig

6

Current above normal or grounded circuit.

111

YL

Acc Bat Pwr

571

OR

Powershift - Ride Control Relay

7

Mechanical system not responding properly.

112

PU

Main Power Rly Output

578

BU

Washer - Aux

8

Abnormal frequency, pulse width, or period.

113

OR

Opr Mon Panel Pwr

619

GN

Headlamp low

13 25 10 9

9

Abnormal update.

115

RD

Acc Socket Pwr

C558

YL

Front Wiper Switch Jumper

10

Abnormal rate of change.

11

Failure mode not identifiable.

116

BR

Std Rear Flood Pwr

C559

YL

Rear Wiper Switch Jumper

12

Bad device or component.

117

YL

Aux Rear Flood Pwr

C593

OR

Power Seat Relay Control

13

Out of calibration.

118

GY

Front Wiper Pwr

C594

YL

Power Seat Motor

14

Parameter failures.

119

PK

Rear Wiper Pwr

C595

GN

Power Seat Heater

15

Parameter failures.

121

YL

Back Alarm Pwr

16

Parameter not available.

122

BU

Heater Pwr

602

RD

Dome Lamp Pwr

17

Module not responding.

18

Sensor supply fault.

123

WH

XMSN Ctrl Pwr

603

PK

Rotary Beacon

19

Condition not met.

124

GN

A/C Pwr

604

OR

Stop Lamp

20

Parameter failures.

128

PK

Bucket Position Pwr

605

YL

Turn Lamp - Left

130

GN

Radio Pwr

606

GY

Turn Lamp - Right

136

GN

Suppl Steer Pwr

607

PK

Flood Lamp - Front

9 10

The FMI is a diagnostic code that indicates what type of failure has occurred.

140

Component Identifiers (CID¹) Module Identifier (MID²) Power Train Control (MID No. 081)

CID

Component

0041

+ 8 Volt Sensor Supply

0138

Reduced Rimpull Selection Switch

0143

Neutralizer Press Switch

0144

Backup Alarm Relay

0168

System Voltage

0190 0191

16 7

E F

1 A

Blower Pwr

608

GN

Flood Lamp - Rear

143

BR

AWD Pwr

610

OR

Head Lamp Basic

144

GN

Beacon Pwr

611

PU

Head Lamp Hi

157

YL

Aux Front Flood Pwr

614

PU

Park/Tail/Dash/Lamp

161

RD

Flasher Pwr

617

BR

Tail/Position Lamp - Left

170

RD

Radio Memory Pwr

618

YL

Tail/Position Lamp - Right

194

GN

Cab Bat Pwr

620

WH

Flood Lamp - Front (Attach)

197

GN

Cab Relay Output

627

YL

Fog Lamp

198

PK

A/C Relay Output

630

GY

Flood Lamp Rear (Attach)

634

WH

Head Lamp SW To Work/Head Lamp Jumper

GN

XMSN Speed Pickup Signal

Ground Circuits

D

B

2

19

8

14

416C, 426C, 428C, 436C and 438C Backhoe Loader With European Cab Electrical System

21 19 18

A

26 F 1

7

25 20

Control Circuits

Main Chassis Operator Monitor return

710

202

BK

XMSN Ctrl Gnd

752

YL

XMSN Shift Sol 1st and 2nd Gear

Eng Speed Sensor Signal

217

BK

Start relay return

754

BU

XMSN Shift Sol 3rd Gear

Transmission Speed Sensor Signal

218

BK

Drop valve relay return

755

OR

XMSN Shift Sol 4th Gear

0248

Data Link

265

BK

Loader Lock Gnd

762

YL

Bucket Positioner Sol

0254

Electronic Control Module (ECM)

0444

Start Relay

270

BK

Loader Lock Gnd

766

GN

XMSN Disconnect SW

0590

Eng Electronic Control Module

276

BK

Pshift Ctrl Harn Code 0

779

WH

Coupler Engage Sol

0603

Impeller Clutch Press Sensor

277

BK

Pshift Ctrl Harn Code 1

C720

BU

XMSN Neutral Lock Sig

0623

Direction Switch

278

BK

Pshift Ctrl Harn Code 2

E701

PK

Ride Control

0626

Steering/Transmission Lock Switch

279

BK

Pshift Ctrl Harn Code 3

E702

OR

Ride Control SW

0627

Parking Brake Press Switch

280

BK

Pshift Ctrl Harn Code 4

E764

OR

AWS Circle Steer/Lock Sol

0628

Quick-Shift Switch

281

BK

Pshift Ctrl Harn Code 5

F738

WH

Loader Rod End Pressure SW

0650

Harness Code

Basic Machine Circuits

F748

WH

Powershift - Ride Control Manual

0672

Torque Converter Output Speed Sensor

F765

BR

Park Brake SW To Relay

F-5

B

Torque Converter Impeller Clutch Solenoid

Key SW ACC Position

Action - Lightbar

0678 0679

Torque Converter Lockup Clutch Solenoid

AWS Shut Off Sol

Alarm - Backup

D-18

1

0826

Torque Converter Oil Temperature Sensor

AWS Relay Coil to Diode

Alarm - Light Bar

D-16

1401

Transmission Clutch 1 Solenoid Valve (Reverse)

AWS Relay Coil to Diode

Alternator

1402

Transmission Clutch 2 Solenoid Valve (Forward)

308

1403

Transmission Clutch 3 Solenoid Valve (Speed) 3

309

GY

Alternator Regulator Term.

G795

1404

Transmission Clutch 4 Solenoid Valve (Speed) 4

310

PU

Start Aid Sol

G796

1405

Transmission Clutch 5 Solenoid Valve (Speed) 5

321

BR

Backup Alarm

322

GY

334 367

3

G 16

13

11

6 24 4

5

12

14

17 22 2

8

15 23

416C: 5YN3800-15147 1BR649-UP 1LR416-UP 1XR684-2183

Solenoid - Cold Start Advance

H-5

12

Solenoid - Engine Shutdown

G-3

17

A

Solenoid - First and Second Gear

H-13

G

E-3

2

Solenoid - Front Drive

F-3, I-5

G

AWS Mode SW To Press SW

Assembly - Fan

E-17

3

Solenoid - Fuel Shutdown

I-4

7

OR

AWS Mode SW To Rear Steer SW Pwr

Batteries

C-3

4

Solenoid - Group A (Forward High and Low)

I-13

G

YL

AWS Mode SW To Rear Steer SW Gnd

Breaker - Running Lamp

F-10

A

Solenoid - Group B (Third & Fourth Gear)

I-13

G

G797

BU

AWS Left Steer Relay Gnd

Coil - Forward Solenoid

G-3

G

Solenoid - Hydraulic Shutoff

B-18

1

Forward Horn

G798

PU

AWS Right Steer Relay Gnd

Coil - Reverse Solenoid

F-3

G

Solenoid - Left Steer

K-9

7

BU

Cold Start Adv Sol

H767

BR

AWS Circle Steer/Lock Sol Gnd

Coil - Thermostart

J-4, E-3

5

Solenoid - Loader Lock LH

I-7

18

BU

Rear Horn

H768

BR

AWS Left Steer Sol Gnd

Control - Powershift

L-12

4

Solenoid - Loader Lock RH

I-7

19

H769

BR

AWS Right Steer Sol Gnd

Control - Shuttle

E-8

D

Solenoid - Lock

L-9

7

K-13

D

Solenoid - Reverse

I-13

G

K-9

7

WH GN OR YL

Start Relay Output Starter Relay Coil Key Sw Start Position Key Sw Run Position

G726 G742 G743 G789

GY GN OR BR

Component

Schematic Location

Component Location

Machine Location

BR

Machine Location

Component

405

GY

Opr Mon Oil Press. (Low Setting)

H770

BR

AWS Shut Off Sol Gnd

Control - Shuttle (Powershift)

406

PU

Opr Mon Coolant Temp

H771

BR

Side Shift Lock Sol

Flasher

F-10

B

Solenoid - Right Steer

419

YL

Opr Mon Parking Brake

H772

YL

Backhoe Shutoff Sol

Fuses

F-11

D

Solenoid - Shutoff

K-9

7

429

YL

AWS Position Gage

F871

PU

AWS Left Steer Sol

Fuses

F-14

C

Solenoid - Side Shift Lock

B-18

1

441

OR

Eng Coolant Temp Gage

F872

BU

AWS Right Steer Sol

Fuses

K-3

C

Solenoid - Valve Group A

F-1

8

443

YL

Converter Temp Gage

F873

YL

Relay Contact To Diode As

Gauge - AWS Position

L-5

B

Switch - Air Conditioner Blower

K-16

A

447

PK

Fuel Level Gage

F874

PK

AWS Left Steer Relay Ctrl

Gauge - Converter Temperature

B-15

A

Switch - Aux Coupler

C-6

B

450

YL

Tach Sender (+)

F877

WH

AWS Right Steer Relay Ctrl

Gauge - Coolant Temperature

B-16

A

Switch - Aux Rear Flood

G-13

C

FWD Solenoid Rtn

Gauge - Fuel Level

B-16

A

Switch - AWD

E-6

B

G-3

6

Switch - AWS Mode Select

L-5

B

K-8

20

483

BR

Opr Mon Brake Fluid Level Accessory Circuits

922

BR

923

GY

REV Sol Rtn

Ground - Engine

OR

Data Link + (CAT)

Ground - Headliner

B-12

C

Switch - AWS Pressure

500

BR

Wiper - Front (Park)

944

501

GN

Wiper - Front (Low)

945

BR

Data Link

Ground - Platform

B-14

7

Switch - Backhoe Shutoff

D-17

A

502

OR

Wiper - Front (HI)

975

WH

Powershift - Sol Return

Ground - Steer Column

E-10

3

Switch - Beacon

E-12

C

503

BR

Wiper - Rear (Park)

976

OR

Ride Control Relay

Horn - Forward

B-3

8

Switch - Brake A

D-9

E

D-18

1

Switch - Brake B

D-9

E

B

Switch - Brake Fluid Level

C-4

21

- (CAT)

504

YL

Wiper - Rear (Low)

991

WH

XMSN Neut SW

Horn - Rear

505

BU

Wiper - Rear (HI)

C920

GY

Diagnostic Indicator - Powershift

Horn - Stabilizer Leg

H-8

506

PU

Washer - Front

C993

WH

Shuttle Ctrl Pwr

Junction - Power

D-9

3

Switch - Cold Start Temperature

L-5

B

Switch - Coolant Temperature

WH

Washer - Rear

L998

OR

Aux Hyd Sol B

Lamp - Indicator

Aux Hyd Sol C

LED - Service

L-14

A

Switch - Coupler

D-6

B

CONN 1

J-18

9

509

WH

Radio Speaker - Left (Common)

M913

PU

Diode to AWS Indicator Lamp

Meter - Service

D-14

A

Switch - Coupler Detent

A-15

A

CONN 2

J-17

9

M968

BU

Coupler Switch Interconnect

9

Switch - Dip Beam

F-6

B

A

Radio Speaker - Right

K-18

L-17

BR

Motor - Air Conditioning Blower

CONN 3

511

Radio Speaker - Right (Common)

N904

PU

Forward High Solenoid

3

Switch - Engine Oil Pressure

F-3, H-4

22

9

GN

E-17

L-17

512

Motor - Fan Assembly

CONN 4 CONN 5

H-7, H-8, J-15

A

513

OR

A/C Compressor/Refrigerant Pressure SW

N905

OR

Forward Low Solenoid

Motor - Front Washer

C-3

21

Switch - Fog Lamp

K-17

A

G-5

C

Switch - Front Roading

G-12

C

L-15

4

515

GY

Blower Motor (HI)

N907

GN

Reverse Low Solenoid

B-14

A

516

GN

Blower Motor (Medium)

P909

PK

Autoshift Disable

Motor - Heater Blower

D-17

A

Switch - Front Roading OROPS

CONN 8

B-14, L-9, L-10

A

517

Stabilizer leg sw

Motor - Rear Washer

C-3

21

Switch - Front Wiper

CONN 9

C-14, I-3

A

520

WH

Opr A/C SW To Thermostat/Fuse

Shuttle control jumper

Motor - Rear Wiper

E-17

10

Switch - Hazard

CONN 10

C-14, I-3

A

A/C SW To Refrigerant SW

11

A

YL

D-3

C-14

521

Motor - Starter

CONN 11 CONN 12

I-14

G

Power Port

D-14

A

CONN 13

K-14

25

Radio

H-17

CONN 14

K-14

25

F-9

L-14

4

CONN 16

B-13, K-2

CONN 17

C-13, K-2

CONN 18

J-13

3

CONN 19

J-13

3

CONN 20

D-11, J-3

3

3E-1908

Solenoid: A/C Clutch

17.6 ± 0.6

CONN 21

D-11, J-3

3

3E-6184

Resistor: Powershift

100 ± 5

CONN 22

B-10, K-2

C

3E-8620

Solenoid: Aux Dent, Bucket Pos

32.1

CONN 23

D-10, J-2

3

CONN 24

D-10, J-2

3

3E-8622

Solenoid: Sideshift Lock, Shutoff, Valve Group A

10.5

CONN 27

I-8

1

CONN 28

F-7

B

CONN 29

F-7, J-1

B

CONN 30

F-7, J-1

B

CONN 31

J-7

3

CONN 32

K-7

7

CONN 33

K-7

3

CONN 34

K-7

3

CONN 35

D-5, I-1, I-6

6

CONN 36

D-5, I-1, I-6

6

CONN 37

D-5, I-1, I-6

6

CONN 38

B-5

3

CONN 39

B-5, H-1

6

CONN 40

K-5

3

CONN 41

K-5

3

CONN 42

C-4

G

CONN 43

B-3

6

CONN 44

F-1

8

CONN 15

Data Link

R977 R978

BU YL

Relay - Accessory

L-1

C

E-12

C

F-6

B

Switch - Head Flood Atch

G-13

C

Switch - Head to Floodlights

F-12

C

C

Switch - Heater

A-14

B

D

Switch - Horn

C-6

B

Relay - Air Conditioning

F-9

B

Switch - Loader Lock

I-7

1

C

Relay - Cab

E-9

D

Switch - Loader Transmission Neutralizer

D-5

E

C

Relay - Left Steer

D-4

B

Switch - OROPS Beacon

K-1

C

CONN 45 F-1 8 The connectors shown in this chart are 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.

Resistor, Sender, and Solenoid Specifications Component Description

Part No.

4W-9972 7N-8532 8C-5541

Sender: Converter Temp Sender: Coolant Temp Solenoid: LH/RH Loader Lock

Resistance (Ohms)¹

560 to 716 at 54°C (130°F) 72 to 82 at 110°C (230°F) 560 to 716 at 54°C (130°F) 72 to 82 at 110°C (230°F) 560 to 716 at 54°C (130°F) 72 to 82 at 110°C (230°F)

113-5320

Solenoid: Right/Left Lock

8.5

121-4036

Solenoid: Front Drive

10.5

126-3707

Solenoid: Ride Control

2.8 ± 0.3

Fuel Level 128-2875

Sender: Empty:

240 to 260

Full:

27.5 to 39.5

A/C

Overall: 1.0 ± 0.1

134-2885

Resistor:

Heater

Tap: 0.5 ± 0.05

138-1976

Solenoid: Hydraulic Shutoff

8.15 ± 0.6

¹ At room temperature.

Relay - Loader Lock

I-9

A

Switch - OROPS Head To Flood

K-1

C

Relay - Main

F-9

D

Switch - OROPS Rear Floods

K-1

C

Relay - Park Brake

K-15

A

Switch - Overdrive Disable

J-11

B

Relay - Right Steer

K-4

B

Switch - Park Brake

B-8

A

Relay - Seat

L-10

F

Switch - Rear Floods

F-12

C

Relay - Shutoff

J-4

B

Switch - Rear Horn

B-17

A

Relay - Start

E-9

D

Switch - Rear Steer

K-8

B

Relay - Stabilizer Leg

H-8

E

Switch - Rear Wiper

D-13

E

Resistor - Air Conditioning

K-17

A

Switch - Refrigerant

J-16

23

Resistor - Heater

E-16

A

Switch - Return to Dig

L-16

13

Resistor - Powershift

K-10

B

Switch - Seat

K-10

F

Sender - Converter Temperature

G-3, I-5

6

Switch - Side Shift

D-16

A

Sender - Coolant Temperature

E-3, I-4

12

Switch - Stabilizer Leg

B-18

26

Sender - Fuel Level

G-4, H-5

13

Switch - Start

D-14

A

J-9

7

Switch - Start Aid

D-14

A

Sensor - RTD

L-18

14

Switch - Thermostat

Sensor - Speed

H-13

G

Switch - Transmission Neutral

Solenoid - Air Conditioning Clutch

J-17

15

Solenoid - Aux Detent

A-5

Solenoid - Bucket Position Solenoid - Circle Steer

Sensor - Rear Steer Position

J-18

9

D-4, I-5, K-8

24

Switch - Transmission Neutral Lock

D-6

B

16

Switch - Turn Signal

F-5

B

A-4

16

Switch - Washers

C-13

C

L-9

7

Tachometer

B-16

A

Machine locations are repeated for components located close together. A = Operator Compartment - Right Console B = Operator Compartment - Front Console C = Operator Compartment - Overhead Console D = Operator Compartment - Steering Column Top Panel E = Operator Compartment F = Inside Seat Assembly G = Under Cab Floorplate

Title

Form Number Alternator:

SENR7508 SENR3828

GN

Circuit Breaker Symbol

Flow Symbol

Level Symbol

Temperature Symbol

Related Electrical Service Manuals

SENR1274

L999

CONN 7

Pressure Symbol

Starter:

Radio Speaker - Left

CONN 6

T

Power Shift Transmission Control:

PU

Motor - Front Wiper

Electrical Schematic Symbols And Definitions

12

508

Printed in U.S.A.

© 2000 Caterpillar All Rights Reserved

12

Machine Location

Blower Motor (Low)

436C: 9JN384-883 1GR416-915 1RR498-997 2BR411-910

438C: 9KN561-1060 1JR607-1106 1TR783-1283 2DR1050-2716

H-4

Schematic Location

BU

428C: 8RN1629-4088 1HR403-UP 1SR423-UP 2CR4428-16211

F-3, H-4

507

Connector Number

426C: 7WN439-938 1ER364-863 1NR454-953 1ZR426-925

MACHINE HARNESS CONNECTOR AND COMPONENT LOCATIONS

Schematic Location

Monitoring Circuits

Connector Location

12

11 5

E

BK

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.

23

C

BK

307

15

17

4

201

306

6

26

200

304

G

22

Lighting Circuits

BU

303

20

18 C 24 21 3 D B

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.

Off Machine Switch Specification Part No. 6T-2665 9X-5446

Function Engine Coolant Temperature Thermostat

114-5333

Refrigerant Pressure

128-5091

AWS Pressure

Actuate

Deactuate

Contact Position

107.2 ± 2.8ºC

93ºC MIN

Normally

(225 ± 5ºF)

(196ºF MIN)

Open

.25Nm to .43Nm

--

Normally

(.19 lb ft to .32 lb ft)

--

Open

275 to 1750 kpa¹

--

Normally ²

(40 to 255 psi)

--

Open

551 kPa

344 kPa ± 20 kPa

A-C Normally Closed

(36.3 psi)

(49.9 psi ± 2.9 psi)

A-B Normally Open

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".

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.

* * 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


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