SENR1229-03 September 2004
Electrical Schematic Symbols And Definitions Diagnostic Code Conversion
12
No Active Faults No Inactive Faults
14
Description
Part No. 163-7355
Component Location
928G 924G Standard Speed
16
IT28G
17
Not Available
18
924G Low Speed
19
Not Available 641 - 05
Function
Not Applicable
15
31
Off Machine Switch Specification
Not Applicable
Schematic Location
Machine Location
Arc Suppressor
I-12
3
Breaker - Air Seat
H-13
Cigar Lighter
E-8 A-7,8 A-4
Component
Forward High Solenoid Open Circuit
32
642 - 05
Reverse Solenoid Open Circuit
33
643 - 05
Forward Low Solenoid Open Circuit
34
644 - 05
35 36
Control - CST Autoshift Control - FNR
Schematic Location
Machine Location
Relay - Park Brake Alarm
H-12
E
E
Relay - Park Brake LT/Seat Alarm
C-12
E
C
Relay - Ride Control/load Check
C-12
E
1
Socket - Aux 24v
I-13
5
A
Speedometer
H-2
A D
Component
Control - Secondary Steer
B-6
1
Switch - Kickout
G-10
Converter - 12v to 24v DC
I-12
2
Switch - Beacon
F-9
B
Speed 1 Solenoid Open Circuit
Coolant Temperature
H-2
A
Switch - Blower
G-10
D
645 - 05
Speed 2 Solenoid Open Circuit
CST Shifter
I-3
A
Switch - Bucket Fork Select
G-10
D
646 - 05
Speed 3 Solenoid Open Circuit
Diode Block B
I-5
C
Switch - Defrost
G-10
D
37
346 - 05
Ride Control Relay Open Circuit
Flasher
G-4
D
Switch - Dimmer
G-6
D
38
683 - 05
Parking Brake Alarming Open Circuit
FNR - Relay
E-13
E
Switch - Downshift
B-12
D
39
421 - 05
Load Check Relay Open Circuit
FNR LED Panel
F-2
A
Switch - Forward Horn
I-6
A
41
641 - 06
Forward High Solenoid Short to Ground
Fuel Level Gauge
G-2
A
Switch - Front Wiper
D-8
C
42
642 - 06
Reverse Solenoid Short to Ground
Fuses
H-12,13
E
Switch - Hazard Lamp
G-9
B
43
643 - 06
Forward Low Solenoid Short to Ground
Fuses
G-12,13
E
Switch - Hyd Lock Detent Override
H-9
A
44
644 - 06
Speed 1 Solenoid Short to Ground
Fuses
F-12
E
Switch - Key Start
G-6
A
A-14
9
Switch - Parking Brake
I-13
5
45
645 - 06
Speed 2 Solenoid Short to Ground
Ground - Cab Boss
46
646 - 06
Speed 3 Solenoid Short to Ground
Ground - Shell Stud
D-14
8
Switch - Quick Coupler
E-10
D
H-3
A
Switch - Rear Wiper
C-8
C D
47
346 - 06
Ride Control Relay Short to Ground
Hydraulic Temperature Gauge
48
683 - 06
Parking Brake Alarming Short to Ground
Meter - Service
I-6
A
Switch - Ride Control
F-10
49
421 - 06
Load Check Relay Short to Ground
Motor - Blower
E-14
4
Switch - Secondary Steer
E-8
C
F-2
6
Switch - Service Brake
E-3
10
51
641 - 03
52
642 - 03
Forward High Solenoid Short to Ground Reverse Solenoid Short to Battery
53
643 - 03
Forward Low Solenoid Short to Battery
54
644 - 03
Speed 1 Solenoid Short to Battery
55
645 - 03
Speed 2 Solenoid Short to Battery
56
646 - 03
Speed 3 Solenoid Short to Battery
57
346 - 03
Ride Control Relay Short to Battery
Motor - Front Wiper Motor - Rear Defroster
F-15
4
Switch - Start Aid
Motor - Rear Wiper
F-15
7
Switch - Thermostat
F-9
B
E-14
D
Relay - Alarm Disarm A
C-13
E
Switch - Turn Hazard
G-5
A
Relay - Alarm Disarm B
D-13
E
Switch - XMSN Auto Manuel
F-10
D
Relay - Backup Alarm
C-12
E
Switch - XMSN Neutralizer
F-9
B
Relay - Main Power
H-12
E
Torque Converter Temperature
G-3
A
Low Pressure
160-2609
High Pressure
Actuate
Deactuate
Contact Position
875 ± 20 kPa
517 kPa Min
A-C, Normally Closed
(126 ± 2.9 psi)
(74 psi Min)
A-B, Normally Open
1724 kPa MAX
1325 ± 170 kPa
A-C, Normally Closed
(250 psi MAX)
(192 ± 24 psi)
A-B, Normally Open
683 - 03
Parking Brake Alarm Short to Battery
59
421 - 03
Load Check Relay Short to Battery
B Located in lefthand dash panel.
61
190 - 08
Engine Speed Sensor
C Located in righthand dash panel.
62
191 - 08
Transmission Speed Sensor
63
668 - 02
Invalid Shift Lever input
D Located in the righthand console. E Located in or near relay panel
64
168 - 00
Battery Voltage Above Normal
65
168 - 01
Battery Voltage Below Normal
66
650 - 02
Invalid Harness Code Input
67
687 - 02
Invalid Option Code Input
68
367 - 02
Invalid Ride Control Switch Input
69
621 - 02
Invalid Downshift Switch
71
143 - 02
Invalid Neutralizer Pressure Switch Input
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.
Resistor, Sender and Solenoid Specifications Part No.
Component Description
9G-1950
Resistance (Ohms)¹ Overall: 2.0 ± 5%
Resistor: Blower Motor Speed
Tap: 1 ± 5% ¹At room temperature
Wire Description Wire Color
Description
Wire Number
Wire Color
Description Accessory Circuits (Continued)
101
RD
Battery +
538
BR
COSA Flasher Output
102
RD
Marker Lamps
539
BU
Right Turn Indicator
105
RD
Kay Switch
540
WH
Left Turn Indicator
108
RD
Converter Output
567
WH
Blower To A/C Sw
109
RD
Alt B+
571
OR
Ride Control Signal
110
GN
Flasher
112
PU
Main Breaker Output
603
PK
Beacon
114
RD
Fwd Horn
604
OR
Stop Lamp
115
RD
Aux Circuit Breaker
605
YL
Left Turn
117
RD
Main Breaker
606
GY
Right Turn
118
GY
Wipers
608
GN
Rear Flood Lamps
120
YL
Sw'd Converter
610
OR
Dimmer Switch
122
RD
Misc
611
PU
High Beam Headlights
123
WH
Gauges and Indicator Light
614
PU
Marker Lights
124
GN
Blower
615
YL
Cab Flood Lights
126
PK
XMSN Control
619
GN
Low Beam Headlights
127
OR
Flood Lights
633
BU
COSA Turn Signal
128
PK
Kickout & Ride Control
665
BR
Corner Markers
129
BU
Cigar Lighter
691
GY
COSA Flasher
130
RD
Stop Lamps
133
OR
FNR
702
OR
XMSN Neutralizer XMSN Speed
BU
Sw'd Converter Output
710
GN
136
GN
Secondary Steering
720
PU
Neutralizer 1
Rear Window Defroster
727
GN
Secondary Steering Output
Electrical System
140
BU
0190
Engine Speed Sensor
144
GN
Beacon & Heated Seat
751
GN
XMSN Solenoid 1
0191
Transmission Speed Sensor
158
BR
Condenser Motors
752
YL
XMSN Solenoid 2
0346
Ride Control Relay
161
PK
Ride Control
754
BU
XMSN Solenoid 3
0367
Ride Control Switch
188
WH
Start Aid
755
OR
XMSN Solenoid 4
761
GY
Lift Position
Forward High Solenoid
0642
Reverse Solenoid
0643
Forward Low Solenoid
0644
Speed 1 Solenoid
0645
Speed 2 Solenoid
0646
Speed 3 Solenoid
0650
Harness Code
10
11 5
Shift Lever
0683
Parking Brake Alarm
B A
4
BK
Main Chassis
762
YL
Bucket Positioner
202
BK
Controller
779
WH
Quick Coupler Engaged
276
BK
XMSN Ident Code 0
780
PU
Quick Coupler Disengaged
277
BK
XMSN Ident Code 1
900
PU
XMSN Solenoid 5
278
BK
XMSN Ident Code 2
901
WH
XMSN Solenoid 6
279
BK
XMSN Ident Code 3
944
OR
CAT Data Link +
945
BR
CAT Data Link -
301
BU
Fuel On
963
GN
Tilt Positioner
304
WH
Start Relay Output
964
BU
306
GN
Start Disable Output
973
BR
307
OR
Key Switch Start
975
WH
308
YL
Key Switch Run
976
OR
6
7 3
C
Basic Machine Circuits
14
D E 12
0668
15
200
2
1 9
8
13
0687 Invalid Option Code 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 FMI No.
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.
11
6
Current above normal or grounded circuit.
7
Mechanical system not responding properly.
8
Abnormal frequency, pulse width, or period.
9
7 4
A D
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 20
E 10
B
C 6
5
2 14 1
3 12 13
9
CONN 1 CONN 2
A-15
12
Fork Positioner
CONN 3
A-15
12
Auto/Manuel XMSN
CONN 4
A-15
12
Solenoid Return
CONN 5
B-15
12
Ride Control Output
CONN 6
B-15
12
Start Aid Signal
978
GN
Downshift Signal
CONN 7
B-15
12
Backup Alarm
A221
BK
XMSN Option Code 0
CONN 8
B-15
12
322
GY
Fwd Horn
A222
BK
XMSN Option Code 1
CONN 9
C-15
12
326
PU
Key Switch Off
A514
YL
Parking Brake Alarm
331
OR
XMSN Backup Alarm Output
A519
GN
V-Link Ride Control Output
CONN 10
D-15
5
373
GN
Start Aid Signal
A520
BU
V-Link Ride Control Signal
CONN 11
G-15
11
A538
OR
Rear Window Defroster Signal
CONN 12
F-14
4 13
403
GN
Alternator (R) Treminal
A541
PU
COSA Turn Indicator
CONN 13
D-14
404
YL
XMSN Oil Temperature Indicator
A576
GN
Air Seat
CONN 14 Harness Code Plug
E-10
8
405
GY
Engine Oil Temperature Indicator
C444
YL
Alternator Field Excitation Coil
CONN 15 Options Code
E-10
8
406
PU
Coolant Temperature Indicator
C446
PK
Filter Warning
CONN 16 ECAP
D-10
8
417
GY
Steering Pressure
C470
BR
Alarm Signal
CONN 17
F-6
14
419
YL
Park Brake Indicator
C471
GN
Alternator Warning
CONN 18
F-6
14
441
OR
Coolant Temperature
C904
GN
FNR Solenoid 1
CONN 19
F-6
14
442
GY
Hydraulic Temperature
C920
GY
Diagnostic Indicator
CONN 20
E-6
14
443
YL
Torque Converter Temperature
E417
OR
Parking Brake Signal
CONN 21
E-6
14
CONN 22
H-5
14
CONN 23
H-5
14
CONN 24
B-4
15
CONN 25
A-4
15
PK
Fuel Level
E419
BU
Seat Alarm
BU
Ground Speed
E701
PK
Ride Control On
450
YL
Engine Speed
E800
GN
Seat Alarm Output
453
PK
Secondary Steering Indicator
F748
WH
Ride Control
483
BR
Oil Pressure Indicator
F765
BR
Parking Brake
484
YL
Primary Steering Indicator
F766
WH
Detent Override
500
BR
Wiper - Front (Park)
F853
BR
TUV Speed Limiter
F880
BR
FNR Solenoid 2
GN
Wiper - Front (Low)
G728
YL
Kickouts On/Off
502
OR
Wiper - Front (High)
G742
GN
Key Switch Run Signal
503
BR
Wiper - Rear (Park)
G750
GU
XMSN Fwd
504
YL
Wiper - Rear (Low)
G755
GY
XMSN Rev
505
BU
Wiper - Rear (High)
G757
OR
XMSN Neutralizer 2
506
PU
Washer - Front
G760
WH
XMSN Speed 2
Condition not met.
507
WH
Washer - Rear
G761
YL
XMSN Speed 3
Parameter failures.
508
PU
Radio Speaker - Left
G762
BR
XMSN Speed 4
509
WH
Radio Speaker - Left (Common)
G763
PU
FNR Switch 1
511
BR
Radio Speaker - Right
G768
GN
XMSN Speed 1
Title
Form Number
Transmission Control:
SENR1218
Machine Harness Connector And Component Locations
Connector Number
PU
501
Related Electrical Service Manuals
Pin or Socket Number Machine Location 12
449
512
GN
Radio Speaker - Right (Common)
G787
GN
FNR Fwd
513
OR
A/C Compressor/Refrigerant Pressure Sw
G788
YL
FNR Rev
515
GY
Blower Motor (HI)
G797
BU
FNR Solenoid 2
516
GN
Blower Motor (MED)
H451
GN
Water in Fuel
517
BU
Blower Motor (LOW)
P914
GN
FNR Fwd
518
OR
COSA Flasher Signal
P915
PK
FNR Neutral
521
YL
A/C On/Off
P916
OR
FNR Neutral
522
WH
A/C Thermostat
P976
BR
Quick Coupler Disengaged 2
537
GN
Flasher Output
Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.
2
Connector Location
CONN 26 A-4 15 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.
1 2
1 2
Receptacle
Plug
Schematic Location A-15
447
AA 1
BR
Accessory Circuits
¹The FMI is a diagnostic code that indicates what type of failure has occurred.
A
321
8 15
Harness And Wire Electrical Schematic Symbols
310
Monitoring Circuits
Printed in U.S.A.
© 2004 Caterpillar All Rights Reserved
Control Circuits
135
Ground Circuits
Volume 1 - Cab
Lighting Circuits
0168
0641
The circle indicates that the component has screw terminals and a wire can be disconnected from it.
IT28G: 8CR1 - 1161 9AR1 - 0371
This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.
Component
Load Check Relay
928G: 6XR1 - 1073 7SR1 - 0701
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.
Component identifiers (CID¹) and Module identifier (MID)for Transmission Electronic Control System (MID No. 081)
Downshift Switch
Normally closed switch that will open with an increase of a specific condition.
A Located in the center dash panel.
Power Circuits
0621
928G Wheel Loader IT28G Integrated Toolcarrier Electrical System
No circle indicates that the wire cannot be disconnected from the component.
Wire Number
0421
Flow Symbol
Level Symbol
Machine locations are repeated for components located close together.
58
CID
T
Temperature Symbol
Pressure Symbol
Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets.
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.
20 Page, DGM
11
CID - FMI
SENR1229-03 VOL 1 (Cab)
Code Flashed