Cat 966H & 972H Wheel Loader Electrical System Schematic Manual Vol 1 & 2 - PDF DOWNLOAD

Page 1

UENR2527 January 2012 Wire Description

RD

102

RD

Wire Color

Bat (+)

G790

PK

Not Used

Hd Lmp

G791

BR

Not Used

Description

Component

Failure Mode Identifiers (FMI)¹ Failure Description

PU

Implement Control Reversing Fan Sw (N.O.)

YL

Implement Control Reversing Fan Sw (N.C.)

Arc Suppressor - Quick Coupler

J-2

4

Sensor - Rear Axle Oil Temp.

110

RD

Engine ECM

H704

PK

Auto Reverseing Fan Solenoid

Arc Suppressor - Secondary Steering

I-7

5

Sensor - Tilt Position

PU

Main Power Rly Output

H713

PK

Implement Control Lift Proportional Sol

Arc Suppressor - Start Relay

H-11

6

Sensor - Transmission Oil Temperature

H-7

26

Warning Horn (forward)

H714

OR

Implement Control Lower Proportional Sol

Batteries

J-10

7

Sensor - Transmission Input Speed

H-7

27

124

GN

Auto Lube Pump to Auto Lube Pressure Sw.

H717

BR

Implement Control Pilot Press Sol

Block Asm.

J-10

7

Sensor - Trans. Output Speed (Leading)

G-7

28

129

RD

Fuel Priming Pump to Machine Interface

H718

GY

Implement Control Tilt Cyl Position

Breaker - Alternator

G-12

6

Sensor - Trans. Output Speed (Trailing)

G-7

28

136

GN

Supplemental Steering

H746

YL

Variable Speed Fan Solenoid

138

GN

Auto Lube Pump To PCS

H747

BR

Variable Speed Fan Solenoid

Breaker - Belly Guard Actuator

I-12

6

Sensor - Turbo Inlet Pressure

F-10

29

141

RD

Beacon / Heated Mirrors

H795

PK

Engine Digital Sensor (Return)

Breaker - Hood Actuator

I-12

6

Solenoid - A/C Clutch

B-11

3

147

RD

ECAP / Center Dash Indicator Panel

J764

BR

Transmission Switch/Sensor Return #1

Breaker - Main

H-12

6

Solenoid - Aux Lift Prop

G-2

22

150

OR

Implement/Transmission/Engine ECM

K737

BR

Not Used

Breaker - Running Lamp

I-12

6

Solenoid - Aux Lower Prop

H-2

22

174

RD

Unswitched Bus Power

K738

GN

Not Used

Breaker - Start

175

RD

Hood Actuator

K739

BU

Not Used

Breaker - Unswitched Bus (Cab)

RD

Hood Actuator

N707

PU

Fuel Differential Pressure (Return)

Control - Engine

Ground Circuits

R746

PK

Atmosphereic Pressure Sensor (Ground)

Main Chassis

R747

GY

Boost Pressure Sensor Signal

BK

6

Solenoid - Lower Prop

H-3

22

CONN 6

D-12

8

Ground - LH

J-9

51

Solenoid - On / Off Pilot

G-2

22

CONN 7

E-13

8

Ground - RH

B-8

51

Solenoid - Quick Coupler

J-2

4

CONN 8

J-10

40

22

CONN 9

F-8

14

C-10

30

CONN 10

B-8

41

I-6

31

Engine ECM

Y795

GN

Expanded Can Data Link -

Motor - Autolube Pump

261

BK

Brake Oil Pressure Sw.

838

YL

Belly Guard Actuator

Motor - Belly Guard

C216

BK

Implement Return

839

BU

Belly Guard Actuator

Motor - Front Washer

B-5

9

Solenoid - Rack Back Prop

J-12

10

Solenoid - Reversing Fan

C-4&5

11

Solenoid - Start Aid

H-3

CONN 11

I-7

15

CONN 12

D-6

34

CONN 13

C-6

34

CONN 14

B-5

50 9

A893

OR

Fuel Priming Sw.

Motor - Fuel Priming Pump

B-10

12

Solenoid - Tilt Anti-Drift

H-3

22

304

WH

Starter Relay to Starter Motor

G828

WH

Engine +5V Sensor Supply

Motor - Hood Actuator

F-12

13

Solenoid - Variable Speed Fan

C-10

30

306

GN

Starter Relay Coil to Transmission Control

G829

GN

Engine Sensor Ground

Motor - Rear Washer

C-4&5

11

Solenoids - Cylinder Head ( 1 & 2)

F-14

21

CONN 15

C-5

308

YL

Main Power Relay Coil

G833

PK

Fuel Temperature Sensor (Ground)

321

BR

Backup Alarm Lamp Travel Alarm

G850

BU

Inlet Air Heater

322

GY

Warning Horn (Forward)

G856

WH

Timing/Cal. Probe (+)

326

PU

Key Sw 'C' Term.

G857

YL

Timing/Cal. Probe (-)

397 398

OR BU

Hood Actuator Motor (Lower) Hood Actuator Motor (Raise)

J807 J808

BK BK

Motor - Secondary Steering

H-8

5

Solenoids - Cylinder Head ( 3 - 6)

E-14

21

CONN 16

E-5

43

Motor - Starter

I-9

14

Solenoids - Ride Control (1& 2)

G-2

22

CONN 17

F-5

43

H-12

6

Solenoids - Ride Control (3)

F-2

22

CONN 18

G-5

43

Proportional Return (1-3)

Relay - Secondary Steering

I-8

5

Solenoids - Trans. Clutch (1 - 3)

H-8

32

CONN 19

H-5

42

Proportional Return (4/Rev)

Relay - Secondary Steering Intermediate

I-8

15

Solenoids - Trans. Clutch (4 - 6)

G-8

32

CONN 19

H-4

44

CONN 20

G-3

49

CONN 21

H-3

48

CONN 22

I-3

47

Relay - Main

A300

GN

Lower Hood

J809

BK

Proportional Return (Forward)

Relay - Start

H-12

6

Switch - Autolube Pressure

B-5

9

A301

WH

Raise Hood

J813

BK

Implement Proportional Return

Resistor - CAN

E-8

8

Switch - A/C Refrigerant

B-11

3

Sender - Fuel Level

G-13

8

Switch - Belly Guard Actuator 1,2

J-11

33

CONN 23

J-3

46

Sender - T/C Temperature

E-7&8

3

Switch - Brake Oil Pressure

C-11

30

CONN 24

J-3

45

A307

GY

X337

WH

403

GN

Throttle Position Not Used Monitoring Circuits Alternator (R) Term.

J814

BK

Implement Proportional Return

J815

BK

Ride Control Solenoids Proportional Return

J843

BK

Turbo Inlet Pressure Sensor (Ground)

J844

GY

Turbo Inlet Pressure Sensor (+ Battery)

Sensor - Atmospheric Pressure

E-12

16

Switch - Differential Pressure

C-13

12

Sensor - Boost Pressure

D-13

17

Switch - Disconnect

J-10

33 12

416

OR

Supplemental Steering Sw

T858

GY

Fuel Injector Solenoid #1/2 Common

417

GY

Primary Steering Sw

T859

WH

Fuel Injector Solenoid #3/4 Common

Sensor - Cam Shaft Speed Timing

D-12

18

Switch - Fuel Priming Pump

B-10

E-12

12

Switch - Ground Level Shutdown

G-11

6

D-13

12

Switch - Hood Actuator

G-11

6

439

YL

Lamp Indicator

945

BR

Cat Data Link -

442

GY

Hyd System Temp Gage

976

OR

Ride Cont Solenoid 1

7

Mechanical system not responding properly.

443

YL

Power Train Temp Gage

987

WH

Third Function Diverter Sol

8

Abnormal frequency, pulse width, or period.

447

PK

Fuel Level Gage

994

GY

Oil Pressure Sensor (Signal)

T860

OR

Fuel Injector Solenoid #5/6 Common

Sensor - Coolant Temperature

900

PU

Xmsn Shift Sol No. 5 Or 4

Sensor - Crank Shaft Speed Timing

Opr Mon Air Filter

901

WH

Xmsn Shift Sol No. 6

Sensor - Front Axle Oil Temperature

J-2

19

Switch - Hydraulic Filter Bypass Pressure

D-5

34

Opr Mon Brake Press. (oil)

944

OR

Cat Data Link +

Sensor - Fuel Pressure

C-13

20

Switch - Park Brake Pressure

D-5

35

Sensor - Fuel Temperature

B-13

21

Switch - Primary Steering Pressure

I-6

36

Sensor - Hydraulic Oil Temperature

H-4

3

Switch - Secondary Steering Pressure

I-6

36

Sensor - Intake Manifold Air Temp

E-12

22

Switch - Trans Filter Bypass

D-5

37

9

Abnormal update.

450

YL

Tach Sender (+)

10

Abnormal rate of change.

453

PK

Supplemental Steering Fault Lamp

11

Failure mode not identifiable.

995

BU

Coolant Temperature Sensor (Signal)

A958

WH

Park Brake Sol

484

YL

Primary Steering Lamp

A982

BR

Engine Throttle Cont

E455

BR

Hydraulic Oil Filter

C967

BU

Intake Manifold Air Temperature Sensor (Signal)

12

Bad device or component.

13

Out of calibration.

F421

YL

Fuel Temperature Sensor (Signal)

C991

PK

Fuel Pressure Sensor (Signal)

14

Parameter failures.

G479

WH

Prelube Indicator

E900

WH

Trans Output Spd +

15

Parameter failures.

G485

BU

Opr Mon Front Brake Temperature

E901

GN

Trans Output Spd -

16

Parameter not available.

G486

GN

E906

OR

Trans Output Spd Q+

17

Module not responding.

Opr Mon Rear Brake Temperature Accessory Circuits

18

Sensor supply fault.

506

PU

19

Condition not met.

507

WH

Parameter failures.

513

OR

E907

GY

Trans Output Spd Q-

E908

BR

Trans Input Spd +

Washer - Rear

E909

WH

Trans Input Spd -

A/C Pressure Sw. to A/C Clutch Solenoid

E919

YL

Aux Lower Proportional Sol

Washer - Front

521

YL

A/C Sw To Refrigerant Sw

E920

BR

Aux Lift Proportional Sol

522

WH

A/C Clutch To Thermostat Sw

E921

PK

Rackback Proportional Sol

C529

GY

Lift Press Sensor

E922

GN

Dump Proportional Solenoid

C530

BU

Lift Position Sensor Lighting Circuits

E963

BK

Crank Speed/Timing (-)

E964

WH

Crank Speed/Timing (+)

604

OR

Stop Lamp

E965

BU

Cam Speed/Timing (-)

605

YL

Turn Lamp - Left

E966

YL

Cam Speed/Timing (+)

606

GY

Turn Lamp - Right

K927

BU

On/Off Pilot Solenoid (Return)

611

PU

Head Lamp Hi

K977

PK

Trans Oil Temp Sensor

614

PU

Park/Tail/Dash/Lamp

N939

GN

Ride Control Solenoid 2

617

BR

Tail/position Lamp - Left (Road Pkg)/Width

P945

OR

Anti Drift Sol- Stick

619

GN

Head Lamp Low

P946

BR

Anti Drift Sol- Boom

P976

BR

Quick Coupler Sw To Low Pressure Sol

P990

BR

Start Relay Ctrl (Return) Fuel Injector Solenoid #1

Control Circuits 727

High Intake Manifold Air Temperature

I-10

BK

Current above normal or grounded circuit.

E539

21

Control - Hood Raise/Lower

229

Current below normal or open circuit.

Idle Elevated to Increase Battery Voltage

38

E-13

Expanded Can Data Link +

6

E441

C-14/D-14

CONN 5

Fuel Differential Pressure Signal

Voltage below normal or shorted low.

Fuel Filter Restriction

CONN 4

22

OR

5

High Fuel Temperature

38

22

WH

4

E390

C-14/D-14

G-3

T725

PK

E363

39

CONN 3

G -3

Y794

BU

Engine Overspeed

39

G-14

Solenoid - Lift Anti-Drift

Operator Monitor Return

430

Low Engine Oil Pressure

G-14

CONN 2

Solenoid - Lift Prop

Xmsn Ctrl

432

E362

22

CONN 1

6

BK

Voltage above normal or shorted high.

User Defined Shutdown

H-3

Machine Location

8

BK

Data erratic, intermittent, or incorrect.

E360

Solenoid - Dump Prop

Schematic Location

Connector Number

I-12

201

3

E265

6

Connector Location

C-F/11-12

202

2

High Exhaust Temperature

H-12

199

Opr Mon Parking Brake

E194

25

RD

Opr Mon Power Train Oil Filter

High Air Filter Restriction

21

G -1

112

YL

E172

B-7&8

114

BR

High Fuel Pressure

3

H703

419

E096

B-10

H702

426

Condition

24

Arc Suppressor - A/C

Tilt/Lift Position Sensors

Data valid but below normal operational range.

Event Code

C - 12

2

Auto Lube Pump to Auto Lube Pressure Sw.

1

Event Codes Engine Control

8

Sensor - Oil Pressure

1

B-12

YL

Data valid but above normal operational range.

20

23

G-2

D-14

Alternator

WH

0

¹The FMI is a diagnostic code that indicates what type of failure has occurred.

I-2

Sensor - Lift Position

Alarm - Backup

106

Basic Machine Circuits

² The MID is a diagnostic code that indicates which electronic control module diagnosed the fault.

Sensor - Lift Cylinder Head End Pressure

Component

Component

103

200

¹ The CID is a diagnostic code that indicates which circuit is faulty.

Machine Location

Machine Location

Description Control Circuits

Schematic Location

Schematic Location

GN

Supplemental Steering Motor Relay

728

BU

Supplemental Steering Cont Sw

T957

PU

751

GN

Xmsn Shift Sol No. 1 Or 3

T958

YL

Fuel Injector Solenoid #2

752

YL

Xmsn Shift Sol No. 2

T959

BR

Fuel Injector Solenoid #3

754

BU

Xmsn Shift Sol No. 3 Or 1

T960

BU

Fuel Injector Solenoid #4

755

OR

Xmsn Shift Sol No. 4 Or 5

T961

GN

Fuel Injector Solenoid #5

E748

BK

Auto Reverse Fan/Start Aid Solenoid Return

T962

WH

Fuel Injector Solenoid #6

F713

OR

Turbo Inlet Pressure Sensor (Signal)

X918

PU

Ground Level Shut Down (N.O.)

F762 G764

GY

Start Aid Solenoid

X919

WH

Ground Level Shut Down (N.C.)

PK

Xmsn Cont Park Brake Lever Sw To Gnd

966H and 972H Wheel Loader Electrical System 966H: A6D1347-UP RYF458-UP A6G5295-UP

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.

Volume 1 of 2: Chassis © 2012 Caterpillar, All Rights Reserved

Symbols

T

Pressure Symbol

13

6 33

40

Function

Actuate

Deactuate

Contact Position

47

14 29

15

10 36

5

Ground (Wired): This indicates that the component is connected to a grounded wire. The grounded wire is fastened to the machine. Ground (Case): 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.

24

38

19

50

46

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.

20

18 4 49

43

2

12 30

3

8 21

27 42

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.

45

26 32

25

28

41

9

35

Magnetic Latch Solenoid: A magnetic latch solenoid is an electrical component that is activated by electricity and held latched 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.

23 48

Resistor, Sender and Solenoid Specifications

Related Electrical Service Manuals

Engine Control:

44

22

17

11

Form Number

165-4619 (Delco 42MT)

Circuit Breaker Symbol

Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.). No circle indicates that the wire cannot be disconnected from the component.

² Contact postion at the contacts of the harness connector.

31

16

Electric Starting Motor:

Flow Symbol

Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it.

275 to 1750 kPa¹ 114-5333 A/C (High / Low) Pressure Normally Open² (39.9 to 253.8 psi) 138 ± 28 kPa 89 ± 20 kPa 117-7773 Hydraulic Filter Bypass Pressure Normally Closed (20 ± 4 psi) (12.9 ± 2.9 psi) A-B, Normally Open 8270 kPa MAX 6890 ± 345 kPa 174-4312 Park Brake Pressure A-C, Normally Closed (1200 psi MAX) (1000 ± 50 psi) A-B, Normally Open 10700 kPa MAX 8960 ± 537 kPa 175-3244 Brake Oil Pressure A-C, Normally Closed (1550 psi MAX) (1300 ± 79 psi) 1200 kPa MAX 700 ± 100 kPa A-B Normally Open 230-5771 Secondary Steering Pressure (174.0 psi MAX) (102 ± 14.5 psi) A-C Normally Closed 110.3 ± 13.8 kPa 69 kPa MIN 258-0883 Fuel Differential Pressure Normally Closed (16 ± 2 psi) (10 psi MIN) 1200 kPa MAX 700 ± 100 kPa A-B Normally Open 3E-6450 Primary Steering Pressure (174.0 psi MAX) (102 ± 14.5 psi) A-C Normally Closed 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). T

197-8820 (Denso HDB 95A)

Level Symbol

Fuse: A component in an electrical circuit that will open the circuit if too much current flows through it.

Off-Machine Switch Specification Part No.

51

177-9953 (Denso HDB 80A)

Temperature Symbol

Symbols and Definitions

39

Alternator:

Printed in U.S.A.

Harness And Wire Electrical Schematic Symbols

7

Title

972H: LCC1-UP A7D566-UP A7G2062-UP

Part No.

34 37

SENR4130

Component Description

128-7991

Solenoids:

134-2540

Resistor:

138-2924

Solenoids:

SENR3581 RENR9318

145-7028 148-2350

Sender: Solenoid:

152-8340 163-0872 168-6452 216-5338

Solenoid: Solenoid: Solenoid: Solenoids:

220-8214

Sender:

225-0300

Solenoid:

237-2234

Solenoid

239-1134

Solenoid:

Fuel Injection CAN Data Link Aux Lift Raise Prop Aux Lower Prop Dump Prop Lift Prop Lower Prop Rackback Prop T/C Temperature Variable Speed Fan Auto Reversing Fan A/C Compressor Clutch Axle Oil Cooler Clutch Transmission Clutch Fuel Level On/Off Pilot Left Anti-Drift Ride Control (3) Tilt Anti-Drift Start Aid

¹ At room temperature unless otherwise noted.

31

2

43

9

23

12

16

38 39

13

1

19

3

21

17

8

30

29

20

11

41

51

14

32

27

15

42

24

5

26

28

7

45 47

33 44

40

48 36

6

49

46

22

34 35

37

25

10

4

50

18

Resistance (Ohms)¹

Harness and Wire Symbols

1.06 ± 0.05 108 - 132

7.75 ± 1.0

Wire, Cable, or Harness Assembly Identification: Includes Harness Identification Letters and Harness Connector Serialization Codes (see sample).

Harness Identification Letter(s): (A, B, C, ..., AA, AB, AC, ...)

L-C12 3E-5179

AG-C4 111-7898 1000 5.0 ± 0.3 32.6 ± 1.6 17.6±0.6 9.4 ± 5.0 8.7 ± 0.4 Empty: 240 - 250 Full: 28 - 33 38.12 ± 1.9 33.8 20.0

L-C12 3E-5179

1

Part Number: for Connector Plug

Harness Connector Serialization Code: The "C" stands for "Connector" and the number indicates which connector in the harness (C1, C2, C3, ...).

Part Number: for Connector Receptacle

2 Plug

Receptacle Pin or Socket Number

1 2

Deutsch connector: Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.

1 2

Sure-Seal connector: Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.

5A Fuse (5 Amps)

9X-1123

Component Part Number

325-AG135 PK-14 Harness identification code: This example indicates wire group 325, wire 135 in harness "AG".

Wire Gauge Wire Color

(Dimensions: 48 inches x 35 inches)

101

Component Location

Wire Number

Power Circuits

Fuel Injector Solenoid #1 Fuel Injector Solenoid #2 Fuel Injector Solenoid #3 Fuel Injector Solenoid #4 Fuel Injector Solenoid #5 Fuel Injector Solenoid #6 ECM 8V DC Supply Throttle Sensor Fuel Pressure Sensor Oil Pressure Sensor Engine Coolant Temperature Sensor Electrical Power Supply Intake Manifold Air Temperature Sensor Fuel Temperature Sensor Engine Speed Sensor Personality Module Engine Speed Sensor 5 Volt Sensor Supply Engine Shutdown Switch Check Programmable Parameters Atmospheric Pressure Sensor Right Turbo Inlet Pressure Sensor Filter Restrict Lamp Engine Cooling Fan Solenoid Transmission ECM Camshaft Position Sensor Implement Control Machine Security System Intake Manifold Pressure Sensor Start Aid Solenoid

FMI No.

Wire Color

36 Page,

CID 0001 0002 0003 0004 0005 0006 0041 0091 0094 0100 0110 0168 0172 0174 0190 0253 0261 0262 0267 0268 0274 0275 0283 0291 0296 0342 0596 1639 1785 2417

Wire Number

UENR2527 VOL 1 of 2

Component Identifiers (CID¹) Module Identifier (MID²) Engine Control System (MID No. 036)


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