CAT 966K and 972K Wheel Loader Electrical System Schematic Manual Vol 1 & 2 – PDF DOWNLOAD

Page 1

NOT SHOWN

76

23

Connector Number

CONN 16 237

39

81

20

24 101 31 56

COMPONENTS NOT SHOWN

155

106 156

28

4

120

11

50

58 9 33

57

8

32

COLD START BATTERIES

5

16 47

15 48 112

BEHIND PLATE 121 13

110

109

17 14

44

115

18

Schematic Location

Component

30

J-13

1

Sensor GP - Pressure (Brake Accumulator Oil)

D-2

Alarm AS - Backup

H-13

2

Sensor GP - Pressure (Crankcase Breather)

H-15

80

CONN 3

C-15

Alternator

B-10

3

Sensor Gp - Pressure (DPF Delta P)

D-13

237

CONN 4

D-15

Arc Suppressor -Starter Relay

C-8

4

Sensor GP - Pressure (DPF Inlet)

D-13

81

CONN 5

D-14

Bar - Buss A

B-8

5

Sensor GP - Pressure (Engine Oil)

H-15

82

CONN 6

E-15

Battery 1

C-10

6

Sensor GP - Pressure (Fuel Filter) (Aft)

F-13

83

CONN 7

E-15

Battery 2

C-10

7

Sensor GP - Pressure (Fuel Filter) (Fore)

F-13

84

CONN 8

E-15

Battery 3 ATCH

C-10

8

Sensor GP - Pressure (Fuel Rail)

I-15

85

CONN 9

F-15

Battery 4 ATCH

C-10

9

Sensor GP - Pressure (Hydraulic Pump)

E-8

86

CONN 10

G-13

Block AS - Junction

B-8

10

Sensor GP - Pressure (Intake Manifold)

G-15

87

CONN 11

G-12

Block AS - Junction (Battery)

C-10

11

Sensor GP - Pressure (Lift Cylinder) (Head End)

H-2

88

CONN 12

G-12

Camera GP - Rear (115°, Color) ATCH

G-13

12

Sensor GP - Pressure (Lift Cylinder) ATCH

F-1

89

CONN 13

G-12

Circuit Breaker AS - Engine Control

C-8

13

Sensor GP - Pressure (NOX Reduction System)

G-15

90

CONN 14

J-12

Circuit Breaker AS - Machine Control

C-8

14

Sensor GP - Pressure (Park Brake)

D-2

91

CONN 15

J-12

Circuit Breaker AS - Main

B-8

15

Sensor GP - Pressure (Secondary Steering)

E-8

92

CONN 16

C-11

Circuit Breaker AS - Starting Motor

C-8

16

Sensor GP - Pressure (Transmission Bypass) ATCH

G-9

93

CONN 17

B-10

Coil AS - ARD Fuel Pressure

E-13

17

Sensor GP - Pressure (NOX Reduction System Intake)

G-15

94

CONN 18

E-8

Coil AS - ARD Fuel Pressure #2 Cont Actuator

E-13

235

Sensor GP - Soot

F-12

95

CONN 19

E-8

Coil AS - Ignition (ARD)

E-13

18

Sensor GP - Speed (Engine Timing)

G-15

96 97

CONN 20

F-8

Compressor GP - Refrigerant

B-14

19

Sensor GP - Speed (Input)

J-9

CONN 21

G-8

Control GP - ARD Air Flow

F-12

20

Sensor GP - Speed (Output 1)

J-9

98

CONN 22

G-8

Control GP - Engine (J1 Connector)

B-16

21

Sensor GP - Speed (Output 2)

J-9

99

CONN 23

I-7

Control GP - Engine (J2 Connector)

J-14

22

Sensor GP - Temperature (Coolant)

G-15

100

CONN 24

I-7

Ground - ARD Head

E-13

23

Sensor GP - Temperature (DPF)

E-13

101

CONN 25

J-7

Ground - CEM

D-13

24

Sensor GP - Temperature (Front Axle Oil)

H-2

102

CONN 26

I-5

Ground - Engine 1

E-13

25

Sensor GP - Temperature (Torque Converter)

A-14

103

CONN 27

F-7

Ground - Engine 2

B-11

26

Solenoid - Fuel Pump (Aft)

H-15

104

CONN 28

B-5

Ground - Frame 1

B-10

27

Solenoid - Fuel Pump (Fore)

H-15

105

CONN 29

D-5

Ground - Frame 2

C-10

28

Spark Plug

D-13

106

CONN 30

G-2

Ground - Main Chassis

G-7

29

Starting Motor GP - Electric

B-10

107

CONN 31

G-2

Ground - Resistor AS 1

C-10

30

Switch AS - Engine Shutoff

I-13

108

CONN 32

J-2

Ground - Resistor AS 3

C-10

31

Switch AS - Fuel Filler

E-4

109

CONN 33

E-3

Ground - Resistor AS 4

E-9

32

Switch AS - Hood Tilt Actuator

I-13

110

CONN 34

H-3

Ground - Resistor AS 5

B-8

33

Switch AS - Hydraulic Filter Bypass

C-2

111

CONN 35

I-3

Ground - Resistor AS 6

D-8

34

Switch AS - Liquid Level (Low Coolant)

F-8

112

CONN 36

I-2

Ground - Secondary Steering Pump ATCH

D-8

35

Switch AS - Power Train Guard ATCH

J-13

113

CONN 37

J-2

Horn AS - High Tone

J-2

36

Switch AS - Pressure (Power Train Oil)

C-2

114

CONN 38

J-2

Horn AS - Low Tone

J-2

37

Switch GP - Disconnect

D-10

115

CONN 39

D-4

Injector 1-6

E-14

38

Switch GP - Pressure (A/C High/Low)

A-14

116

CONN 40

C-4

Module AS - Aftertreatment ID

F-13

39

Switch GP - Pressure (A/C Low)

A-14

117

CONN 55

A-9

Motor AS - Hood Tilt

I-13

40

Switch GP - Pressure (Autolube) ATCH

G-3

118

CONN 56

B-9

Pump AS - Washer (Front)

C-2

41

Switch GP - Secondary Steering Relay ATCH

E-8

119

CONN 57

B-9

Pump AS - Washer (Rear)

C-2

42

Switch GP - Starter Relay

C-8

120

CONN 58

B-9

Pump GP - Autolube Pump ATCH

G-9

43

Valve GP - Air Control (ARD Combustion)

F-13

121

CONN 59

B-9

Pump GP - Fuel Priming

E-4

44

Valve GP - Clutch 1 (Reverse)

I-9

122

CONN 60

B-9

Pump GP - Secondary Steering ATCH

D-8

45

Valve GP - Clutch 2 (Forward)

I-9

123

CONN 61

H-5

Pump GP - Variable Pitch Fan ATCH

J-13

46

Valve GP - Clutch 3 (Speed 4)

I-9

124

235 70

Receptacle AS - Auxiliary Start

D-10

47

Valve GP - Clutch 4 (Speed 3)

I-9

125

Relay AS - ARD Fuel Nozzle Heater

D-13

48

Valve GP - Clutch 5 (Speed 2)

I-9

126

Relay AS - Backup Lamps ATCH

E-10

50

Valve GP - Clutch 6 (Speed 1)

J-9

127

Relay AS - Hood Raise/Lower Control

I-13

50

Valve GP - Exhaust Gas (NOX Reduction System)

Resistor AS - CAN Data Link A

B-15

51

Valve GP - Fuel Priming

EXHAUST MODULE

HARNESS R

REAR CAB

ENGINE COMPARTMENT SHEILD

LEFT CHASSIS - UNDER LEFT CAB DOOR

128

E-4

129 130

Resistor AS - Engine CAN Data Link 1

G-15

52

Valve GP - Quick Coupler ATCH

I-2

F-12

53

Valve GP - Solenoid (Cold Start/Hydraulic Fan) ATCH

F-9

131

Resistor AS 1

C-10

54

Valve GP - Solenoid (Demand Speed Fan)

B-3

132

Resistor AS 2

B-11

55

Valve GP - Solenoid (Dump)

G-1

133

Resistor AS 3

C-10

56

Valve GP - Solenoid (Dump/Anti-Drift)

G-1

134

Resistor AS 4

E-9

57

Valve GP - Solenoid (Implement Pilot Supply)

G-1

135

Resistor AS 5

B-8

58

Valve GP - Solenoid (Implement Pump Torque Limit)

D-4

136 137

Resistor AS 6

D-8

59

Valve GP - Solenoid (Lower)

G-1

Sender AS - Fuel Level

H-13

60

Valve GP - Solenoid (Lower/Anti-Drift)

G-1

138

Sensor - Temperature (Rear Axle Oil)

G-12

61

Valve GP - Solenoid (NOX Reduction System)

H-14

139

Sensor AS - Position (Steering Valve Spool)

H-8

62

Valve GP - Solenoid (Park Brake)

C-3

140

Sensor AS - Temperature (Charge Air Cooler Outlet)

H-15

63

Valve GP - Solenoid (Prime Steering) (LH)

I-8

141

Sensor AS - Temperature (Fuel)

G-13

64

Valve GP - Solenoid (Prime Steering) (RH)

I-8

142 143

F-8

65

Valve GP - Solenoid (Rackback)

H-1

Sensor AS - Temperature (Inlet Air)

G-12

66

Valve GP - Solenoid (Raise)

G-1

144

Sensor AS - Temperature (NOX Reduction System)

G-14

67

Valve GP - Solenoid (Ride Control 1)

H-1

145

Sensor AS - Temperature (Torque Converter Oil)

10

G-15

Resistor AS - Engine CAN Data Link 2

Sensor AS - Temperature (Hydraulic Oil)

CONN 14

79

Actuator GP - Power Train Guard ATCH

77

6

Machine Location

B-15

53

7

Schematic Location

A-15

108

46

Component

CONN 2

54 236

Machine Location

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.

129

Schematic Location

J-9

68

Valve GP - Solenoid (Ride Control 2)

G-1

146

Sensor Gp - ARD Fuel Pressure #2 (Main)

E-13

236

Valve GP - Solenoid (Ride Control 3)

G-1

147

Sensor GP - Liquid Level (Oil)

C-14

69

Valve GP - Solenoid (Secondary Steering) (LH)

I-8

148

Sensor GP - Liquid Level (Water Separator)

E-4

70

Valve GP - Solenoid (Secondary Steering) (RH)

H-8

149

Sensor GP - Position (Lift)

F-2

71

Valve GP - Solenoid (Steering Pilot Supply)

I-8

150

Sensor GP - Position (Steering Cylinder) (LH)

F-7

72

Valve GP - Solenoid (Third Function/Port A) ATCH

F-1

151

Sensor GP - Position (Steering Cylinder) (RH)

F-9

73

Valve GP - Solenoid (Third Function/Port B) ATCH

F-1

152

Sensor GP - Position (Tilt)

I-2

74

Valve GP - Solenoid (Transmission Bypass) ATCH

G-9

153

Sensor GP - Pressure (Air Filter)

F-12

75

Valve GP - Start Aid

E-8

154

Sensor GP - Pressure (ARD Combustion Air)

D-13

76

Wire AS - Heater

E-14

155

Sensor GP - Pressure (ARD Pilot Fuel)

E-13

77

Wire AS - Ignition

E-13

156

Sensor GP - Pressure (Atmospheric Pressure)

H-15

78

966K and 972K Wheel Loader Electrical System 972K: PEM1-UP Z4W1-UP

966K: PBG1-UP TFS1-UP

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

Printed in U.S.A.

Harness And Wire Electrical Schematic Symbols Symbols

T

Pressure Symbol

Temperature Symbol

Level Symbol

Circuit Breaker Symbol

Flow Symbol

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

100

CONN 5

CONN 9

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.

HARNESS EN 94

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

HARNESS AM

CONN 8 91

Ground (Case): This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.

2

38

87

CONN 1

HARNESS FK

90

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.

52

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

19

CONN 7 CONN 2

140

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.

139

104 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.

67 79

105

117

111 84

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.

40

Harness and Wire Symbols

64

CONN 3

114

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

96 116

CONN 40

L-C12 3E-5179

AG-C4 111-7898

103 132

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

1

Part Number: for Connector Plug

Part Number: for Connector Receptacle

2

83 Plug

CONN 39

REAR RIGHT FRAME

CONN 6

42 69

CONN 4

51

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.

85 80

CONN 4

63

ENGINE HARNESS

FUEL HARNESS

1 2

5A Component Part Number

9X-1123

Fuse (5 Amps)

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

Wire Gauge Wire Color

82

128

HARNESS FA

HYDRAULIC SERVICE CENTER

Receptacle Pin or Socket Number

325-AG135 PK-14

78 41

L-C12 3E-5179

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

21

Resistor, Sender and Solenoid Specifications

22

Part No.

CORE ENGINE

Component Description

134-2540

Resistor

240-7192

Resistor

175-4034

Sender

Resistance (Ohms)¹

CAN Data Link A

120 ± 10%

Engine CAN Data Link Resistor AS 1-6

1500 ± 5% Empty 240-250

Fuel Level

Full 28-33

Dump/Anti-Drift 328-4314

Solenoid

66

33.8

Lower/Anti-Drift Ride Control 1

75

Off-Machine Switch Specification 154

CONN 34 37

68

36

CONN 36

Part No.

CONN 28

71

65

HARNESS JC

CONN 23

Function

114-5333

A/C High/Low Pressure

149-6371

A/C Low Pressure

Actuate

Deactuate

275 to 1750 kPa¹

-

(39.9 to 253.8 psi)

-

103.4 ± 13.8 kPa

34.5 ± 7 kPa

14.9 ± 2.0 psi

5.0 ± 1 psi

Contact Position Normally Closed² 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).

CONN 29

² Contact position at the contacts of the harness connector.

102

CONN 24

CONN 31 CONN 30

FRONT AXLE TEMPERATURE SENSOR

CONN 25

HARNESS E 138

133

147

134

145

Related Electrical Service Manuals Title

Form Number

Cross Reference for Electrical Connectors:

HARNESS R

CONN 37

143

REHS0970

Alternator:

272-1889

SENR4130

Starting Motor:

350-8694

SENR3860

Engine Control:

KENR9796

146 89 95

149

137

HARNESS JA

60

CONN 33

148

151

97

29

CONN 57 CONN 56

142

HARNESS EK 123

135

CONN 19

122

HARNESS JY

124

144

119

CONN 18

125

150

CONN 55 CONN 59

126

152

127

CONN 27 HARNESS E

141

59

HARNESS HR

34 62 99

35

98

CONN 32 HARNESS EC

TRANSMISSION

CONN 26

CONN 38

FRONT HARNESS

45

FUEL TANK

92

LEFT FRAME

86

72

BATTERY WIRING

74

CONN 60

HARNESS EY

FRONT FRAME

(Dimensions: 56 inches x 35 inches)

CONN 58

RENR9766-04 VOL 1 of 2

25

RENR9766-04 August 2012

Component Location

42 Page,

Connector Location


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