Circuit Number Chart Circuit Number
Color
101 102 103 105 107 109 110 112 113 114 118 119 121 122 123 124 125 130 140 165 173
RD BU YL BR WH OR GN PU OR GN GY PK YL BU WH GN OR GN BU YL YL
200 201 202 203 207
BK BK BK BK BK
301 302
BU OR
304 306 308 310 311 321 322 326 327
WH GN YL PU WH BR GY PU PK
403 405 406
GN GY PU
407
PK
408 409 410 411
WH OR WH PK
413 415 419 443 446 449 450 451 454
BR GN YL YL PU BU YL BR GN
Description POWER DISTRIBUTION CIRCUITS BATTERY HEAD LAMP DOME/DASH/PARK/TAIL LAMP KEY SWITCH ENGINE SHUTDOWN CONTROL ALTERNATOR OUTPUT (+) TERM. WINDSHIELD WIPER SW. (REAR) MAIN POWER RELAY OUTPUT OPERATOR MONITOR PANEL WARNING HORN (FORWARD) WINDSHIELD WIPER SW. (FRONT) WINDSHIELD WIPER SW. (REAR) BACK UP ALARM/LAMP AIR DRYER GAUGES HEATER/AIR CONDITIONER SW. SUSPENSION FUSE TO SUSPENSION INDICATOR LAMPS LOCK UP FUSE TO CONTROL START AID FEED WORK/STOP LAMP GROUND CIRCUITS MAIN CHASSIS OPERATOR MONITOR PANEL TRANSMISSION CONTROL CHASSIS DIAGNOSTIC STARTER DIAGNOSTIC MACHINE BASIC CIRCUITS STARTER NO.1 SOL. TO RESISTOR STARTER NO.1 TO DIAGNOSTIC/ RESISTOR TO DIAGNOSTIC STARTER RELAY TO NO.1 OUTPUT START RELAY TO NEUTRAL START SW. MAIN POWER RELAY COIL START AID SW. TO START AID SOL. START AID SOL. TO TEMP SW. BACK UP ALARM/LAMP WARNING HORN (FORWARD) KEY SWITCH "C" TERMINAL SHUT DOWN SOL. MONITORING CIRCUITS ALTERNATOR (R) TERMINAL OPERATOR MON PANEL OIL PRESS. OPERATOR MON PANEL COOLANT TEMP. OPERATOR MON PANEL CONV/RET OIL TEMP. OPERATOR MON PANEL BRAKE PRESS. OPERATOR MON PANEL NEUTRAL OPERATOR MON PANEL FAULT ALARM OPERATOR MON PANEL MASTER FAULT LAMP OPERATOR MON. PANEL FUEL PRESS. OPERATOR MON PANEL TEST SW. OPERATOR MON PANEL PARK BRAKE POWER TRAIN TEMP GAUGE BRAKE OIL TEMP SENDER SPEEDO SENDER TACHOMETER SENDER(+) TACHOMETER SENDER(-) RETARDER INDICATOR LAMP
Component Locations Circuit Number
Color
469 472 477 488 490 498
GN OR YL WH GN WH
500 501 502 503 504 505 506 507 513 515 516 517 521 522 537 539 540 572 573 589
BR GN OR BR YL BU PU WH OR GY GN BU YL WH GN BU WH PU GN GN
602 604 605 606 610 611 614 619 624
WH OR YL GY OR PU PU GN YL
705
PK
706 709 710
BR OR GN
790 791 792 793 794 815 821 A789
WH OR BU YL GN GN YL PK
A790
WH
A791 A792 A793 A794 A982 B958
OR BU YL GN BR GN
Description MONITORING CIRCUITS FUEL LEVEL SENDER SERVICE BRAKE INDICATOR LAMP SPEEDO PROBE AIR PRESS. SW. LINK LOCK UP INDICATOR LAMP DIFF LOCK INDICATOR LAMP ACCESSORY CIRCUITS WIPER - FRONT (PARK) WIPER - FRONT (LOW) WIPER - FRONT (HIGH) WIPER - REAR (PARK) WIPER - REAR (LOW) WIPER - REAR (HIGH) WASHER-FRONT WASHER-REAR AIR CONDITIONER COMPRESSOR BLOWER MOTOR (HIGH) BLOWER MOTOR (MEDIUM) BLOWER MOTOR (LOW) AIR COND. SW. TO REFRIGERANT SW. AIR COND. COMPR. TO THERMO. SW. TURN SIGNAL SW TO FLASHER TURN SIGNAL INDICATOR BASIC/RIGHT TURN SIGNAL INDICATOR BASIC/LEFT RETARDER SOL. TO GROUND SW. LOCK UP SW. TO RETARDER SW. PRESS. SW. TO AIR COND. CLUTCH LIGHTING CIRCUITS DOME LAMP STOP LAMP TURN LAMP - LEFT TURN LAMP - RIGHT HEAD LAMP BASIC HEAD LAMP HIGH PARK/TAIL/DASH LAMP HEADLAMP - LOW WORK LAMP CONTROL CIRCUITS TRANSMISSION LOCK UP CLUTCH SOL. BASIC TRANSMISSION RETARDER SW. TRANSMISSION PICK UP POWER TRANSMISSION SPEED PICK UP SIGNAL PARK BRAKE & SUSPENSION CONTROL FRONT SUSPENSION FRONT SUSPENSION REAR SUSPENSION REAR SUSPENSION TRANSMISSION PRESSURE SENSOR TRANSMISSION PRESSURE SENSOR SERVICE BRAKE TO PARK BRAKE INHIBIT SW. SUSPENSION GROUND TO PARK BRAKE INHIBIT DOWN SOL. FRONT UP SOL. FRONT DOWN SOL. REAR UP SOL. REAR RETARDER SOL. TO THROTTLE SW. LOCK UP CLUTCH CONTROL TO PRESS. SW.
SENR8208 January 1990
Tractor (Except Engine and Transmission) 1
FOR USE IN SERVICE MANUALS: D40D, D400D ARTICULATED DUMP TRUCKS, SENR 8200
A - COMPONENTS IN OPERATOR COMPARTMENT Ident 49 49 8 41 23 16 20 20 20 20 20 20 21 46 5 21 21 26 21 20 20 20 20 20 20 20 20 20 20 20 20 21 21 21 10 21 21 21 21 21 21 21 21 21 13 7 11 11 11 11 21 47 47 48 48 48 48 11 11 21
Schematic Components ALARM - BACK UP (D40D) ALARM - BACK UP (D400D) ALARM - FAULT ALTERNATOR AUXILIARY START RECEPTACLE BATTERIES BREAKER - AIR CONDITIONER BREAKER - ALTERNATOR BREAKER - ENGINE SHUTDOWN BREAKER - HEADLAMP BREAKER - KEY BREAKER - TURN/PARK CONTROL - ENGINE SHUTDOWN CONTROL - REAR SUSPENSION CONTROL - FRONT SUSPENSION CONTROL - LOCKUP CONNECTOR - DIAGNOSTIC DRYER - AIR FLASHER FUSE - AIR DRYER FUSE - BACK UP ALARM FUSE - DOME LIGHT FUSE - FRONT WIPER FUSE - HORN FUSE - GAUGES FUSE - INDICATOR LAMP FUSE - RETARDER SOLENOID FUSE - OPERATOR MONITOR FUSE - REAR WIPER FUSE - START AID FUSE - SUSPENSION CONTROL GAUGE - BRAKE OIL TEMPERATURE (D40D) GAUGE - CONVERTER TEMPERATURE GROUND - DASH PANEL HORN - WARNING INDICATOR - DIFFERENTIAL LOCK INDICATOR - HIGH BEAM INDICATOR - LEFT TURN INDICATOR - RETARDER INDICATOR - RIGHT TURN INDICATOR - SERVICE BRAKE INDICATOR - TORQUE CONVERTER LOCK LAMP - BRAKE AIR PRESSURE GAUGE LAMP - BRAKE AIR PRESSURE GAUGE LAMP - CAB LAMP DOME LAMP - HIGH BEAM HEAD RH LAMP - HIGH BEAM HEAD LH LAMP - LOW BEAM HEAD RH LAMP - LOW BEAM HEAD LH LAMP - MASTER FAULT LAMP - BACK UP (D40D) LAMP - BACK UP (D400D) LAMP - STOP/TAIL/TURN RH (D40D REAR) LAMP - STOP/TAIL/TURN LH (D40D REAR) LAMP - STOP/TAIL/TURN RH (D400D REAR) LAMP - STOP/TAIL/TURN LH (D400D REAR) LAMP - TURN/PARK RH (FRONT) LAMP - TURN/PARK LH (FRONT) METER - SPEEDO
Location A-11 A-12 C-5 A-2 A-5 A-5 D-4 E-9 E-4 D-4 D-9 D-4 E-1 B-10 F-12 D-1 F-9 E-11 D-3 E-5 D-7 E-7 E-5 D-7 E-7 E-5 E-5 E-7 E-5 D-7 E-7 E-6 F-3 D-2 B-1 F-4 F-5 F-6 F-5 F-4 F-5 F-6 E-6 F-6 B-8 B-7 B-1 C-1 A-1 C-1 F-2 A-11 A-12 A-11 B-11 A-12 B-12 A-1 C-1 E-4
Ident 21 21 A A A A A 38 21 42 40 43 20 21 A 39 50 32 44 28 34 36 25 28 A 1 21 17 17 21 2 31 29 35
Schematic Components METER - SERVICE HOUR METER - TACHO MOTOR - BLOWER MOTOR - FRONT WASHER MOTOR - FRONT WIPER MOTOR - REAR WASHER MOTOR - REAR WIPER MOTOR - STARTER PANEL - OPERATOR MONITOR PICK - UP - SPEEDOMETER PICK - UP - TACHOMETER PICK - UP - TRANSMISSION SPEED RELAY - START RELAY - MAIN POWER RESISTOR - AIR CONDITIONER RESISTOR SENDER - BRAKE OIL (D40D ONLY) SENDER - CONVERTER TEMPERATURE SOLENOID - AIR CONDITIONER CLUTCH SOLENOID - FRONT SUSPENSION SOLENOID - ENGINE SHUTDOWN SOLENOID - LOCK - UP CLUTCH SOLENOID - RETARDER SOLENOID - REAR SUSPENSION SOLENOID - START AID SWITCH - BACK - UP ALARM SWITCH - BLOWER SWITCH - BRAKE AIR PRESSURE SWITCH - BRAKE AIR PRESSURE SWITCH - CAB LAMP SWITCH - CONVERTER LOCK INDICATOR SWITCH - CONVERTER TEMPERATURE SWITCH - COOLANT TEMPERATURE SWITCH - COOLANT TEMPERATURE (ETHER INHIBIT) SWITCH - DIFF LOCK SWITCH - DIMMER SWITCH - DISCONNECT SWITCH - DOME LAMP SWITCH - ENGINE OIL PRESSURE SWITCH - FRONT BRAKE OVERSTROKE SWITCH - FRONT WIPER SWITCH - FUEL SWITCH - FUEL LEVEL SWITCH - HORN SWITCH - KEY START SWITCH - LOCK UP INDICATOR SWITCH - LOCK UP CONTROL PRESSURE SWITCH - OPERATOR MONITOR TEST SWITCH - PARK BRAKE INDICATOR SWITCH - PARK BRAKE INHIBIT SWITCH - SERVICE BRAKE INHIBIT SWITCH - BRAKE OVERSTROKE (D400D) SWITCH - BRAKE OVERSTROKE (D40D) SWITCH - REAR WIPER SWITCH - REFRIGERANT SWITCH - RETARDER INDICATOR SWITCH - RUNNING LAMP SWITCH - TURN SIGNAL SWITCH - START AID SWITCH - STOP LAMP THERMOSTAT
37 9 12 4 30 24 21 33 3 21 21 6 15 21 27 24 19 45 45 21 21 14 21 22 21 18 A
Location E-5 E-5 B-4 D-11 B-6 D-10 C-7 A-6 F-1 E-11 A-3 D-11 D-9 D-4 B-5 A-6 B-10 C-11 B-3 F-12 A-2 D-11 F-11 F-12 B-2 C-3 B-5 B-2 C-2 F-7 D-10 E-11 A-4 A-4 D-11 C-2 A-4 B-7 A-3 E-10 E-8 A-2 A-2 F-8 E-3 D-11 D-1 F-3 F-10 C-2 C-2 B-12 B-11 F-7 B-2 E-10 F-8 E-2 F-3 C-2 B-5
Machine locations are repeated for components located close together. A = Components located at right console. B = Components located at breaker box. C = Components located in dash area.
3
7
2
5
28 11
25
24 21 12
6
26
11 27
10
20
16
9
23
7
4
8
13
22 4 14
A
21
8
15
D40D, D400D Articulated Dump Trucks Electrical System
6
20
2JJ1-UP 8TF1-UP
28 12 26
10
9 19
17 18
16
24
23
C32110P1
© 1990 Caterpillar All Rights Reserved
Engine and Transmission - Right Side
44
D40D Trailer 45
31
32
46
47
47
30
50
48
48
49
34
50
47
45 33
48
49
D400D Trailer
Engine and Transmission - Left Side 29
47
46
49
35
36
42
49
C32112P1 41
40
39
38
43
37
C32111P1
48
48
47
47
48
Printed in U.S.A.