RENR1440 January 1998
Alarm - Action Alarm - Backup
F-15
1
Solenoid - Centershift
B-3
16
Alternator (35A STD)
D-14
2
Solenoid - Differential Unlock
E-14
17
Battery
C-14
3,4
Solenoid - Dual Horsepower
A-13
5
Breaker - Alternator (35A)
D-13
5
Solenoid - Engine Shutdown
D-13
5
Breaker - Headlamp (15A)
D-10
B
Solenoid - Forward Horn
A-3
16
Control - Neutral Start
A-6
10
Solenoid - Park Brake
B-12
16
Control - Transmission
A-7
E
Solenoid - Start Aid
A-13
18
Fuses
B-6
C
Solenoids - Transmission Valve (8)
D-15,E-15
14
Fuses
D-9
B
Switch - Beacon
B-16
C
Gauge Cluster
F-5
A
Switch - Blower (Heater)
A-10
C
C-13
12
Switch - Brake Air Pressure
A-2
16
Ground - Front Frame
D-6
21
Switch - Centershift Indicator
B-3
19
C-13
28
Switch - Centershift Pin
B-8
C
Component
Connector Location
3
6 26
8
23
Component Location
Schematic Location B-8
Machine Location C
Component Sender - Transmission Speed
Schematic Location C-15
Machine Location 14
Schematic Location
Machine Location
CONN 1
C-15
26
CONN 2
E-15
26
CONN 3
F-14
6
CONN 4
A-14
5
CONN 5
B-13
29
CONN 6
B-13
29
CONN 7
D-13
30
CONN 8
D-13
29
CONN 9
E-12
21
CONN 10
E-12
25
CONN 11
E-12
25
CONN 12
E-12
25
Ground - Rear Frame
D-6
24
Switch - Defroster (Front)
A-6
C C
Connector Number
18 14
13
11
22
7
17
1 2
12
5
B
E
20
30
29
21
D
9
A 24
C
28
25 4
19
16
10
27
15
Ground - Engine
CONN 13
D-12
21
Ground Strap - Cab to Front Frame
CONN 14
D-12
21
Ground Strap - Front Frame to Rear Frame
C-12
20
Switch - Defroster (Rear)
B-6
CONN 15
B-12
25
Horn - Forward
E-3
16
Switch - Differential Unlock
D-8
B
CONN 16
D-10
23
CONN 17
C-10
23
Meter - Service
E-10
B
Switch - Disconnect
C-14
13
CONN 18
A-11
C
Motor - Blower (Heater group)
A-10
E
Switch - Engine Coolant Temp (Start Aid)
A-14
11
CONN 19
B-9
25
Motor - Blower/Defroster
A-11
E
Switch - Flood Lamp
D-8
B
CONN 20
E-9
B
Motor - Blower/Defroster
E-4
E
Switch - Forward Horn
E-9
B
CONN 21
A-8
C
Motor - Starter
C-13
S
Switch - Fuel Pressure
B-13
13
CONN 22
B-7
25
Motor - Washer (Front Lower)
F-6
8
Switch - Head/Tail Lamp
E-8
B
CONN 23 Service Tool
B-7
C
Motor - Washer (Front Upper)
F-6
8
Switch - Headlamp Dimmer
E-9
B
CONN 24
E-6
24
Motor - Washer (Rear)
F-6
8
Switch - Inching Pedal Pressure
D-15
14
CONN 25
E-6
24
Motor - Wiper (Front Lower)
C-4
9
Switch - Key Start
CONN 26
C-6
24
Motor - Wiper (Front Upper)
D-4
D
Switch - Park Brake Pressure
CONN 27
C-6
27
CONN 28
A-6
27
Motor - Wiper (Rear)
B-11
D
Switch - Start Aid
E-8
B
CONN 29
C-5
27
Relay - Start
D-13
5
Switch - Stoplamp Pressure
A-2
16
CONN 30
C-5
27
CONN 31
B-3
15
CONN 32
E-3
23
CONN 33
F-3
23
CONN 34
F-3
23
27
D
A 18
B
11
22 12
1 6
2
14
4
24
E
13 5
9
C
30 3 29
28
23
8 20
26
25
10
15 19
16 21
7 17
E20367
Machine Harness Connector And Component Locations
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.
B-9
C
B-11
16
Relay - Transmission Action Lamp
C-10
8
Switch - Tail Lamp
D-8
B
Resistor - Blower Speed
A-12
E
Switch - Transmission Direction & Speed
A-8
C
Resistor - Blower Speed
E-4
E
Switch - Transmission Oil Temperature
D-15
26
Resistor - Blower Speed (Heater)
A-10
E
Switch - Wiper (Front Lower)
A-5
C
Sender - Articulation
C-1 2
7
Switch - Wiper (Front Upper)
B-5
C
Sender - Engine Coolant Temp
A-14
11
Switch - Wiper (Rear)
A-5
C
Sender - Engine Oil Pressure
B-14
13
120H, 135H Motor Grader (Standard Version) Electrical System 120H: 5FM1-799 6TM1-365
135H: 7MM1-248 8WN1-349
Machine locations are repeated for components located close together A= Operator’s compartment (Dash). B= Operator’s compartment (Steering console). C= Operator’s compartment (Right side console). D= Operator’s compartment (Headliner). E= Operators compartment (Under seat).
Related Electrical Service Manuals Title
Form Number
Alternator (6N-9294 35A): STD Consist No. 3T-6352 Consist No. 7N-9720 Consist No. 9G-4574
SENR4978 SENR2082 SENR4130
Alternator (100-5047 50A): ATT
SENR2082
Transmission Electronic Shift Control
SENR6982
Starting Motor: (106-8558) Consist No. 106-8557 Consist No. 106-8559
SENR3559 SENR3581
Printed in U.S.A.
© 1998 Caterpillar All Rights Reserved
Transmission Diagnostic Code Conversion
Resistor, Sender and Solenoid Specifications
Part No.
Component Description
Wire Number
Description
506
PU
Washer - Front
Range - 3 to 97 Ohms
102
BU
Hd Lmp
507
WH
Washer - Rear
560 to 716 @ 54°C (130°F) 72 tO 82 @ 110°C(230°F)
103
YL
Aux Ckt
515
GY
Blower Motor (HI)
105
BR
Key Start Sw
516
GN
Blower Motor (Medium)
No diagnostics active
12
N/A
No logged diagnostic codes
21
641 F05
Transmission Solenoid A open circuit
22
642 F05
Transmission Solenoid B open circuit
23
643 F05
Transmission Solenoid C open circuit
24
644 F05
Transmission Solenoid D open circuit
25
645 F05
Transmission Solenoid E open circuit
26
646 F05
Transmission Solenoid F open circuit
27
647 F05
Transmission Solenoid G open circuit
28
648 F05
Transmission Solenoid H open circuit
31
641 F06
Transmission Solenoid A short to ground
32
642 F06
Transmission Solenoid B short to ground
33
643 F06
Transmission Solenoid C short to ground
34
644 F06
Transmission Solenoid D short to ground
35
645 F06
Transmission Solenoid E short to ground
36
646 F06
Transmission Solenoid F short to ground
37
647 F06
Transmission Solenoid G short to ground
200
BK
38
648 F06
Transmission Solenoid H short to ground
201
41
641 F03
Transmission Solenoid A short to battery
277
42
642 F03
Transmission Solenoid B short to battery
43
643 F03
Transmission Solenoid C short to battery
44
644 F03
Transmission Solenoid D short to battery
45
645 F03
Transmission Solenoid E short to battery
46
646 F03
Transmission Solenoid F short to battery
47
647 F03
Transmission Solenoid G short to battery
48
648 F03
Transmission Solenoid H short to battery
52
637 F06
Backup alarm short to ground
54
444 F05
Starter relay open circuit
55
444 F06
Starter relay short to ground
56
444 F03
Starter relay short to battery
58
688 F06
VHP solenoid short to ground
59
688 F03
VHP solenoid short to battery
61
668 F02
Shift lever input invalid
62
668 F03
Shift lever open/short to +battery
63
269 F00
Sensor supply voltage above normal
64
269 F0l
Sensor supply voltage below normal
65
701 F02
Transmission output speed signal incorrect
68
168 F0l
System voltage below normal
71
520 F02
Invalid transmission configuration code
72
268 F02
Check programmable parameters
73
764 F05
Transmission indicator lamp open circuit
74
764 F06
Transmission indicator lamp short to ground
75
764 F03
Transmission indicator lamp short to battery
500
BR
77
762 F04
Transmission oil temperture switch short to ground
501 502 503
3E-5383
Sender - Articulation Position
7N-8532
Sender - Engine Coolant Temp
7T-4003
Resistors - Defroster Blower
10.0 ± 0.5
108
BU
Aux Ckt
517
BU
Blower Motor (Low)
7T-9073
Solenoid - Differential Unlock
33.6 ± 1.0
109
OR
Alt Output (+) Term.
521
YL
A/C SW To Refrigerant SW
7T-9074
Solenoids - Forward Horn Park Brake
113
OR
Opr Mon Panel
522
WH
A/C Clutch To Thermostat SW
114
GN
Warning Horn (Forward)
556
WH
Differential Lock
116
BR
Aux Ckt
575
YL
Wiper - Aux (Park)
8C-3663
Solenoid - Engine Shutdown Start (Latch) Coil Stop (Unlatch) Coil
118
GY
Aux Ckt
576
PK
Wiper - Aux (Low)
119
PK
Aux Ckt
577
PU
Wiper - Aux (Hl)
124
GN
A/C
578
BU
Washer - Aux
130
GN
Aux Ckt
584
YL
Wiper SW Jumper
141
PK
Aux Ckt
A503
PK
Front Defroster Fan (Low)
144
GN
Aux Ckt
A504
GN
Rear Defroster Fan (Low)
149
PU
Aux Ckt
A506
OR
Front Defroster Fan (HI)
151
GN
Aux Ckt
A507
YL
Rear Defroster Fan (HI)
152
BU
Aux Ckt
165
YL
Aux Ckt
55.17 ± 5.77 1.55 ± 0.1510.3 ± 1.03
8T-8808 9G-1950 9G-4365 104-6387 111-0570
Solenoid - Centershift Resistor - Blower Speed Solenoid - Start Aid Sender - Transmission Speed Solenoid - Dual Horsepower
34.3 ± 1.7 Overall 2.00 ± .10 Tap 1.00 ± .05 6 1000 to 1200 31.1 ± 2.4
116-9937
Sender - Engine Oil Pressure
21.5- 49.5 @552 kPa (80.1 psi) 227 - 257 @ 21 kPa (3.0 psi)
127-0574 Solenoids - Transmission ¹ At room temperature unless otherwise noted.
31 ± 3
PK
Rotary Beacon
604
OR
Stop Lamp
Main Chassis
608
GN
Flood Lamp - Rear
BK
XMSN CtrI
609
YL
Flood Lamp - Side
BK
XMSN Ctrl Ident Code 1
611
PU
Head Lamp Hi
278
BK
XMSN CtrI Ident Code 2
614
PU
Park/Tail/Dash/Lamp
619
GN
Head Lamp LoControl Circuits
301
BU
Starter No. 1 Sol
304
WH
Starter Relay No. 1 OutpuT
306
GN
307
OR
Starter Relay Coil To Neut Start SW Or KeyStart SW Key Start SW To Neutral Start SW
308
YL
Main Power Relay Coil
310
PU
Start Aid SW To Start Aid Sol
311
WH
Start Aid Sol To Temp SW
321
BR
Backup Alarm Lamp Travel Alarm
322
GY
Warning Horn (Forward)
326
PU
Key Start SW C Term.
Basic Machine Circuits
112-2024 115-7103
Function Stop Lamp Pressure Coolant Temperature (Start Aid) Inching Pedal Pressure
Off Machine Switch Specification Actuate
Deactuate
Contact Position
45 kPa MAX (6.5 psi MAX)
5 kPa MIN (0.5 psi MIN)
NormallyOpen
38 ± 3°C (1 00.4° ± 5.4°F) 75.0 kPa MAX (10.9 psi MAX)
27 °C MIN (80.6°F MIN) 50.0 kPa MIN (7.3 psi MIN)
NormallyClosed NormallyOpen
Brake Air Park Brake Pressure
640 kPa MAX (92.0 psi MAX)
530 ± 40 kPa (77.0 ± 6.0 psi)
NormallyOpen
Fuel Pressure (EMS)
93 ± 21 kPa (13.5 ± 3.0 psi)
69 ± 21 kPa (10.0 ± 3.0 psi)
Normally Closed
Monitoring Circuits
A
AA
2
GN
XMSN Speed Pickup Signal
751
GN
XMSN Shift Sol No. 1 Or 3
752
YL
XMSN Shift Sol No. 2
754
BU
XMSN Shift Sol No. 3 Or 1
755
OR
XMSN Shift Sol No. 4 Or 5
758
GN
AWD Clutch SW
795
YL
Dual Hp Sol
B751
BU
(NFND) Centershift Lock Sol
892
BR
Start Mod Right (-) Port/CAT Data Link (-)
893
GN
Start Mod Right (+) Port/CAT Data Link (+)
G865
BU
+12 Volt Switch Power
404
GN
Alternator (R) Term.
439
YL
Lamp Indicator
900
PU
XMSN Shift Sol No. 5 or 4
441
OR
Eng Coolant Temp Gauge
901
WH
XMSN Shift Sol No. 6
A429
YL
Articulation Indicator
902
BR
XMSN Shift Sol No. 7
A476
PU
Eng Oil Press Gauge To Sender - Eng #1
903
GY
XMSN Shift Sol No. 8
B476
BU
(NFND) Transmission Indicator Lamp
921
WH
XMSN Sol No 1 Or 3 Return
C491
PU
Park Brake Pressure
E937
PU
MG MESH CNTL - Redundant Neutral
E458
YL
Low Air Pressure Lamp
E938
OR
MG MESH CNTL - First Gear
E459
WH
Low AIr Pressure Alarm
E939
WH
MG MESH CNTL - Second Gear
E460
BR
Trans Cntl To Relay Coil
E940
BU
MG MESH CNTL - Third Gear
G460
GN
Transmission Temperature
E941
YL
MG MESH CNTL - Fourth Gear
Accessory Circuits
E942
GN
MG MESH CNTL - Fifth Gear
Wiper - Front (Park)
E943
BR
MG MESH CNTL - Sixth Gear
GN
Wiper - Front (Low)
E944
GY
MG MESH CNTL - Seventh Gear
OR
Wiper - Front (HI)
E945
PU
MG MESH CNTL - Eighth Gear
BR
Wiper - Rear (Park)
E946
OR
MG MESH CNTL - Forward Direct
504
YL
Wiper - Rear (Low)
E947
WH
MG MESH CNTL - Reverse Direct
505
BU
Wiper - Rear (HI)
E948
BU
MG MESH CNTL - Park
E949
YL
MG MESH CNTL - Neutral
E975
PU
MESH Lamp
Electrical Schematic Symbols And Definitions
Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. T
Pressure Symbol
Pin or Socket Number Wire, Cable, or Harness Assembly Identification
C
A
A 325-PK-14
Pin
AA 1
9X-1123 325-PK-14
Wire Color
Socket
2
Level Symbol
Flow Symbol
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.
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
Temperature Symbol
Component Part Number
Single Wire Connector
Control Circuits 710
Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.
Receptacle
Plug
1 2
1 2
1
Lighting Circuits 603
Ground Circuits
111-7088
Description Accessory Circuits (Continued)
Bat (+)
N/A
8C-3569
Harness And Wire Electrical Schematic Symbols
RD
11
2W-9346
Wire Color
101
Resistance (Ohms)¹
CID - FMI
Part No.
Wire Number
Power Circuits
Code Flashed
Description
Wire Description
Wire Color
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.
Normally closed switch that will open with an increase of a specific condition.
Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition.
The circle indicates that the component has screw terminals and a wire can be disconnected from it.
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.