Wire Number
Wire Description
Wire Color
Wire Number
Description
Wire Color
Power Circuits 101
RD
Battery (+)
A513
RD
Description Accessory Circuits (Continued) DC/DC Converter Memory Output
Schematic Location A-9
Component Actuator - Engine Gov
Component Location Machine Location 1
Component Sender - Hydraulic Oil Temp
Schematic Location A-5
Machine Location 12 2
Air Inlet Heater
C-8
2
Sensor - Air Inlet Heater Coolant Temp
C-9
3
2
103
RD
Dome Lamp
A571
PU
Aux Ckt 1
Alarm - Travel
G-9
Sensor - Coolant Temperature
C-8
105
RD
Key Sw
A572
PK
Aux Ckt 2
Alternator
B-8
4
Sensor - Fuel Level
A-5
13
107
RD
Engine Shutdown
A579
OR
Wiper Motor +
Assembly - Terminal Block
F-8
D
Sensor - Pump Discharge Press
B-8
14
108
BU
Aux Ckt
A586
OR
Wiper Sw to Wiper Ctrl
Batteries - 12VDC
l-8,H-8
5
Sensor - Sun Load
F-1
E
109
RD
Alt Output (+) Term
A588
GN
Safety Sol Relay to Sol
Breaker - Alternator
I-8
D
Solenoid - A/C Clutch
C-9
15
111
RD
Timer Relay Output 1
C537
GN
A/C Photo Sensor + Sig
Breaker - Main
I-8
D
Solenoid - Eng/Pump Control
A-7
16
112
PU
Main Power Rly
C538
OR
A/C Photo Sensor - Sig
Control - Engine/Pump
F-2
C
Solenoid - Engine Shutdown
B-9
17
113
OR
Opr Mon Panel B+ Switched
Controller - Wiper/Washer
E-1
A
Solenoid - Fine Swing
E-7
18
C-5
A
Solenoid - Grapple
E-7
18
Lighting Circuits
114
RD
Warning Horn (Forward)
607
PK
Flood Lamp - Front
Converter - Voltage
115
PK
Aux Ckt
615
YL
Cab Flood Lamp
Diode
G-7
D
Solenoid - Hydraulic Lock
I-1
A
Boom Flood Lamp
Diode - Main Relay
H-7
D
Solenoid - Level Finish
A-7
16
I-4,5,6
B
Solenoid - Rotate
D-7
18
118
GY
AuxCkt
616
BU
120
YL
Aux Ckt
123
WH
Aux Ckt
763
BU
Torque Converter Sw
124
GN
A/C
786
GN
Engine Speed Cont - Hi Press Sw
129
BU
Aux Ckt
788
YL
Engine Speed (+)
140
BU
Aux Ckt
791
PK
Engine Speed Cont - Lo Sol
147
PU
Aux Ckt
A718
PU
Start Aid Coolant Sensor Signal
149
PU
Aux Ckt
A755
PK
Throttle Sw #1
150
RD
Hyd Lock
A756
BU
Throttle Sw #2
151
GN
Aux Ckt
A757
GY
Throttle Sw #3
152
BU
Aux Ckt
A758
BR
Throttle Sw #4
154
RD
Neut Start Relay
A761
PU
Electronic Pump Cont Ground
168
RD
Aux Ckt
A762
PU
Electronic Pump Cont Engine Speed Ground
172
RD
Eng Gov
A768
BU
Pump Control Valve #1 (+)
177
RD
Main Breaker
A769
GY
Pump Control Valve #2 (-)
180
GN
Aux Ckt
A770
PK
Electronic Pump Control Bypass Sw
185
YL
Aux Ckt
A771
PU
Float Sw
189
RD
Timer Relay Output 2
F771
OR
Backup Sw
191
WH
Aux Ckt
F772
WH
Backup Sw
F773
OR
Governor Accel
200
BK
Main Chassis
F774
WH
Governor Decel
201
BK
Opr Mon Panel
J704
WH
Hyd Lock Sol Relay to Grapple and Rotate Sw
235
BK
Electronic Pump Ctrl Gnd
J705
WH
Rotate CCW Relay to Sol
J706
PU
Grapple Close Relay to Sol
Control Circuits
Ground Circuits
Basic Machine Circuits
Fuses Ground - Cab
B-5
6
Solenoid - Start Aid
H-9
19
Ground - Cab
E-1
E
Solenoid - Swing Brake
E-7
18
Ground - Chassis
A-3
7
Solenoid - Travel Speed
A-7
16
Ground - Chassis
A-9
8
Solenoid - Trenching
A-7
16
Ground - Chassis
I-8
D
Switch - Air Cleaner Flow
H-9
20
Ground - Platform
G-2
B
Switch - Aux Hydraulic Pressure
H-3
B
Ground - Platform
H-1
9
Switch - Backup EPR Valve
E-5
C
Ground - Relay Panel
H-7
D
Switch - Backup Governor
D-5
C
Ground Strap - Chassis to Platform
I-6
10
Switch - Boom Raise Pressure
D-8
18
Ground Strap - Chassis to Riser
H-1
F
Switch - Coolant Level
H-9
19
Horn
A-2
7
Switch - Disconnect
I-8
D
Lighter
E-1
E
Switch - Engine Oil Level
A-8
1
Meter - Service
F-1
E
Switch - Engine Oil Press
B-9
15
Monitor
F-1
E
Switch - Fine Swing Control
D-4
C
Motor - Lower Washer
I-9
D
Switch - Grapple Close
F-2
C
Motor - Lower Wiper
H-1
9
Switch - Grapple Open
I-1
B
Motor - Starter
A-9
8
Switch - Horn
I-1
B
Motor - Tilt
I-9
F
Switch - Hydraulic Control
D-4
C
Motor - Upper Washer
I-9
D
Switch - Hydraulic Oil Filter
A-5
12
Motor - Upper Wiper
C-5
6
Switch - Hydraulic Oil Level
A-5
12
Pickup - Engine Speed
B-9
11
Switch - Implement Pressure
D-8
18
C-6,I-3
A
Switch - Key
F-3
C
Relay - Boom Lamp
I-7
D
Switch - Lower Washer
D-4
C
Relay - Cab/Chassis Lamp
E-7
D
Switch - Lower Wiper
D-3
C
Relay - Cab/Chassis Lamp
I-7
D
Switch - Neutral Start Limit
I-1
B
Relay - Grapple Close
H-5
F
Switch - One Touch Low Idle
F-2
C
Relay - Grapple Open
H-5
F
Switch - Refrigerant Low Press
C-9
15
Radio - 12VDC
301
BU
Starter No. 1 Sol
J707
YL
Grapple Open Relay to Sol
304
WH
Starter Rly No. 1 Output
J708
BR
Rotate CW Relay to Sol
306
GN
Starter Rly Coil
J709
GN
Cab/Chassis Lamp Relay
307
OR
Key Sw to Neut Start Sw
J710
WH
Aux Ckt
308
YL
Main Power Rly Coil
J711
GN
Aux Ckt
Relay - Heater
F-7
D
Switch - Rotate CCW
F-2
C
309
GY
Alt Regulator Term
J712
YL
AuxCkt
Relay - Horn
I-7
D
Switch - Rotate CW
I-1
B
310
PU
Start Aid Sw to Start Aid Sol
J713
BU
Aux Ckt
Relay - Hydraulic Lock Solenoid
I-7
D
Switch - Start Aid
D-5
C
311
WH
Start Aid Sol to Temp Sw
J714
BR
Aux Ckt
Relay - Main
G-7
D
Switch - Start Aid Coolant Temp
B-9
4
320
OR
Horn Rly Coil to Sw
J715
OR
Aux Ckt
Relay - Neutral Start
F-7
D
Switch - Suction Line Shutoff Limit
A-6
12
321
BR
Travel Alarm
877
YL
Glow Plug Magnetic Sw to Glow Plug
Relay - Rotate CCW
H-6
F
Switch - Throttle Position
E-3
C
322
GY
Warning Horn (Forward)
961
GN
Hyd Cont Sw
Relay - Rotate CW
H-5
F
Switch - Travel Pressure
D-8
18
326
RD
Key Sw "C" Term
K904
GN
Pump Discharge - Signal
Relay - Start
F-8
D
Switch Panel
F-2
C
386
PK
Air Shutoff Sol Enable
K905
RD
Pump Discharge - +B
Relay - Timer
E-7
D
Unit - A/C, Heater
H-5
21
K906
GN
Swing Brake Sol - Signal
Resistor - Backup
I-8
D
Unit - Air Inlet Heater Control
I-7
D
E-7
D
Monitoring Circuits 403
GN
Alternator (A) Term
K907
BU
Swing Brake Sol - +B
Resistor - Timer Relay
405
GY
Opr Mon Oil Press (Lo Setting)
K909
BU
Backup Sw - +B
Machine locations are repeated for components located close together.
412
BU
Opr Mon Cool Flow
K911
PK
E/P Controller - RS485 (+)
Area A = Located in operator’s compartment.
430
BU
Opr Mon Air Filter
K912
GN
E/P Controller - RS485 (-)
Area B = Located in operator’s left console area.
487
OR
Hyd Oil Flow Sw
K915
GN
Fine Swing Sw - E/P Controller
Area C = Located in operator’s right console area.
491
PK
Hyd Oil Temp Sensor
K997
BU
+V Sensor
Area D = Located on or near relay panel.
492
GY
Coolant Temp Sensor Signal
L908
OR
Controller RS-232C TX
Area E = Located in dash area.
495
GN
Fuel Level Signal
L909
BU
Controller RS-232C RX
Area F = Located in Cab Riser.
496
WH
Opr Mon Panel Hyd Oil Level
L968
OR
Electronic Pump Cont PS Valve (-)
A495
GY
Alternator (A) Terminal #2
L969
WH
Electronic Pump Cont PS Valve (+)
C468
BU
Engine Oil Level
L970
GY
Electronic Pump Cont to Switch Common
L971
GN
Electronic Pump Cont to Travel Press Sw
Accessory Circuits 501
GN
Wiper - Front (Lo)
L972
BU
Low Idle Sw
506
PU
Washer - Front
L973
GN
Fine Swing Cont Relay to Sol Valve
508
PU
RADIO SPEAKER - Left
L974
GN
Electronic Pump Ctrl Boom Raise Press Sw
509
WH
Radio Speaker - Left (Common)
L975
PK
Start Aid Cont Lamp 1 Output
511
BR
Radio Speaker - Right
L977
YL
Trenching Sol
512
GN
Radio Speaker - Right (Common)
L978
GY
Level Finish Sol
513
OR
A/C Compressor/Refrigerant Press Sw
519
PK
Thermostat to Refrigerant Press Sw
546
BU
Aux Hyd - Rotate CW
547
OR
Aux Hyd - Rotate CCW
548
GY
Aux Hyd - Open
549
PK
Aux Hyd - Close
576
PK
Wiper - Aux (Lo)
578
BU
Washer - Aux
590
GY
Wiper Sw to Intermittent Module
592
BU
DC/DC Converter Power Output
19 5
3
1
D
21
10
4
6
A
Air filter is clogged.
1305
Battery voltage is not normal.
2201
Governor actuator feedback sensor circuit is open or shorted to battery voltage.
2202
Governor actuator feedback sensor circuit is shorted to body ground.
2301
Governor actuator feedback signal is not stable.
2302
Governor actuator feedback signal deviates.
2303
Governor actuator does not move.
2304
Calibration data error.
3201
Monitor RAM is not normal.
4101
Electric power supply to the controller is too much (43 volts).
4102
Over-current in proportional reducing valve.
4103
Proportional reducing valve circuit is open.
4105
Over-current in digital output (trenching solenoid).
4106
Over-current in digital output (fine control solenoid).
4107
Over-current in digital output (travel speed change solenoid).
4108
Over-current in digital output (travel alarm).
410A
Over-current in digital output (swing brake solenoid).
4201
Engine speed is not normal.
4202
Engine coolant temperature sensor is shorted to body ground.
4203
Hydraulic oil temperature sensor is shorted to body ground.
4204
PWM sensor of pump delivery pressure is shorted to body ground.
4207
PWM sensor of pump delivery pressure is open in circuit.
420A
Fuel sensor is shorted to body ground
420B
Fuel sensor is open or shorted to battery voltage.
420C
Electric power supply is to low (below 23 volts).
420D
Electric power supply is to high (above 32 volts).
420E
Engine speed dial is not in one of the 10 specified positions.
4301
Data mismatch 1 between alternator and speed sensor (alternator is abnormal).
4302
Data mismatch 2 between alternator and speed sensor (speed sensor is abnormal).
4303
Engine stalls.
A201
Monitor communication is not normal.
A202
Monitor takes too much time to respond to controller's signal.
A203
Communication is abnormal in controller.
3E-6455
Engine Oil Pressure
90 ± 21 kPa (13 ± 3.0 psi)
70 ± 21 kPa (10 ± 3.0 psi)
106-0179
Implement Pressure Travel Pressure
1225.00 ± 98.00 kPa (177.67 ± 14.21 psi)
882.00 kPa MIN (127.92 psi MIN)
Normally Open
106-0180
Boom Raise Pressure
2646.00 ± 196.00 kPa (383.77 ± 28.43 psi)
2156.00 ± 196.00 kPa (312.70 ± 28.43 psi)
Normally Open
106-0181
Hydraulic Pressure
490.00 ± 49.00 kPa (71.07 ± 7.11 psi)
290.00 kPa MIN (42.06 psi MIN)
Normally Open
114-5333
A/C High/Low Pressure
275 to 1750 kPa¹ (40 to 255 psi)
Normally Closed A-B, Normally Open A-C, Normally Closed
-
Title
325B L, 325B LL, 325B MPS, and 325B MPH Forest Swing Machines Electrical System
Normally Open ²
Form Number
Alternator: (9W-3043)
SENR4252
Engine/Pump Control
SENR9291
Starting And Charging
SENR9292
Starting Motor: (104-7040) Consist: 6V-5720 Consist: 106-8557
SENR3581 SENR3859
2JR1-UP
Resistor, Sender and Solenoid Specifications
Part No.
Component Description
Resistance (Ohms)¹
102-8016
Resistor - Backup
47.0 ± 2.35
7Y-8242
Resistor - Timer Relay
47.0 ± 4.7
134-3998
Solenoid - A/C Clutch
17.6 ± 0.6
111-9916
Solenoid - Engine/Pump Control
11.7 ± 1.2 Start (Latch) Coil - 1.55 ± 0.15 Stop (Unlatch) Coil - 10.3 ± 1.03
8C-3663
Solenoid - Engine Shutdown
3E-9205
Solenoid - Grapple
121-1491
Solenoid - Hydraulic Lock Swing Brake Travel Speed
32.0 ± 3.2
121-1490
Solenoid - Level Finish Trenching
32.0 ± 3.2
3E-6332
24.9
Solenoid - Start Aid
6.0
¹ At room temperature unless otherwise noted.
Connector Number
C
E
22
8
12 16
Description of Problems
1304
Start Aid Coolant Temperature
Related Electrical Service Manuals
Connector Location¹
13
11
Real Time Error Codes
Hydraulic oil temperature is too high.
Contact Position
² Contact postion at the contacts of the harness connector.
9
14
1303
27 °C MIN (80.6 °F MIN)
Printed in U.S.A.
T
2
Engine coolant temperature is too high.
Deactuate
¹ A hysteresis band exists: 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).
F
7
Engine oil pressure is too low.
Actuate
38.0 ± 3.0°C (100.4 ± 5.4°F)
3E-6449
B 20
18
1302
Off Machine Switch Specification
Function
© 1996 Caterpillar All Rights Reserved
17
1301
Part No.
Electrical Schematic Symbols And Definitions
15
Code
SENR9323 November 1996
6 A 22
B 17 19
14 1
11
2
4
16
D
12
8
15
21
20
3
5
C
E
9
F 18
10
13 7
D78225
MACHINE HARNESS CONNECTOR AND COMPONENT LOCATIONS
Schematic Location
Pressure Symbol
Machine Location
CONN 1
A-9
1
CONN 2
F-9
D
CONN 3
F-9
D
CONN 4
G-9
D
CONN 5
G-9
D
CONN 6
G-8
D
CONN 7
G-8
D
CONN 8
G-8
D
CONN 9
F-8
D
CONN 10
C-6
A
CONN 11
C-5
A
CONN 12
C-5
A
CONN 13
C-4
A
CONN 14
F-5
C
CONN 15
F-5
C
CONN 16
F-5
C
CONN 17
F-5
C
CONN 18
F-4
C
CONN 19
F-4
C
CONN 20
F-4
C
CONN 21
F-4
C
CONN 22
H-5
B
CONN 23
H-5
B
CONN 24
H-4
B
CONN 25
H-4
B
CONN 26
H-4
B
CONN 27
H-4
B
CONN 28
H-3
B
CONN 29
H-3
B
CONN 30
C-3
A
CONN 31
B-3
7
CONN 32
A-3
13
CONN 33
B-2
7
CONN 34 Service Connector
D-2
C
CONN 35
B-2
22
CONN 36
G-5
F
CONN 37
G-5
F
CONN 38
G-8
F
CONN 39
G-8
F
CONN 40
G-8
F
CONN 41
F-9
F
CONN 42
F-9
F
CONN 43
G-9
F
CONN 44
G-9
F
CONN 45
G-9
D
CONN 46
G-9
F
Circuit Breaker Symbol
Flow Symbol
Level Symbol
Temperature Symbol
Normally open switch that will close with an increase of a specific condition (temp-press-etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Normally closed switch that will open with an increase of a specific condition. 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. 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.
T
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. 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.
Harness And Wire Symbols Pin
Socket
Wire Color
A
Circuit Number Identification
105-9344
Receptacle
Wire Gauge
Ground Connection
CONN 47 G-9 D ¹The 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.
Fuse
AA 1
325-PK-14
Single Wire Connector
Component Part Number
Wire, Cable, or Harness Assembly Identification
Plug
2
200-BK-14
Pin or Socket Number 1 2
Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.
1 2
Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.