SENR1361-01 April 2001 Schematic Location
Alarm - Action
D-5
Machine Location B
Sender - Converter
D-9
Machine Location 20
Alarm - Backup
B-9
1
Sender - Coolant
D-3
20
Alternator
C-2
21
Sender - Fuel Level
B-9
2
Batteries - 12V
F-2
23
Sender - Hydraulic
D-3
18
Breaker - Lamps Circuit (15A)
A-2
C
Solenoid - Diff Lock
C-9
3
Breaker - Main (80A)
A-3
C
Solenoid - Fuel Shut Dn
C-2
C
Control - Caterpillar Monitoring System
E-4
B
Solenoid - Start Aid
E-2
18
Control - Relay
C-3
C
Solenoids - CST Valve
D-9,E-9
13
Control - Secondary Steering
E-3
C
Suppressor - Arc
C-9
20
B-5
B
Switch - Accumulator Charge Pressure
C-3
C
Component
CID
0096 0100 0110 0177 0248 0263 0271 0324 0600 0819 0821 0830
Component Identifiers (CID¹) Module Identifier (MID²) Caterpillar Monitoring System (MID No. 030) Component
Fuel Level Sender Engine Oil Pressure Sensor Engine Coolant Temperature Sensor Torque Converter Oil Temperature Sensor Data Link Sensor Power Supply Action Alarm Action Lamp Hydraulic Oil Temperature Sensor Display Data Link Display Power Supply Brake Oil Temperature Sensor
Electronic Transmission Control System (MID No. 081)
CID
0070 0149 0168 0190 0248 0356 0363 0367 0368 0596 0621 0622 0623 0631 0632 0633 0634 0635 0636 0638 0650 0671 0687 1521
Component
Parking Brake Switch Ride Control Solenoid 2 Electrical System Voltage Engine Speed Sensor CAT Data Link Tilt Dump Solenoid 1 Ride Control Solenoid 1 Ride Control Switch Transmission Auto/Manual Switch Implement ECM Downshift Switch Upshift Switch Directional Switch Transmission Clutch 1 Solenoid Transmission Clutch 2 Solenoid Transmission Clutch 3 Solenoid Transmission Clutch 4 Solenoid Transmission Clutch 5 Solenoid Transmission Clutch 6 Solenoid Starter Solenoid Harness Code Transmission Output Speed Sensor Options ID Code Part-Throttle Autoshift Selector Switch
¹ The CID is a diagnostic code that indicates which component is faulty. ² The MID is a diagnostic code that indicates which electronic control module
Electrical Schematic Symbols And Definitions
Component Location
Control - Shift
Component
Schematic Location
F-4
B
Switch - Coolant
D-1
20
C-2,F-2
21
Switch - Diff Lock
B-7
A
Ground - Lower Cab
A-7
9
Switch - Disconnect
F-2
21
Ground - Lower Cab - Frame
A-7
9
Switch - Cat Monitoring System Select
C-5
B
Ground - Platform
B-7
9
Switch - Engine Oil Press
D-2
19
Ground - To Cab Roof
E-8
A
Switch - Forward Horn
B-6
B
Ground - To Engine Block
C-2
21
Switch - Front Differential Pressure
F-5
12
Holder - Fuse
B-3
C
Switch - Front Lamp
D-6
14
Horn - Forward
D-1
11
Switch - Key
C-6
B
Lamp - Action
D-5
B
Switch - Park Brake
D-3
C
Lamp - Primary Steering Press Warning
B-6
B
Switch - Primary Steering Pressure
F-3
3
Lamp - Quad Gauge
F-4
B
Switch - Rear/Center Lamp
D-6
14
Lamp - Secondary Steer Press Warning
B-6
B
Switch - Secondary Steering Pressure
E-3
3
Motor - Sec Steer
D-2
3
Switch - Secondary Steering Test
B-6
B
Motor - Starting
C-2
19
Switch - Start Aid
C-7
B
Receptacle - Auxiliary Start
F-2
21
Switch - Xmsn Neutral Lock
C-6
B
Relay - Main
A-2
C
Switch - Xmsn Press Filter
F-7
13
Relay - Sec Steer
D-2
C
Switch As.
C-6
B
Gage - Quad Ground - Frame
T
8
10 12
4
2 3
1
5
17
7
11 9
6
B
22
13
A
20
18
15
C
14
Flow Symbol
Level Symbol
23
21
19
Temperature Symbol
Pressure Symbol
Normally open switch that will close with an increase of a specific condition (temp-press-etc.).
16
Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition.
515 & 525 Wheel Skidder Electrical System 6
7
10
14
515 4LR1-UP
16 15
17
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.
525 1DN524-UP
The circle indicates that the component has screw terminals and a wire can be disconnected from it.
A = Components in right console area. B = Components in dash area.
B
C = Components in relay panel area.
4
C
8
Connector Number
Schematic Location
Machine Location
1
CONN 1 C-9 1 CONN 2 D-9 5 CONN 3 C-8 A CONN 4 B-7 A CONN 5 C-5 B CONN 6 Service Tool D-5 B CONN 7 Service Mode Plug D-5 B CONN 8 Harness Code Plug E-5 B CONN 9 C-4 C CONN 10 D-3 C CONN 11 B-2 C CONN 12 A-2 C 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.
18
9
3
Connector Location
No circle indicates that the wire cannot be disconnected from the component.
A 12
19
21
22
20
This indicates that the component has a wire connected to it that is connected to ground.
13
2
23
11
5
This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.
Machine Harness Connector And Component Locations
For Cable Machines Printed in U.S.A.
© 2001 Caterpillar All Rights Reserved
Harness And Wire Electrical Schematic Symbols A
AA
Related Electrical Service Manuals Title
Form Number
Alternator: 114-2401
FMI No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
SENR3536
6V-5226 (F8.0)
SENR4975
Caterpillar Monitoring System:
SENR1394
Shift Control:
SENR6685
Failure Mode Identifiers (FMI)¹ Failure Description
Data valid but above normal operational range. Data valid but below normal operational range. Data erratic, intermittent, or incorrect. Voltage above normal or shorted high. Voltage below normal or shorted low. Current below normal or open circuit. Current above normal or grounded circuit. Mechanical system not responding properly. Abnormal frequency, pulse width, or period. Abnormal update. Abnormal rate of change. Failure mode not identifiable. Bad device or component. Out of calibration. Parameter failures. Parameter failures. Parameter not available. Module not responding. Sensor supply fault. Condition not met. Parameter failures.
Off Machine Switch Specification
SENR3581
6V-5023 (KE 7.5)
Wire Color
Wire Number
Wire Color
101
RD
Bat (+)
411
PK
Action Lamp
103 105
YL
Panel Lamps/Gauges
417
GY
Secondary Steering Control
RD
Key Start Switch
419
YL
108
Park Brake Pressure Sw.
BU
To Seat
426
BR
Xmsn Filter Switch
109
RD
Alt Output (+) Term.
432
PK
Accumulator Charge Pressure Switch
112
PU
Main Power Relay Output
441
OR
Coolant Sender
114
RD
Forward Horn
442
GY
Hydraulic Sender
115
RD
Std. Lamps
443
YL
Converter Sender
124
GN
Blower Motor
447
PK
Fuel Level Sender
126
PK
Battery +24V
453
PK
Secondary Steering Pressure Switch
127
OR
Rear/Center Lamp Switch
484
YL
Primary Steering Pressure Switch
136
GN
Tranmission Control
498
WH
Differential Lock
136
RD
Secondary Steering
165
YL
Differential Lock Switch
Description Power Circuits
SENR7508
Starting Motor: 6V-5207 (42MT)
Wire Number
Wire Description
Part No.
Function
3E-6625
Coolant Temperature
3E-7806
Accumulator Charge Pressure
3E-7808
Secondary Steering Pressure
101-5459
Engine Oil Pressure
117-7773
Front Differential Pressure/ Transmission Pressure Filter
128-5091
Actuate 38 ± 3°C (100.4 ± 5.4°F) 9500 kPa (1377 psi MAX) 1100 kPa MAX (160 psi MAX) 90 kPa (13.0 psi MAX) 138 ± 28 kPa (20 psi ± 4 kPa) 551 kPa MAX (80 psi MAX)
Primary Steering Pressure
Deactuate 27 °C (80.6°F MIN) 8300 ± 350 kPa (1200 ± 50psi) 860 ± 170 kPa (125 ± 25 psi) 70 ± 20 kPa (10.0 ± 3.0 psi) 69 kPa MIN (9 psi MIN) 344 ± 20 kPa (50 ± 3 psi)
Contact Position Normally Closed A-B: Normally Open A-C Normally Closed Normally Closed Normally Open Normally Closed A-C: Normally Closed A-B Normally Open
Ground Circuits
Monitoring System Modes
Description Monitoring Circuits
PK
Front Flood Lamp
608
GN
Rear Flood Lamp
200
BK
Main Chassis
614
PU
Switch Lamps
201
BK
Operator Monitor Return
630
GY
Front Flood Lamp
202
BK
Xsmn Ground
270
BK
Harness Code 0
727
GN
Secondary Steering Test Switch
271
BK
Harness Code 1
751
GN
#1 CST Solenoid Valve
272
BK
Harness Code 2
752
YL
#2 CST Solenoid Valve
273
BK
Harness Code 3
754
BU
#3 CST Solenoid Valve
0
274
BK
Harness Code 4
755
OR
#4 CST Solenoid Valve
Harness Code
1
275
BK
Harness Code 5
900
PU
#5 CST Solenoid Valve
Numeric Readout
2
290
BK
Service
901
WH
#6 CST Solenoid Valve
Service
3
291
BK
Clear
921
WH
Solenoid Return
Digital Tattletale
4
944
OR
CAT Data Link +
Number
¹The FMI is a diagnostic code that indicates what type of failure has occurred.
Basic Machine Circuits 301
BU
Starter No. 1 Sol
945
BR
CAT Data Link -
304
WH
Starter Relay No. 1 Output
991
WH
Xsmn Neutral Lock
306
GN
Starter Relay Coil
C436
BU
Front Differential Pressure Switch
307
OR
Key SW
C413
YL
Module Data
308
YL
Main Power Relay Coil
C414
BU
Module Load
310
PU
Start Aid SW To Start Aid Sol
E707
GN
Cluster +V
311
WH
Start Aid Sol To Temp SW
E708
PK
Module Clock
Latch 1.55±10% Unlatch 10.3±10% Empty 96 ± 3; Full 1.75 ± 1.75
321
BR
Bckp Alarm
E735
PU
Operator Switch Input
322
GY
Forward Horn Switch
G750
BU
Forward Sw.
322
GY
Warning Horn (Forward)
G755
GY
Reverse Sw.
31±3 at 25±5 °C
324
BU
Diff Lock Switch to Diff Lock Solenoid
G760
WH
Upshift (N/O)
326
RD
Key SW "C" Term.
G761
YL
Downshift (N/C)
G762
BR
Downshift (N/O)
Resistor, Sender and Solenoid Specifications
Part No. 3E-6332
Machine
Machine Codes
Code
Component Description Solenoid - Start Aid
4W-9972
Sender - Hydraulic
7N-8532
Sender - Converter/ Coolant
152-8385
Solenoid - Diff Lock Solenoid - Fuel Shut Dn
515
59
155-4653
525
60
157-8852
Sender - Fuel Level
186-1526
Solenoids - CST Valve
¹ At room temperature unless otherwise noted.
Resistance (Ohms)¹ 6 560 to 716 at 54 °C 72 to 72 at 110 °C 560 to 716 at 54 °C 72 to 72 at 110 °C 32.6 ± 1.6 at 25 ± 5 °C
Monitoring Circuits 403
GN
Alternator (R) Term.
G763
PU
Neutral Sw.
405
GY
Opr Mon Oil Press. (Low Setting)
G768
GN
Upshift (N/C)
410
WH
Action Alarm
Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets.
Pin or Socket Number Wire, Cable, or Harness Assembly Identification
Component Part Number
Single Wire Connector C
A
A 325-PK-14
Pin
AA 1
9X-1123 325-PK-14
Wire Color
Socket
2
Control Circuits
Operator Mode Sequence
Service Mode
2
Lighting Circuits 607
Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.
Receptacle
Plug
1 2
1 2
1
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
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.