Cat Electrical 776D Tractor And 777D Truck Electrical System Schematic Manual - PDF DOWNLOAD

Wire Wire Number Color

MODULE IDENTIFIER (MID) 27

EPTC II

30

Caterpillar Monitoring System

36

Engine Control ECM

83

Automatic Retarder Control

COMPONENT IDENTIFIER (CID) LIST CIDNo. Component 168 190 248 269 571 572 575 627 650 672 700 701 702 704 705 706 707 708 709 96 110 177 248 263 271 324 600 601 819 821 830 1 2 3 4 5 6 7 8 91 100 101 102 110 168 190 248 253 254 261 262 263 267 268 273 274 275 276 291 338 526 542 544 545 546 569 827 828 829 91 168 190 248 627 650 700 702 710 711 712 713 714 715

FMI No.

EPTC II (MID No. 27)

Electrical System Voltage Engine RPM Sensor CAT Data Link Sensor Power Supply Forward Elevator Solenoid Reverse Elevator Solenoid Elevator Lever Sensor Parking Brake Switch Harness Code Torque Converter Output Speed Sensor Actual Gear Switch Transmission Output Speed Sensor Shift Lever Switch Service Brake Pressure Switch Body Raise Switch Body Up Switch Up Solenoid Down Solenoid Lockup Solenoid Caterpillar Monitoring System (Mid No. 30) Fuel Level Sensor Engine Coolant Temperature Sensor Torque Converter Oil Temperature Sensor CAT Data Link 8 Volt Sensor Power Supply Action Alarm Action Lamp Hydraulic Oil Temperature Sensor Brake Air Pressure Display Data Link 9 Volt Display Power Supply Brake Oil Temperature Engine Control (MID No. 36) Cylinder 1 Injector Solenoid Cylinder 2 Injector Solenoid Cylinder 3 Injector Solenoid Cylinder 4 Injector Solenoid Cylinder 5 Injector Solenoid Cylinder 6 Injector Solenoid Cylinder 7 Injector Solenoid Cylinder 8 Injector Solenoid Throttle Position Sensor Engine Oil Pressure Sensor Crankcase Air Pressure Sensor Boost Pressure Sensor Engine Coolant Temperature Sensor Electrical System Voltage Engine RPM Sensor CAT Data Link Personality Module Mismatch Electronic Control Module Timing Calibration Analog Sensor Power Supply 8 Volt Sensor Power Supply Shutdown Inputs Are Incorrect Programmed Parameter Fault Turbo Outlet Pressure Atmospheric Pressure Right Turbo Inlet Pressure Left Turbo Inlet Pressure Engine Cooling Fan Solenoid Engine Prelubrication Pump Relay Turbo Waste Actuator Engine Oil Pressure Sensor Engine Cooling Fan Speed Sensor Start Aid Control Relay Start Aid Current Limit Relay Oil Injection Solenoid Left Exhaust Temperature Sensor Right Exhaust Temperature Sensor Rear Aftercooler Coolant Temperature Sensor Automatic Retarder Control (MID No. 83) Throttle Position Sensor Electrical System Voltage Engine RPM Sensor CAT Data Link Parking Brake Switch Harness Code Actual Gear Switch Shift Lever Switch ARC Supply Solenoid ARC Control Solenoid Retarder Lamp ARC On/Off Switch Auto Retarder Pressure Switch Retarder Pressure Switch

Electrical Schematic Symbols And Definitions

Wire Description Chart

Wire Wire Number Color

Description Power Distribution Circuits

101 102 103 105 109 112 113 121 122 123 124 126 129 132 135 136 137 138 140 141 150 173 176

RD BU YL BR OR PU OR YL BU WH GN PK BU PK BU GN OR GN BU PK OR YL OR

BAT (+) HD LMP AUX CKT KEY SW ALT OUTPUT (+) TERM. MAIN POWER RL Y OUTPUT OPR MON PANEL BCKP ALARM AUX CKT AUX CKT A/C XMSN CTRL AUX CKT AETA CTRL AUX CKT SUPPL STER SUPPL STER MOTOR FUSE AUTO LUBE PUMP TO PAYLOAD MON AUX CKT AUX CKT BAT(+) AUX CKT AUX CKT

200 201 202 213 215 216 217 218 219 227 229 231 250 251 280 290 291 A215 A216 A217 A218 A231

BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK

MAIN CHASSIS OPR MON PANEL XMSN CTRL AETA CODING PIN 17 AETA CODING PIN 19 AETA CODING PIN 20 XMSN ID CODE 2 XMSN ID CODE 1 XMSN ID CODE 0 XMSN ID CODE 3 BAT(-) XMSN SW PAYLOAD MON - CUSTOMER GND PAYLOAD MON - SYSTEM GND XMSN CTRL IDENT CODE 4 CMS SERVICE CMS CLEAR AUTO RETARD CTRL HARNESS CODE 0 AUTO RETARD CTRL HARNESS CODE 1 AUTO RETARD CTRL HARNESS CODE 2 AUTO RETARD CTRL HARNESS CODE 3 AUTO RETARD CTRL HARNESS CODE 4

306 307 308 315 317 321 337

GN OR YL GN YL BR WH

STARTER RLY COIL KEY SW TO NEUT START SW MAIN POWER RL Y COIL START AID BRKR TO START AID RLY START AID RL Y TO START AID SOL BCKP ALARM LAMP PRELUBE SW TO PRELUBE TIMER

403 408 410 411 412 417 426 446 447 450 452 454 462 472 481 C413 C414

GN WH WH PK BU GY BR PU PK YL PU GN YL OR GN YL BU

ALTERNATOR (R) TERM. OPR MON SYSTEM AIR PRESS. OPR MON ACTION ALARM OPR MON MASTER ACTION LAMP OPR MON COOL FLOW PRIMARY STER SW OPR MON POWER TRAIN OIL FILTER BRAKE OIL TEMP GAUGE FUEL LEVEL GUAGE TACH SENDER (+) TORQUECONVERTER RETARDER INDICATOR LAMP SUPPL STER MOTOR INDICATOR PARKING BRAKE SW TO OVER STROKE SW CONVERTER TEMP SW TO BRAKE OIL TEMP SW DISPLAY DATA DISPLAY LOAD

508 509 511 512 513 515 516 517 518 520 521 522 537 539 540 A513 511 512 513 515 516 517 518 520 521 522 537 539 540 A513

PU WH BR GN OR GY GN BU OR WH YL WH GN BU WH PK BR GN OR GY GN BU OR WH YL WH GN BU WH PK

RADIO SPEAKER - LEFT RADIO SPEAKER - LEFT (COMMON) RADIO SPEAKER - RIGHT RADIO SPEAKER - RIGHT (COMMON) A/C COMPRESSOR/REFRIGERANT PRESS. SW BLOWER MOTOR (HI) BLOWER MOTOR (MEDIUM) BLOWER MOTOR (LO) HAZARD FLASHER TO SW OPR A/C SW TO THERMOSTAT/FUSE A/C SWTO REFRIGERANT SW A/C CLUTCH TO THERMOSTAT SW TURN SIGNAL SW TO FLASHER TURN SIGNAL INDICATOR BASIC/RIGHT TURN SIGNAL INDICATOR LEFT DC/DC CONVERTER MEMORY OUTPUT RADIO SPEAKER - RIGHT RADIO SPEAKER - RIGHT (COMMON) A/C COMPRESSOR/REFRIGERANT PRESS. SW BLOWER MOTOR (HI) BLOWER MOTOR (MEDIUM) BLOWER MOTOR (LO) HAZARD FLASHER TO SW OPRA/C SW TO THERMOSTAT/FUSE A/C SWTO REFRIGERANT SW A/C CLUTCH TO THERMOSTAT SW TURN SIGNAL SW TO FLASHER TURN SIGNAL INDICATOR BASIC/RIGHT TURN SIGNAL INDICATOR LEFT DC/DC CONVERTER MEMORY OUTPUT

602 604 605 606 608 610 611 612 614 619 635 636 661 662 663

WH OR YL GY GN OR PU GY PU GN BU GN GN YL GY

DOMELAMP STOP LAMP TURN LAMP - LEFT TURN LAMP - RIGHT FLOOD LAMP - REAR HEAD LAMP BASIC HEAD LAMP HI BACKUP LAMP PARK/TAIL/DASH LAMP HEAD LAMP LO PAYLOAD MON RED LAMP PAYLOAD MON GREEN LAMP TACHOMETER LAMP SPEEDOMETER LAMP GAUGE LAMPS

700 703 704 705 706 707 709 710

PK BU GY PK BR PU OR GN

AETA TEST SW XMSN UP SOL XMSN DOWN SOL XMSN LOCKUP CLUTCH SOL BASIC XMSN RETARDER SW XMSN BED RAISE SW SENSOR POWER SUPPLY XMSN SPEED PICKUP SIGNAL

Ground Circuits

Basic Machine Circuits

Monitoring Circuits

Accessory Circuits

Lighting Circuits

Control Circuits

711 712 713 714 715 716 720 721 722 723 724 725 726 727 728 767 768 769 770 772 773 774 775 794 799 A700 A701 A702 A703 A704 A705 A706 A707 A708 A746 A747 A751 E707 E708 E729 E735 E750 E793 E794 E795 E796 E799 F700 F702 F703 F704 F705 F707 F708 F709 F710 F713 F714 F715 F716 F717 F718 F719 F720 F721 F722 F723 F724 F725 F726 F727 F728 F729 F732 818 819 820 858 859 860 861 863 864 865 866 867 891 F728 F729 F732 818 819 820 858 859 860 861 863 864 865 866 867 891 892 893 956 958 987 993 994 995 996 997 998 999 E986 F975 J992 K972 K984 K985 K986 K986 K988 K989 K991 K992 L918

BR WH OR YL GN BU PU BR WH OR YL GN BU GN BU WH OR BU GN BR GY YL BR YL WH OR GY PU BR GN BU GY PU BR PK GY YL GN PK GN PU PU BU YL YL GN BR BU GN GY OR PK WH YL BU BR OR PK PU WH YL BU BR GN GY OR PK PU WH YL BU BR GN PK BR GY BU GY YL PK PU BU BR GY PK PU BU BR GN PK BR GY BU GY YL PK PU BU BR GY PK PU BU BR GN BR YL WH BR GY BU GN OR BR WH YL OR YL BR GY BR PK PK WH BU OR PU GN

XMSN LEVER CODE 1 XMSN LEVER CODE 2 XMSN LEVER CODE 3 XMSN LEVER CODE 4 XMSN LEVER CODE 5 XMSN LEVER CODE 6 XMSN BRAKE SW XMSN GEAR CODE 1 XMSN GEAR CODE 2 XMSN GEAR CODE 3 XMSN GEAR CODE 4 XMSN GEAR CODE 5 XMSN GEAR CODE 6 SUPPL STER MOTOR RELAY SUPPL STER CONT SW AETA PICKUP POWER AETA PICKUP XMSN WHEEL SPEED PICKUP LEFT WHEEL SPEED PICKUP RIGHT AETA RETARDER SW AETA SERVOVALVE AETA SOL - LEFT AETA SOL - RIGHT PAYLOAD MON XMSN SPEED SENSOR POWER DIGITAL SENSOR POWER(+8V) INJECTOR #1 INJECTOR #2 INJECTOR #3 INJECTOR #4 INJECTOR #5 INJECTOR #6 INJECTOR #7 INJECTOR #8 TURBO OUTLET PRESSURE ATMOSPHERIC PRESSURE AFTER COOLER TEMP) DISPLAY +V DISPLAY CLOCK FAN BRAKE RL Y TO FAN BRAKE SOL TACK/SERV MTR/ODOMETER SELECT BODY POSITION SENSOR SIGNAL TLM ATA DATA LiNKATA DATA liNK + CRANKCASE PRESS OIL PRESS (UNFILTERED) PWM #1 AND #2 RETURN PWM#1 OUT (3.5A) THROTTLE LH TURBINE INLET EXH TEMP RH TURBINE INLET EXH TEMP DOUT 6 START AID CURRENT LEVEL RLY DOUT 3 DOUT 2 START AID ON RELAY LEFT TURBO INLET PRESS RIGHT TURBO INLET PRESS SHUTDOWN (NO) SHUTDOWN (NC) SW4 SW5 SW 6/1 SW 8/3 SW 9/4 SW 10/5 TBC PROBE + TDC PROBEFUEL PRESS INJECTOR COMMON 1 & 3 INJECTOR COMMON 2 & 4 INJECTOR COMMON 5 & 7 INJECTOR COMMON 6 & 8 BACKUP CAMSHAFT SPD/TMG SERIAL DATA (TRANSMIT) SERIAL DATA (RECEIVE) TRANSMIT KEY PAYLOAD MON RIGHT FRONT SENSOR PAYLOAD MON LEFT FRONT SENSOR PAYLOAD MON RIGHT REAR SENSOR PAYLOAD MON LEFT REAR SENSOR PAYLOAD MON TRANSMIT LCD OUT PAYLOAD MON CLOCK LCD OUT PAYLOAD MON LATCH LCD OUT PAYLOAD MON TEST/SET PAYLOAD MON MODE NEUT START CONT TO PAYLOAD MON SYSTEM INJECTOR COMMON 5 & 7 INJECTOR COMMON 6 & 8 BACKUP CAMSHAFT SPD/TMG SERIAL DATA (TRANSMIT) SERIAL DATA (RECEIVE) TRANSMIT KEY PAYLOAD MON RIGHT FRONT SENSOR PAYLOAD MON LEFT FRONT SENSOR PAYLOAD MON RIGHT REAR SENSOR PAYLOAD MON LEFT REAR SENSOR PAYLOAD MON TRANSMIT LCD OUT PAYLOAD MON CLOCK LCD OUT PAYLOAD MON LATCH LCD OUT PAYLOAD MON TEST/SET PAYLOAD MON MODE NEUT START CONT TO PAYLOAD MON SYSTEM CAT DATA LINK (-) CAT DATA LINK (+) RELAY LOGIC LARGE PUMP RELAY LOGIC DIVERTER SOL ANALOG SENSOR COMMON OIL PRESSURE (FILTERED) COOLANT TEMPERATURE ENGINE SPEED/TIMING SENSOR POWER ANALOG SENSOR POWER (+ 5V) DIGITAL SENSOR RETURN (PIN 29) PRIMARY CAMSHFT SPEED/TIMING CONTINUOUS OIL INJECTOR SOLENOID + 8V SENSOR SUPPLY MISCELLANEOUS SWITCH #1 EPTC-II START RELAY RETURN START AID TIMER OUTPUT AUTO RETARD ON SW AUTO RETARD OFF SW AUTO RETARD OFF SW AUTO RETARD AIR CONT VALVE AUTO RETARD AIR SUPPLY VALVE AUTO RETARD PRESS SW AUTO RETARD MANUAL RETARD SW BRAKE OIL DIVERTER TEMP SW TO SOLENOID

Failure Mode Identifiers (FMI)¹ Failure Description

0

Data valid but above normal operational range.

1

Data valid but below normal operational range.

2

Data erratic, intermittent, or incorrect.

3

Voltage above normal or shorted high.

4

Voltage below normal or shorted low.

5

Current below normal or open circuit.

6

Current above normal or grounded circuit.

7

Mechanical system not responding properly.

8

Abnormal frequency, pulse width, or period.

9

Abnormal update.

10

Abnormal rate of change.

11

Failure mode not identifiable.

12

Bad device or component.

13

Out of calibration.

14

Parameter failures.

15

Parameter failures.

16

Parameter not available.

17

Module not responding.

18

Sensor supply fault.

19

Condition not met.

20

Parameter failures.

¹The FMI is a diagnostic code that indicates what type of failure has occurred.

Part No.

Function

2M-9346

Stop Lamp Pressure Trailer Stop Lamp Pressure

3E-2033

Secondary Brake Pressure

3E-2034

Service Brake Pressure

3E-6429

Steering Oil Flow

3E-6430

Coolant Flow

3E-6449

Brake Oil Diverter Temperature

9X-7781

Transmission Filter Pressure

103-4977 111-9560 111-9563

Off Machine Switch Specification

Retarder Brake Pressure A/C Fan Pressure Auto Retarder Pressure

114-5333

A/C High/Low Pressure

116-9933

Fuel Filter Press

Actuate

45kPa MAX (6.5 psi MAX) 640 kPa (92.0 psi) 80 kPa (12.0 psi) 4 grams (.14 oz.) .

362.0 ± 29.0 N m (266.2 ± 21.3 lb ft) 38.0 ± 3.0 °C (100.4 ± 5.4 °F) 210 ± 70 kPa (30 ± 10 psi) 60.0 kPa (8.7psi) 1585.0 ± 103.0 kPa (229.9 ± 14.9 psi) 80.0 kPa MAX (11.6 psi MAX) 275 to 1750 kPa ¹ (40 to 255 psi) 138 ± 17 kPa (20.0 ± 2.0 psi)

Deactuate

5 kPa MIN (0.5 psi MIN) 530 ± 40 kPa (77.0 ± 6.0 psi) 55 ± 20 kPa (8.0 ± 3.0 psi) 1.5 grams (.05 oz.) .

303.0 N m MIN (222.8 lb ft MIN) 27 °C MIN (80.6 °F MIN) _ -_ -1275.0 ± 103.0 kPa (184.9 ± 14.9 psi) 55.0 ± 20.0 kPa (8.0 ± 2.9 psi) _ -83 kPa MIN\ (12.0 psi MIN)

Contact Position Normally Open Normally Open Normally Closed Normally Open Normally Open Normally Closed Normally Open Normally Open Normally Closed Normally Closed Normally Open ² Normally Closed

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). ² Contact postion at the contacts of the harness connector.

SENR6910 May 1996

Description Control Circuits

T

Resistor, Sender and Solenoid Specifications

Component Description

Part No.

Pressure Symbol

Resistance (Ohms)¹

Resistor- Blower Motor Solenoid- ARC Control Valve ARC Supply Valve Solenoid- Brake Oil Diverter Smoke Box Solenoid- Downshift Upshift Lockup Solenoid- Fan Clutch

125-9740

Overall 2.6 ± 0.12

3E-8691

31 ± 3

105-3025

4.3

Solenoid- Four Way

9G-9988

24.9

Solenoid- Proportional

3T-0062

16.0

Solenoid- Shutter

9X-9482

68

101-3430

31.1 ± 2.4

7X-1120

33.7

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.

¹ At room temperature

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.

T

776D Tractor And 777D Truck Electrical System Monitoring System Modes

Mode of Operation

776D: 5ER1-UP

Mode Number

Normal

0

Harness Code

1

Numeric Readout

2

Service

3

Tattletale

4

Units

5

Total Load Count Display

6

Calibration (EPTC II)

7

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.

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.

777D: 3PR1-UP

Harness And Wire Symbols Pin

Socket

Wire Color

A

Circuit Number Identification

Fuse

AA

105-9344

1

325-PK-14

Single Wire Connector

Component Part Number

Wire, Cable, or Harness Assembly Identification

Receptacle

Wire Gauge Plug

Ground Connection

2

200-BK-14

Pin or Socket Number Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.

1 2 Component Location

Component

Schematic

Machine

Location Location Alarm - Backup A-15 1 Alarm - Monitor Action C-4 A Alternator A-5 2 Batteries A-7,A-8 3 Boss - Power C-6 D Breaker - Air Conditioner D-6 C Breaker - Alternator C-6 C Breaker - Dome And Stop Lamp C-6 C Breaker - Engine (ECM) D-5 C Breaker - Headlamp D-5 C Breaker - Key D-6 C Breaker - Supplemental Steer D-6 C Breaker - Turn Lamp D-5 C Caterpillar Monitoring System F-1 B Control - ARC D-13 D Control - Automatic Electronic Traction Aid (TCS) E-15 D Control - Engine (ECM) A-2 2 Control - Oil Burn C-14 D Control - Payload Monitor C-14 D Control - Supplemental Steering F-15 D Control - Transmission D-13 D Converter - 12V to 24V C-4 A Dimmer - Light F-14 D Display - Payload Monitor Operator C-7 A Distributor - Transmission Speed E-15 D Flasher C-15 D Fuse - Supplemental Steering (10 Amp) A-8 3 Fuses (10 Amp) D-6 C Ground - Cab D-14,E-12 D Ground - Caterpillar Monitoring System E-2 B Ground - Cylinder Head To Frame B-2 4 Ground - Engine A-4 2 Ground - Engine Block A-6 5 Ground - Frame A-6 5 Ground - Frame B-9 2 Lamp - Body Up F-2 B Lamp - High Beam F-2 B Lamp - Left Turn F-2 B lamp - Monitor Action F-2 B Lamp - Payload Monitor Green A-5 6 Lamp - Payload Monitor Green D-1 A Lamp - Payload Monitor Red A-5 6 Lamp - Payload Monitor Red D-1 A Lamp - Retardeeer F-2 B Lamp - Reverse F-2 B Lamp - Right Turn F-2 B Lamp - Shift Lever Position D-11 F Lamp - Supplemental Steer F-2 B Lighter - Cigar C-3 B Module - Gauge F-1 B Motor - Blower E-10 E Motor - Starter A-6 5 Motor - Supplemental Steering A-8 3 Radio D-3 A Receptacle - Aux Start A-6 7 relay - Backup C-15 D Relay - Headlamp C-7 C Relay - Main Power (Front) D-6 C Relay - Main Power (Mid) C-6 C Relay - Main Power (Rear) C-6 C Relay - Prelubrication C-6 C Relay - Shutter Control C-14 D Relay - Start A-6 5 Relay - Start B-6 5 Relay - Start Aid B-15 D Relay - Start Aid Hold C-51 D Relay - Steering Motor A-8 3 Relay - Stop Lamp D-7 C Resistor - Blower Motor D-10 E Resistor - Exhaust Diverter B-14 D Resistor - Oil Burn B-14 D Resistor - Start Aid B-15 D Sender - Engine Speed A-5 8 Sender - Fuel Level A-11 9 Sender - Torque Converter output Speed A-12 8 Sender - Transmission Speed A-13 10 Sensor - Aftercooler Temp C-3 8 Sensor - Atmospheric Press C-3 2 Machine locations are repeated for components located close together.

A = Located in operator's compartment.

B = Located on dash.

C = Located behind operator's seat.

D = Located in rear compartment.

E = Located in front compartment.

F = Located in transmission shift console.

Component

Sensor - Body Up Sensor - Brake Air Pressure Sensor - Brake Oil Temp Sensor - Crankcase Press Sensor - Engine Coolant Temp Sensor - Engine Oil Press (Filtered) Sensor - Engine Oil Press (Unfiltered) Sensor - Engine Speed/ Timing Sensor - Fan Speed Sensor - Left Front Strut Sensor - Left Hand Turbo Inlet Exhaust Temp

Sensor - Left Rear Strut Sensor - Left Turbo Inlet Press Sensor - Right Front Strut

Sensor - Right Hand Turbo Inlet Exhaust Temp

Sensor - Right Rear Strut Sensor - Right Turbo Inlet Press Sensor - Shift Lever Position Sensor - Throttle Position Sensor - Torque Converter Temp Sensor - Turbo Outlet Press Sensor - Wheel Speed Sensor - Wheel Speed Solenoid - Air Conditioner Clutch Solenoid - Brake Oil Diverter Solenoid - Continuous Oil Burn Injector Solenoid - Down Shift Solenoid - Fan Clutch Solenoid - Four Way Solenoid - Lockup Solenoid - Proportional Solenoid - Shutter Solenoid - Smoke Box solenoid - Start Aid Solenoid - Up Shift Solenoids - Cylinder Head (1 Per Cylinder) Speedometer/ Tachometer Suppressor - Arc Suppressor - Arc Switch - A/C Fan Pressure Switch - A/C Refrigerant Press Switch - Air Conditioner On/Off Switch - Auto Retard Press Switch - Auto Retarder Off/On Switch - Blowre Switch - Body Raise Switch - Brake Master Cylinder Overstroke Switch - Brake Oil Diverter Temp Switch - Caterpiller Mon Sys Clear Switch - Caterpillar Mon Sys Service Switch - Coolant Flow Switch - Disconnect Switch - Door Courtesy Lamp Switch - Engine Add Oil Level Switch - Engine Low Oil Level Switch - Exhaust Diverter Switch - Fuel Filter Switch - Ground Level Shutdown Switch - Headlamp Dimmer Switch - Key Start Switch - Retarder Brake Switch - Running Lamp Switch - Secondary Brake Switch - Service Brake Switch - Service Brake Switch - Start Aid switch Steering Switch - Stop Lamp Switch Supplemental steering Switch Throttle Backup Switch - Tractioon Aid Test/ Operator Mode switch - Trailer stop Lamp Switch - Transmission Switch - Transmission Filter Switch - Turn Thermostat Valve - ARC Control Valve - ARC Supply

Schematic

Location B-15 C-15 A10 C-3 C-2 C-3 C-3 C-2 A-4 B-5 C-3 B-14 C-4 A-5 C-4 A-14 C-4 D-11 C-6 A-4 C-3 A-15 B-15 A-5 A-12 B-6 A-13 C-2 A-14 A-13 A-14 C-2 B-12 A-5 A-14 C-1,C-2 F-1 B-5 F-15 B-2 B-7 D-2 D-12 D-3 D-2 C-11 A-10 A-12 E-5 E-5 B-2 A-7 C-5 A-4 A-4 E-5 A-2 B-3 D-5 F-3 F-15 E-3 F-1 E-15 E-15 E-15 A-8 F-15 F-3 D-2 D-3 F-15 A-13 A-9 D-5 E-11 E-12 E-12

1 2

Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.

Machine

Location 11 D 12 13 14 15 15 16 31 17 18 19 16 20 21 22 23 F A 24 25 26 27 28 24 29 30 31 11 8 32 33 16 34 30 35 B 28 D 28 B B D B A D 36 24 C C 37 3 A 38 38 C 28 39 A B E B D D D B 40 D B B B D 41 42 A E D D

Printed in U.S.A.

© 1996 Caterpillar All Rights Reserved

9

Connector Location

Schematic Location

Machine Location

CONN 2

B-15

1

CONN 3

D-15

D

CONN 4

D-15

D

CONN 5

E-14

D

CONN 6

B-14

11

Connector Number

38

34 37

39

2

3 21 4

20 40

29

35 14 25 31 28 18 7 15

23 13 8

5

16

17 33

44

42

10

41

30

24 11

22

43

45

12

CONN 1

27

32

1

19

26

36 F E

B

A

D

C

6

B

A F

E

C

6

D

25 14 33 23 16 18 21 3 34 8 2 28 13 35 17 20 7 24 15 4 31 37 29 40 39

38

5

36 9

12 42

44 11

10

45 32 41 30

1 43 26 27

22

19

B-15

Machine Harness Connector and Component Locations

Title

Form No.

Alternator: 30-SI Series

SENR7508

Automatic Electronic Traction Aid (TCS)

SENR2986

Automatic Retarder Control

SENR5683 SENR6717

CONN 7

A-14

44

CONN 8

A-13

45

CONN 9

B-13

D

CONN 10

F-13

D

Caterpillar Monitoring System Electronic Troubleshooting 3508B EUI Engine EPTCII For ICM Transmission

CONN 11

D-12

D

Payload Monitoring System

SENR4733

CONN 12

D-12

D

CONN 13

D-12

D

Starter Motor; 50 MT Series

SENR3860

CONN 14

B-12

D

CONN 15

B-11

D

CONN 16

B-11

D

CONN 17 ECAP

E-12

C

CONN 18

E-10

E

CONN 19

D-10

D

CONN 20

B-10

D

CONN 21

B-10

D

CONN 22

B-9

D

CONN 23

D-9

D

CONN 24

F-9

D

CONN 25

D-8

C

CONN 26

B-8

D

CONN 27

B-6

29

CONN 28

B-6

35

CONN 29

B-6

5

CONN 30

C-5

D

CONN 31

E-6

D

CONN 32

B-5

E

CONN 33

B-4

35

CONN 34

D-4

E

CONN 35

F-4

E

CONN 36

A-3

2

CONN 37

B-2

7

CONN 38

C-2

35

CONN 39

C-2

35

CONN 40

C-2

35

CONN 41

C-2

35

CONN 42

C-2

35

CONN 43

C-1

35

CONN 44

C-1

35

CONN 45

C-1

35

CONN 46

F-2

E

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.

D61230

Related Service Manuals

43

SENR1128 SENR9122

TRUCK PAYLOAD MEASUREMENT SYSTEM (TPMS) Fault

Circuit

Description

F01

Suspension cylinder charge

F02

Suspension cylinder charge

F03

Suspension cylinder charge

F04

Suspension cylinder charge

F05

Left front suspension cylinder pressure sensor circuit

F06

Right front suspension cylinder pressure sensor circuit

F07

Left rear suspension cylinder pressure sensor circuit

F08

Right rear suspension cylinder pressure sensor circuit

F09

Batt backup/real time clock setting

F10

System_setting/memory

F13

Green light open circuit or ground short circuit

F14

Green light + battery short circuit

F15

Red light open circuit or ground short circuit

F16

Red light + battery short circuit

WIRES THAT HAVE BATTERY VOLTAGE WHEN THE KEY SWITCH IS OFF. WIRES THAT HAVE BATTERY VOLTAGE WHEN THE KEY SWITCH IS ON. STARTING CIRCUIT. AUTOMATIC ELECTRONIC TRACTIONAID (TCS).

CATERPILLAR MONITORING SYSTEM. PANEL LAMP CIRCUIT. AUTOMATIC RETARDER CONTROL. HEATER AND AIR CONDITIONER CIRCUIT. GROUND CIRCUIT. ENGINE ECM. TURN SIGNAL CIRCUIT. PAYLOAD MONITOR CIRCUIT. START AID CIRCUIT. TRANSMISSION CONTROL CIRCUIT.

ALL DASHED LINES ARE ATTACHMENTS.

TRANSMISSION SW 118-8471

231-BK-18 726-BU-18

G H I F E C B A D J

725-GN-18 724-PU-18 723-OR-18 722-WH-18 721-BR-18 308-YL-18 Z

13

L72

BRAKE MASTER CYLINDER OVERSTROKE SW 7V-5647

F975-OR 201-BK 446-PU

A B C

OR-18 BK-18 WH-18

L73 L72

201-BK

D D

426-BR

TRANSMISSION FILTER SW 9X-7781

+V GROUND SIGNAL

H

122-BU

200-BK 728-BU

2 1

10

9

8

LL

AA

BK-00

AA

RD-00 DD

DD

RD-000

AAA

POS NEG

POS NEG

12V BATTERY 9X-9731 STD NOTE B

12V BATTERY 9X-9731 STD NOTE B

BUS BAR 8C-6358 GG NOTE B RD-00 GG

LL

AA

BK-00

STARTER 1W-6363 NOTE B

MOTOR

EE DISCONNECT SW 7N-0718

AA

JJ

POS NEG

POS NEG

12V BATTERY 9X-9731 STD

12V BATTERY 9X-9731 STD

BK-00 BK-00

7

HH BB JJ

BK-00

MM

MM BB

AAA

HHH

AP

MOTOR

AN

G BK-00

MTR BAT

BK-00

EE

YY

TO ENG BLOCK

6

BK-4

C

ALT R

+

BK BU STARTER 1W-6363 NOTE B

2 1

6

C

G

G

200-BK-18 200-BK-18 200-BK-18 200-BK-18

124-GN-14 515-GY-18 516-GN-18 517-BU-18 518-OR-18

L98

BK RD 2 1

BK RD 2 1 NNN

6 BLOWER SW 123-6389

G 2

BK-18 BK-18

1 2

C

L6

A B C

F975-OR-18 201-BK-18 481-PK-18

ENGINE GROUND

998-BR-18

L1

3

TO MOUNTING BOLT

14 GA

KKK

D

1 2

1 2

CONN 45

A708-BR-18 F729-GN-18

T HI BEAM HEAD LAMP 9X-7170

540-WH 614-PU 200-BK-14 200-BK-14 200-BK-14

539-BU 614-PU 619-GN-14 611-PU-14

HI BEAM HEAD LAMP 9X-7170 T

619-GN-14 200-BK-14

T P

T T

T LOW BEAM HEAD LAMP 9X-7169 PARK-TURN LAMP 129-5688

P2

KKK

T

200-BK-14 T

C

ENGINE CONTROL 132-8900

A707-PU-18 F728-BR-18

A706-GY-18 F729-GN-18

BK-18 RD-18 WH-18 200-BK-14 200-BK-14 200-BK-14

A B C F715-PU-18 F716-WH-18 998-BR-18

L7

COLOR

ATCH WIRE, CABLE, COMPONENT CIRCUIT GROUPING DESIGNATION

IDENT

T

200-BK-14 540-WH 614-PU 619-GN-14 611-PU-14 539-BU

UU TO FRAME

L1

J2

A C D E F G H H J K L M N P Q R S T X Y Z NN PP SS WW ZZ CCC JJJ NNN RRR TTT UUU VVV XXX ZZZ AL AM

PART NO. CHG LOC NOTE HARNESS AS. 116-9308 06 C-9 117-0035 01 A-3 118-0290 01 B-10 136-2197 00 B-15 116-9304 01 F-2 116-9305 04 E-3 118-6751 02 B-11 STD 118-6756 00 B-11 ATCH C 118-2891 02 B-12 123-6866 01 A-4 ATCH C 116-9307 02 D-13 116-9306 04 C-4 118-8580 00 E-10 116-9303 03 E-1 116-2654 05 E-5 126-8865 02 D-15 ATCH H 6G-9462 02 D-5 118-5772 01 B-1 118-6675 00 A-15 ATCH 118-2430 01 B-13 120-9288 01 A-13 132-4859 02 B-4 123-6991 01 B-6 NOTE H 118-7118 01 B-8 ATCH H 117-2931 02 F-15 NOTE E 116-9310 03 D-10 116-9309 01 D-4 NOTE F 124-8794 00 B-2 117-2930 00 C-14 ATCH H 132-6469 00 C-1 118-0291 01 A-10 117-2929 02 D-13 ATCH H 117-2933 02 C-12 ATCH H 118-7952 00 C-4 124-8837 00 C-2 ATCH 135-5452 00 A-15/B-15 130-6614 01 B-6 ATCH

WIRE AS. W 116-2655 YY 7I-4731 BBB 7G-1060 EEE 125-7128 FFF 125-7129 GGG 128-8479

01 01 00 00 00 01

D-6 A-6 C-11 D-9 D-15 A-3

CABLE AS. 117-2932 9G-0549 8W-3713 2A-7093 125-3565 6S-1061 2A-7098 2A-7096 2A-7097 2A-7094 118-6753 7I-5516 2G-5786 2G-4177 109-4394 123-6867 4N-6580 31-8761 7X-6315 2G-4177 134-4410 134-4411

00 01 00 01 00 02 00 00 00 01 00 00 00 00 00 00 02 03 01 00 00 00

B-4 A-7/A-8 A-6 A-7 A-7 A-6 A-7 A-7 A-7 A-8 A-7 A-7 A-6 A-7 A-7 B-2 A-5 A-6 A-2 A-6 A-6 A-6

V AA BB CC DD EE GG HH JJ KK LL LL MM QQ RR UU AAA HHH KKK AN AP AQ

B

STD ATCH C

ATCH C ATCH ATCH ATCH

A

THIS SCHEMATIC IS FOR THE 776D/777D TRUCK (116-4597 CHG00) COMPONENTS ARE SHOWN INSTALLED ON A FULLY OPERABLE MACHINE WITH THE KEY AND ENGINE OFF AND THE XMSN SHIFTER IN NEUTRAL. UNLESS OTHERWISE SPECIFIED: ALL WIRE IS 16 GAGE NOTE A: NORMALLY OPEN BEFORE REFRIGERANT CHARGE NOTE B: NOT USED ON MACHINES WITH AIR START NOTE C: USED ON MACHINES WITH AIR START ONLY NOTE E: 776D ONLY NOTE F: NOT USED ON MACHINES WITH ARC NOTE G: USED ON MACHINES WITHOUT A/C FAN PRESS SW NOTE H: 777D ONLY

D59139

1

C

NOTE G

TO FRONT HOUSING

2

E

BR BR

BR BR

BR BR 1 2

CONN 44

1 2

CONN 42

A705-BU-18 F728-BR-18

A704-GN-18 F727-BU-18

L1

BK-2

CONN 37

FUEL FILTER SW 116-9933 BK-18 1 2 BK-18 C 998-BR-18 998-BR-18 L3 998-BR-18

L2

CONN 43

BR BR

BR BR 1 2

BR BR 1 2

CONN 41

A703-BR-18 F726-YL-18

1 2

CONN 39

2 1 E799-BR-18 F700-BU-18

E729-GN 998-BR L9 JJJ

F725-WH-18 998-BR-18

L2

611-PU-14

L1

BK BK

C

LOW BEAM HEAD LAMP 9X-7169

619-GN-14

C

COOLANT FLOW SW 3E-6430

P1 J1

L6

1 2

GGG 1 BR 2 NOTE G

L6

JJJ

T P

F726-YL-18 F726-YL-18 F727-BU-18 F727-BU-18 F728-BR-18 F728-BR-18 F729-GN-18 F729-GN-18 BK-18 2 RD-18 1 WH-18 3

C

BK-18 BK-18

C

200-BK-14

TO CYLINDER HEAD

L7

F722-OR-18 998-BR-18

1 2

F715-PU F716-WH

L2

A/C FAN PRESS SW 111-9560 C

L4

4

C

C

UU

JJJ

1 3

P

RRR

L3

998-BR

P

RRR

200-BK-14

L9

2

RRR

PARK-TURN LAMP 129-5688

FAN CLUTCH SOL 109-3025

L7

C 412-BU-18 998-BR-18

998-BR-18 998-BR-18

CONN 36

L6

C OR-18 BK-18 WH-18

C

RRR

L3

403-GN-18 317-YL-18 450-YL-18 200-BK-14 F705-PK-18 F708-YL-18 F709-BU-18 F721-GY-18 150-RD-14 F707-WH-18 150-RD-14 113-OR-14 F710-BR-18 F717-YL-18 F720-GN-18 892-BR-18 893-GN-18 E794-YL-18 E793-BU-18 998-BR-18 F702-GN-18 L4

L4

C

F719-BR-18 998-BR-18 C

+V GROUND SIGNAL

TIMING CALIBRATION CONNECTOR 1 2

L5

GROUND LEVEL SHUTDOWN SW 4D-1836 JJJ

L4

A700-OR-18 E986-YL-18 201-BK-18 481-PK-18 F975-OR-18

L12

C

998-BR-18 F718-BU-18

L3

998-BR-18

L9

FAN SPEED SENSOR 119-4367

RRR

C

RRR

T

1 2 2 1

E795-YL-18 F703-BR-18 A751-YL-18 A746-PK-18 A747-GY-18 F704-OR-18 F713-OR-18 F714-PK-18

L10 L12

L6

BK-18 BK-18

993-BR-18 997-OR-18 994-GY-18

997-OR-18 997-OR-18 993-BR-18

L10

L12

L12

RRR

2 1 3

997-OR-18 993-BR-18 995-BU-18

SHUTTER SOL 9X-9482

L2

F714-PK-18 F713-OR-18

L3

RRR

C

RRR

BK BK A700-OR-18 A700-OR-18

993-BR-18 993-BR-18 997-OR-18 997-OR-18 997-OR-18 997-OR-18

L70

113-OR-14 150-RD-14 150-RD-14 200-BK-14 317-YL-18 403-GN-18 450-YL-18 481-PK-18 892-BR-18 893-GN-18 998-BR-18 A700-OR-18 E793-BU-18 E794-YL-18 E986-YL-18 F702-GN-18 F705-PK-18 F707-WH-18 F708-YL-18 F709-BU-18 F710-BR-18 F717-YL-18 F720-GN-18 F721-GY-18 F975-OR-18

A702-PU-18 F727-BU-18

OR-18 BK-18 WH-18

C

RRR CONN 40

BR BR

BR BR

1 2 C

RRR

C

C

997-OR-18 993-BR-18 E796-GY-18

RRR

ZZZ

L5

L11 635-BU 799-WH 799-WH 858-GY 251-BK BK RD

2 1

SS

2 35 25 4 11 26 7 1 3 18 15 36 27 22 6 5 9 8 34 33 31 10 20 23 28 12 14 40 37 13 17 16 19 21 24 29 30 32 38 39

CONN 33 201-BK-18 521-YL-14 522-WH-14 452-PU-18 201-BK-18

RRR

RRR

A B C

A B C C

RRR ENGINE SPEED/ TIMING SENSOR RRR 127-1008 +V TIMING DIGITAL RET SIGNAL

+V ANALOG ANALOG RET SIGNAL OR-18 BK-18 WH-18

+V ANALOG ANALOG RET SIGNAL OR-18 YL-18 GN-18 A B C

OR-18 YL-18 GN-18 A B C

C

997-OR-18 993-BR-18 994-GY-18

C

ENGINE COOLANT TEMP SENSOR 102-2240

P

INTERNAL ELECTRICAL CONNECTION TO SURFACE OF COMPONENT CONNECTOR

L# L #

CONN 38

L8

ENGINE OIL PRESSURE SENSOR (UNFILTERED) 103-6092

ENGINE OIL PRESSURE SENSOR (FILTERED) 103-6092 +V ANALOG ANALOG RET SIGNAL

+V ANALOG ANALOG RET SIGNAL 997-OR-18 993-BR-18 E795-YL-18

A700-OR-18 993-BR-18 F703-BR-18

C

A B C

C

CRANKCASE PRESSURE SENSOR 103-6093

OR-18 YL-18 GN-18

OR-18 BK-18 WH-18 A B C

OR-18 BK-18 WH-18

VS GROUND SIGNAL

+V ANALOG ANALOG RET SIGNAL

LH TURBO INLET EXHAUST TEMP 109-4367

A B C

997-OR-18 993-BR-18 A746-PK-18

997-OR-18 993-BR-18 A747-GY-18

C 997-OR-18 993-BR-18 A751-YL-18

A B C

C

A B C

OR-18 YL-18 GN-18

+V ANALOG ANALOG RET SIGNAL

AFTER COOLER TEMP SENSOR 102-2240

OR-18 YL-18 GN-18

+V ANALOG ANALOG RET SIGNAL

VS GROUND SIGNAL OR-18 BK-18 WH-18 A700-OR-18 993-BR-18 F704-GN-18

A B C 997-OR 993-BR F714-PK

TURBO OUTLET PRESSURE SENSOR 103-6091

P

F

ELECTRICAL CONNECTION TO MACHINE STRUCTURE

L15

CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER HEAD HEAD HEAD HEAD HEAD HEAD HEAD HEAD SOL 1 SOL 2 SOL 3 SOL 4 SOL 5 SOL 6 SOL 7 SOL 8

INJECTOR GP (8) 132-0203 RECEPTACLE AS. (8) 9X-0352

GROUND MODULE DATA MODULE +V MODULE CLOCK MODULE LOAD HARNESS CODE

CIRCUIT NOT CONNECTED

L8

A701-GY-18 F726-YL-18

CIGAR LIGHTER 9W-0335

GROUND MODULE DATA MODULE +V MODULE CLOCK MODULE LOAD HARNESS CODE

CIRCUIT CONNECTED

G 5 G 4 G 3

521-YL-14

L15

ATMOS PRESSURE SENSOR 103-6093

A B C

OR-18 YL-18 GN-18

A B C 1 2 3 4

L70

A700-OR-18 A700-OR-18

113-OR-18 200-BK-18

636-GN 799-WH

PAYLOAD MONITOR GREEN LAMP 8T-9684 BULB 8T-9749

G 8

520-WH-18

D

G

L9

F732-PK A700-OR-18

859-YL 251-BK 251-BK 858-GY 635-BU 636-GN 799-WH 799-WH 799-WH

C

NN 521-YL-18 522-WH-18

799-WH 251-BK 859-YL

2 1

C

L70

L70

BK RD

XXX

A700-OR-18 998-BR-18 F732-PK

1 2 3

200-BK-18 200-BK-18

200-BK-18 200-BK-18

200-BK-18

200-BK-18 200-BK-18 200-BK-18 200-BK-18

201-BK-18 TRACTION AID TEST/ OPERATOR MODE SW 125-2063 700-PK-18

129-PU-18 200-BK-18 G

C XXX

997-OR 993-BR F713-OR

L15

RH TURBO INLET EXHAUST TEMP 109-4367

+V ANALOG ANALOG RET SIGNAL

R TURBO INLET PRESSURE SENSOR 103-6093

+V ANALOG ANALOG RET SIGNAL

BULB 7N-9943

OR-18 YL-18 GN-18

OPERATOR STATION

WH-18 RD-18 BK-18

L8

L11

201-BK-18 201-BK-18 201-BK-18

L25 200-BK-18 200-BK-18 200-BK-18

L20

614-PU-18

MONITOR ACTION ALARM 3E-6328

RD BK

A B C

T

G

521-YL-14

D

L8

G

G C

636-GN 799-WH 635-BU 799-WH

G 5

767-WH-18

201-BK-18 201-BK-18 201-BK-18 201-BK-18

123-WH-18 123-W-18 123-WH-18

L22 L23

3 4

996-GN-18 998-BR-18 999-WH-18

1 2

L TURBO INLET PRESSURE SENSOR 103-6093

L4

5

L20

L28 L14

L15

L8

ENGINE LOW OIL LEVEL SW 123-2993 T/C TEMP SENSOR 100-3055

AAA

1 G

B 2

G

200-BK-18 614-PU-18 614-PU-18

V

ENGINE ADD OIL LEVEL SW 123-2993

AUX START RECEPTACLE

G

3 G

P

RD RED WH WHITE OR ORANGE YL YELLOW PK PINK BK BLACK GY GRAY PAYLOAD PU PURPLE MONITOR BR BROWN RED GN GREEN LAMP BU BLUE 8T-9683 BULB 8T-9749 SYMBOL DESCRIPTION NNN BLADE, SPADE, RING, OR SCREW TERMINAL

A/C ON SW 125-9257

B

G 2

521-YL-14

A

L8

K AIR CONDITIONER CLUTCH SOLENOID PAYLOAD PAYLOAD K 7N-4287 K MONITOR MONITOR GREEN RED LAMP LAMP 8T-9684 8T-9683 BULB BULB RIGHT FRONT 8T-9749 8T-9749 STRUT SENSOR 124-0328 SS OR-18 3 858-GY SIGNAL BK-18 2 251-BK GROUND WH-18 1 799-WH +V

ALTERNATOR 9X-7803

C START AID SOLENOID 123-8773

L21

L35

L55 540-WH 539-BU 200-BK

540-WH 539-BU 614-PU 619-GN-14

619-GN-14

200-BK 200-BK 200-BK

109-OR-4

C

GG

RD-00 BK-00 HHH YY BK-4

513-0R-14 522-WH-14 1 2

WH-18 BK-18

(101-RD-10)

H S AQ

MOTOR

BK-00 BK-00

BK-4 TO FRAME

AN

ENGINE SPEED 6V-2455

G

200-BK-18 614-PU-18 614-PU-18 E735-PU-18

ABBREV

A

G

200-BK-18 521-YL-14

200-BK-18

G

3 998-BR

F729-GN-18

GG

S

MTR BAT

RD-00

BK-00 RD-00 HH

G

PRELUBE MOTOR 117-3915

D

B

G 2

3

F728-BR-18

QQ

H

3 1 2

200-BK-18 614-PU-18 614-PU-18 520-WH-18

G

G

F727-BU-18

BK-00

G

L18

G A

200-BK-18 614-PU-18 614-PU-18

A701-GY-18 A702-PU-18 A703-BR-18 A704-GN-18 A705-BU-18 A706-GY-18 A707-PU-18 A708-BR-18 F726-YL-18

QQ

M

G A 200-BK-18 G 614-PU-18 B 614-PU-18 G 2 F717-YL-18 THROTTLE BACKUP SW 126-0236 998-BR-18 F720-GN-18

E799-BR-18 F700-BU-18

MOTOR

602-WH 103-YL-14 200-BK

SS C

2 1

(314-PU-10) WH/BK-10

RD-00

RD-10 (101-RD-10)

(304-WH-10) WH/BK-10

200-BK

CC

KK

BK-18 BK-18

AIR DRYER 2G-2159

BRAKE OIL TEMP SENSOR 100-3055

RR

RD-00 RD-00 BUS BAR KK 8C-6358 NOTE B

J

J

RR RD-00 H

137-OR-12

STEERING SW 3E-6429

C

G

1 G K986-BR-18 3 K985-BR-18 G K985-BR-18

C

A751-YL-18 A747-GY-18 F714-PK-18 995-BU-18 F713-OR-18 A746-PK-18 994-GY-18 F704-OR-18 F703-GY-18 F702-GN-18

10A FUSE 3K-8782

H

H

LL CC H

1 2

START RELAY 118-3534 NOTE B H

G

PANEL LAMP 110-2079

G

P

CATERPILLAR MONITORING SYSTEM 100-5778 P 15 MODULE LOAD 25 MODULE CLOCK 34 MODULE +V 35 MODULE DATA 2 GROUND 8 10 408-WH-18 37 BRAKE AIR PRESS 426-BR-18 27 TRANS FILTER SW 446-PU-18 7 BK OIL TEMP SENSOR 447-PK-18 9 FUEL LEVEL SENDER 481-PK-18 17 T/C TEMP SENSOR 403-GN-18 30 ALTERNATOR 410-WH-18 4 ACTION ALARM 411-PK-18 13 ACTION LAMP 113-OR-18 1 + BATTERY 417-GY-18 40 PRIM. STER F975-OR-18 24 +8V SENSOR SUPPLY 290-BK-18 23 SERVICE 291-BK-18 33 CLEAR 472-OR-18 19 BRAKE OVERSTROKE SW 893-GN-18 5 CAT DATA LINK + 892-BR-18 14 CAT DATA LINK E735-PU-18 18 OPERATOR SW 20 201-BK-18 31 HARNESS CODE 0 3 201-BK-18 12 HARNESS CODE 2 201-BK-18 22 HARNESS CODE 3 201-BK-18 16 HARNESS CODE 4 6 29 21 32 11 26 28 36 38 39

START AID SW 3E-7176

AUTO RETARDER OFF/ON SW 125-2076

B 2

G

BK-18 WH-18 RO-18 GN-18 YL-18 BU-18

P

C414-BU-18 E708-PK-18 E707-GN-18 C413-YL-18 201-BK-18

PANEL LAMP 110-2079

G

200-BK-18 614-PU-18

610-OR 614-PU-18

F722-OR-18 412-BU-18 F725-WH F715-PU-18 F716-WH-18 998-BR-18 E796-GY-18 E795-YL-18 996-GN-18 999-WH-18 997-OR-18 993-BR-18

727-GN 462-YL

BK-18 BK-18

6 G

G A G

200-BK-18 614-PU-18 614-PU-18 200-BK-18 200-BK-18 123-WH-18 K985-BR-18

F708-YL-18 F709-BU-18 F720-GN-18 E794-YL-18 E793-BU-18

L63

SUPPLEMENTAL STEERING 116-4531

1 2 H

337-WH 200-BK AM AM H AM AP AQ START RELAY H 118-3534 NOTE B PRELUBE RELAY 3E-0154 337-WH 200-BK

H

H

101-RD-4

A

L56

ARC SUPPRESSOR 106-8704 1 2 MUR440 C

G 5

G

200-BK-18 614-PU-18

RUNNING LAMP SW 3E-2210 3 G 614-PU-18

A 2

G

102-BU

229-BK-14 229-BK-14 F723-PK-18 F724-PU-18 F718-BU-18 F719-BR-18 F732-PK A700-OR-18 113-OR-14 F710-BR-18 F717-YL-18 F721-GY-18 892-BR-18 893-GN-18 150-RD-14 150-RD-14 F707-WH-18 F705-PK-18

L71

201-BK 201-BK L73 472-OR 201-BK L72 446-PU F975-OR

CONN 27 PP C 2 200-BK-18 1 E986-YL-18

PP 200-BK-18 E986-YL-18

103-YL

CONN 46 P F 3 201-BK-18 17 661-GN-18 19 663-YL-18 200-BK-18 2 662-YL-18 18 10 13 E735-PU 23 E735-PU-18 408-WH 24 408-WH-18 426-BR 12 426-BR-18 446-PU 14 446-PU-18 447-PK 15 447-PK-18 481-PK 481-PK-18 7 403-GN 403-GN-18 6 410-WH 410-WH-18 8 411-PK 411-PK-18 9 113-OR 1 113-OR-18 417-GY 11 417-GY-18 F975-OR 22 F975-OR-18 290-BK 290-BK-18 4 291-BK 291-BK-18 5 472-OR 16 472-OR-18 893-GN 21 893-GN-18 892-BR 20 892-BR-18 201-BK 661-GN 663-YL 200-BK 662-YL

15 20 2 9 14 23 8 1 25 24 35 29 13 7 19 12 28 16 26 32 38 37 31 30 36 5 11 17 18 27 40 39 6 34 10 22 33 21 4 3

L73

447-PK 201-BK

2 1

G B

200-BK-18 614-PU-18 G

+ -

M

24V-12V CONVERTER 119-1733

DOOR COURTESY LAMP SW 6T-6117 M

M

410-WH 201-BK

L13

GROUND GROUND +24 V BATTERY IN +24 V SWITCHED IN +12 V MEMORY OUT +12 V SWITCHED OUT

513-OR 522-WH

CONTINUOUS OIL BURN INJECTOR 109-1374

L20

RIGHT TURN

F

2 4 1 3 5 6

2 BK-18 4 WH-18 1 OR-18 3 GN-18 5 YL-18 6 BU-18 SPEEDO/TACH 6V-6457 LAMPS (2) 7N-5876 661-GN-18 200-BK-18 200-BK-18 662-YL-18

CATERPILLAR MONITORING SYSTEM GROUND

ANTENNA 9W-3072

200-BK-14 611-PU-14 540-WH 539-BU 614-PU 619-GN-14

OR-18 BK-18 WH-18

L4

L4

RD-00 RD-00 RD-10

TTT D 472-OR 1 472-OR 201-BK 2 201-BK

D L72

426-BR 201-BK

3 6 1 2 4 5

200-BK 200-BK 121-YL 113-OR A513-PK 135-BU

L70

109-OR-4

NN C CONN 28

200-BK 337-WH BK-18 1 2 BK-18

200-BK 306-GN

L64

6 3 5 1 4 2

+V GROUND SIGNAL

L20

P

201-BK-18 C413-YL-18 E707-GN-18 E708-PK-18 C414-BU-18

REVERSE

L8

DOME LAMP 8C-9678

L56

200-BK 306-GN

L65

STEERING MOTOR RELAY 3E-0154

604-OR 610-OR-14

101-RD-10

101-RD-10

CONN 32

L18

129-PU-18 E735-PU-18 700-PK-18 767-WH-18 454-GN-18

L98

L98

L18

614-PU-18 103-YL 102-BU 610-OR

SUPP STEER

201-BK F975-OR 472-OR 426-BR 446-PU 447-PK

L24

L24

L15

L26

SS

RD-00

200-BK 200-BK 306-GN 337-WH

M RH SPEAKER 6T-7695

L15

L70 LEFT FRONT STRUT SENSOR 124-0328

L70

M

L98

L20

L98

K985-BR-18 K986-PK-18

OR BK WH

521-YL-14 452-PU-18 201-BK-18 522-WH-14

L65

AIR START SOLENOID 5T-4434

BK GN

511-BR 512-GN

103-YL-14

L9

C OFF S ON B ST

614-PU-18 614-PU-18

L21

L25

201-BK-18 C413-YL-18 E707-GN-18 E708-PK-18 C414-BU-18

LAMPS (7) MONITOR 107-1983 ACTION

E735-PU 408-WH F975-OR 661-GN 663-YL 200-BK 662-YL 481-PK 403-GN 410-WH 411-PK 113-OR 417-GY 290-BK 291-BK 893-GN 892-BR 201-BK

R

YL PU OR BR

1 2 3 4

KEY START SW 110-7887

L20

200-BK-18 518-OR-18 124-GN-14 515-GY-18 521-YL-14 516-GN-18 517-BU-18

RADIO 3E-7140/3E-7141

L15

L14

ZZZ E729-GN 998-BR

GY/VI GY/BK,VI/BK BK WH/GN WH/BK,BN/BK RD YL BU

XXX

200-BK

308-YL-18

ANTENNA RIGHT SPKR + RIGHT SPKR GROUND LEFT SPKR + LEFT SPKR + BATTERY (12V) +B MEMORY +BATTERY (24V)

VS GROUND SIGNAL

1 2

NOTE C

L63

L13

L56

2 1 HH

A

8 7 3 2 1 6 5 4

511-BR 512-GN 200-BK 508-PU 509-WH 135-BU A513-PK 113-OR

L3

H L66

L65

200-BK 306-GN

L67

121-YL 135-BU 410-WH 201-BK 113-OR 200-BK

200-BK-14 317-YL-18

200-BK 200-BK

L67 L63

101-RD-10

112-PU-12 112-PU-12 THROTTLE POSITION SENSOR 3E-7700

L66 L11

L65

M

L26

251-BK

L100

109-OR-12

+V GROUND SIGNAL

200-BK-14 450-YL-18 403-GN-18 317-YL-18

J

150-RD-14 150-RD-14 102-BU-14 173-YL 201-BK 290-BK 291-BK 958-YL 604-OR-14 610-OR-14 L27

L29 10A

10A

10A 112-PU-12

112-PU-12

112-PU-12

10A

10A

10A 112-PU-12

112-PU-12

10A

10A

308-YL

RD-18 BK-18 WH-18

4 5 7 6 3 2 11 12 1 10 8 9

200-BK 450-YL-18

H

L35

105-BR 958-YL 201-BK 105-BR E750-PU 619-GN-14

124-GN-14 E750-PU 136-GN 105-BR 103-YL-14 308-YL J992-YL

619-GN-14 610-OR-14

L31

L31 135-BU 200-BK 200-BK 200-BK 200-BK

337-WH F709-BU

16 29 7 13 14 34 28 18 15 9 6 8 21 19 2 10 40 20 22 36 11 23 12 5 17 4 3 33 25 38 26 24 1 27 30 31 32 39 35 37 135-BU 200-BK 121-YL 126-PK 129-PU 315-GN 176-OR 138-GN 132-PK 123-WH 113-OR 122-BU 141-PK-14 140-BU-14 F709-BU 337-WH 998-BR 140-BU-14

121-YL 135-BU 410-WH 201-BK 113-OR 200-BK 103-YL-14

CONN 29

J H

L64 L65

472-OR

11

A B C

RD-00

L67

L63

BK-18

709-OR CONN 8 Y

87 Q 87a

PRELUBRICATION RELAY 3E-5239

521-YL-14 513-OR-14

A/C REFRIGERANT PRESS SW 114-5333 NOTE A

L67

725-GN 724-YL 723-OR 722-WH 721-BR

Q 30

Q

85

109-OR-4

PK-18 1 2

86

F709-BU 998-BR

G

307-OR-18 105-BR-18

V

611-PU-14

M

403-GN-18

251-BK 251-BK 799-WH 799-WH

1 2

A

L26

L26

M

L20

508-PU + 509-WH LH SPEAKER M 6T-7695

229-BK-14 229-BK-14

447-PK 201-BK

112-PU-12

10A

112-PU-12

10A

112-PU-12

10A 112-PU-12

103-YL-14 113-OR 200-BK L16 410-WH L32 201-BK 135-BU 103-YL-14 121-YL

103-YL-14

BK-18 BK-18

2 3 1

539-BU 540-WH

A

103-YL-14

CONN 30 A

L23

11 5 18 12 20 24 39 35 23 40 14 19 3 9 4 6 22 21 27 28 34 25 7 1 10 33 15 16 13 26 17 2 8 29 37 31 32 38 36 30

L71

MAIN POWER RELAY (REAR) Q 3E-5239 A Q 87 Q 87a 109-OR-12 A 109-OR-4 L100 101-RD-4 POWER BOSS 9G-8451

Q

85

SUPPL STER SW 127-4986

HIGH BEAM LAMP 110-2079 RETARDER

G G G G G G G G

123-WH-18

D

L14

103-YL-14 W 15A 103-YL-14 DOME & STOP LAMP BREAKER 6N-8589 ALT BREAKER A 3E-7294 101-RD-4 A W 109-OR-6 101-RD-10 105A W 101-RD-10

OPERATOR STATION

L65

L71

D

112-PU-12

30

86

G

M

W 15A Q ENGINE CONTROL BREAKER 6N-8589 L14

513-0R-14 522-WH-14

636-GN 635-BU 799-WH

L32

138-GN 799-WH 863-BU 864-BR 865-GY 866-PK 867-PU 251-BK

251-BK 707-PU 891-BU 794-YL 138-GN

7 10 11 12 4 3 2 9 8 6 5 1

L15

L27

Q

L16

L56

L67

BRAKE OIL DIVERTER TEMP SW 3E-6449

121-YL-12 315-GN 173-YL J992-YL 138-GN 102-BU-14 103-YL-14 113-OR 123-WH 124-GN-14 L44 176-OR 126-PK 132-PK L42 136-GN 135-BU 141-PK-14 L40 140-BU-14 150-RD-14 L39 150-RD-14 200-BK 290-BK L38 291-BK 308-YL

998-BR 129-PU 122-BU 121-YL 10A 101-RD-10

L46 113-OR 113-OR 113-OR A700-OR F702-GN

L39

998-BR

F720-GN F717-YL 998-BR

L57

893-GN 892-BR F975-OR E794-YL E793-BU F709-BU E986-YL

85

A

L28

HEAD LAMP DIMMER SW 2H-1855

150-RD-14 150-RD-14

C

L65

J

101-RD-10 TURN LAMP BREAKER 6N-8589 173-YL 15A Q W HEAD LAMP BREAKER 6T-2662 102-BU-14 W 15A 102-BU-14 Q

F717-YL-18 998-BR-18 F720-GN-18 308-YL-18 307-OR-18 105-BR-18 727-GN-18 123-WH-18

3 G

G C

727-GN-18 200-BK-18 200-BK-18

CONN 34 G CCC 454-GN 1 454-GN-18 2 454-GN-18 123-WH 3 123-WH-18 4 123-WH-18 NOTE F

619-GN-14 619-GN-14 611-PU-14

L27

L13 101-RD-10 101-RD-10

SS

L56

L64

SUPP STER BREAKER 9G-9487 Q 136-GN Q 10A KEY BREAKER W 101-RD-10 9G-9487 101-RD-10 105-BR W 10A Q

L16

L15

TO FRAME

FUEL LEVEL SENDER 115-1782

12

604-OR-14 958-YL 103-YL

L37

L57 998-BR

113-OR L52

612-GY L39

998-BR 998-BR 998-BR 998-BR 998-BR A700-OR F702-GN NN CONN 22

L27

124-GN-14 15A Q AIR CONDITIONER BREAKER 6N-8589

112-PU-12 MAIN POWER RELAY (MID) 3E-5239 Q 87a 109-OR-12

Q

A700-OR 998-BR F702-GN

129-PU E735-PU 700-PK 767-WH 454-GN

30

86

140-BU-14 L32

201-BK

E750-PU 200-BK

1 4 5 6 2 3 S

2 3

Q

112-PU-12

337-WH

CONN 26

NNN

Q

537-GN 604-OR 606-GY 605-YL 539-BU 540-WH

5 6

L100

L17

A

Q

L66

200-BK 200-BK-8 200-BK-14

BRAKE OIL DIVERTER SOLENOID 101-3430

L85

+ BATTERY +24V (OUT) GROUND TX LCD OUT LCD CLOCK LCD LATCH TEST/SET MODE

Q

614-PU 103-YL-14 102-BU-14 610-OR-14

998-BR-18 998-BR-18

GN GN

L15

GN-18 WH-18 BK-18 BU-18 BR-18 GY-18 PK-18 PU-18

Q

MAIN POWER RELAY (FRONT) 85 3E-5239 87 Q 87a 109-OR-12

H

T~

1 2

619-GN-14

NNN 1 3 2 4 5 6 7 8

Q

Q

1 Q 3 Q

J992-YL EXHAUST DIVERTER SW AUTO/MUFFLER 6T-3991 (SHOWN IN AUTO MODE)

TURN SW 9G-5589

FUSE HOLDERS 4K-5122

Q

308-YL 200-BK

PAYLOAD MONITOR OPERATOR DISPLAY 9X-6847

Q

30

86

109-OR-4

BK BK

J

L100

HEADLAMP RELAY 3E-5239

L15

Q

Q

Q

308-YL 200-BK

L32

L66 CONN 15 H NN

L86 SMOKE BOX SOLENOID 101-3430

102-BU-14

87 Q 87a

Q

308-YL 200-BK

L17

L11

L71

L918-GN 126-PK

251-BK

Q 30

Q

Q

RD-00

709-OR 710-GN 705-PK 704-GY 202-BK K972-BR 202-BK 202-BK 703-BU 231-BK 726-BU

L16

138-GN 799-WH 251-BK 863-BU 864-BR 865-GY 866-PK 867-PU

860-PK 861-PU 251-BK 859-YL 858-GY 636-GN 635-BU 799-WH

REF: 108-1029 BEACON 9U-7206 FLORESCENT LAMP

635-BU 636-GN 799-WH 799-WH

635-BU 636-GN 799-WH

799-WH 799-WH 251-BK 251-BK

BBB

A700-OR-18 F702-GN-18

CONN 21

F720-GN-18 F717-YL-18 F721-GY-18

D CONN 20

893-GN-18 892-BR-18 F975-OR-18 E794-YL-18 E793-BU-18 F709-BU-18 E986-YL-18

24V ACCESSORY OUTLET 9R-7941

317-YL-18 113-OR-18 201-BK-18 521-YL-18 522-WH-18 450-YL-18 200-BK-18 403-GN-18 481-PK-18 F710-BR-18 F707-WH-18 F705-PK-18 F708-YL-18

101-RD-4 109-OR-4

462-YL 727-GN

E729-GN

337-WH 998-BR 306-GN

CONN 16

A

452-PU

H

F

A

L43

4 19 21 24 16 15 26 2 35 25 27 18 36 22 14 23 20 29 32 7 6 17 33 34 12 31 11 37 40 13 28 1 3 9 38 5 39 8 10 30

J

4

452-PU-18

A

472-OR 446-PU 426-BR 201-BK F975-OR 447-PK

BBB

CONN 14 A

317-YL 113-OR 201-BK 521-YL-14 L61 522-WH-14 450-YL 200-BK 403-GN L60 481-PK F710-BR L59 F707-WH F705-PK F708-YL

2 1 3 4 L100

L34

727-GN

L76

BODY RAISE SW 8C-5681

L24

L52

L

998-BR F708-YL E729-GN

L75

L17

150-RD-14 150-RD-14 998-BR-18

E750-PU 707-PU 202-BK

J 1 2

L37

L53

2 1 4 5 3 6

L17

200-BK 200-BK

L74

L61

L62

612-GY

E750-PU E750-PU

707-PU 891-BU 794-YL 635-BU 636-GN 799-WH 799-WH 863-BU 864-BR 865-GY 866-PK 867-PU 858-GY 859-YL 251-BK 861-PU 860-PK

251-BK

L61

135-BU 200-BK 200-BK

86 610-OR-14 Q 200-BK 85

L29

Q

Q

L32

87 Q 87a STOPLAMP RELAY 3E-5239

L100

L37

Q

201-BK

E750-PU-18 540-WH-18 611-PU 612-GY-18 411-PK-18 201-BK-18 462-YL-18 539-BU-18

BODY UP

AFTERCOOL TEMP ATMOSPHERIC PRESS R TURBO INLET COOLANT TEMP SIG L TURBO INLET BOOST PRESSURE OIL PRESS (FLTR) R TURBINE EXHAUST L TURBINE EXHAUST THROTTLE SIGNAL UNUSED UNUSED UNUSED SOLENOID RETURN FAN CLUTCH SOL UNUSED UNUSED SOLENOID 1 POWER SOLENOID 2 POWER SOLENOID 3 POWER SOLENOID 4 POWER SOLENOID 5 POWER SOLENOID 6 POWER SOLENOID 7 POWER SOLENOID 8 POWER SOL 1&3 RETURN UNUSED SOL 2&4 RETURN UNUSED SOL 5&7 RETURN UNUSED SOL 6&8 RETURN UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

GEAR 5 GEAR 4 GEAR 3 GEAR 2 GEAR 1

10 1 9 2 3 6 7 8 5 4

138-GN 707-PU 891-BU 794-YL L59

L34

L34

L76

L28

L76

L57

L57

Q

Q

G 26 15 18 17 10 7 13 14 38 22 40 30 9 8 4 24 5 29 6 23 31 32 20 34 35 36 27 28 37 19 3 1 16 33 2 39 21 25 12 11

B G 2

-BATTERY -BATTERY TIMING CAL + TIMING CAL OIL LEVEL SW (ADD) OIL LEVEL (LOW) FAN SPEED + +V THROTTLE KEYSWITCH ON ETHER ON RELAY THROTTLE OVERRIDE IDLEDOWN/SHUTDOWN CAT DATA LINK CAT DATA LINK + +BATTERY +BATTERY ETHER HOLD OIL BURN RELAY UNUSED SHUTTER SOLENOID PRELUBE RELAY MAN ETHER ATA DATA LINK + ATA DATA LINK UNUSED UNUSED UNUSED UNUSED A/C FAN PRESS SW COOLANT FLOW SW FUEL FILTER SW SHUTDOWN SIGNAL C SHUTDOWN SIGNAL D DIGITAL RETURN OIL PRESS (UNFLTR) CRANKCASE PRESS +V TIMING ENGINE SPEED +V ANALOG SUPPLY ANALOG RETURN

GROUND GND VERIFY

202-BK

WITH TCS AND W/O PAYLOAD MONITOR CONNECT WIRE AS. EEE TO HARNESS A

L59

L76 L39 L45

T/C OUTPUT SPEED SENDER 6V-2455 1 2

200-BK L918-GN

L100

Q 30

L47

998-BR 337-WH 604-OR F709-BU

C

Y

Q 85

RD-00

Y

86

Q

L47

RD-00

Y

452-PU-18 201-BK-18

BK

4 5 6 2 1 3

L54

126-PK

L61 102-BU

614-PU

201-BK

L62

L76

101-RD-4 727-GN 462-YL

L65

135-BU 200-BK

L75

L66

GN GN

Q

ACCESSORY OUTLET 117-2311

L47

126-PK L75 317-YL 998-BR L76 122-BU L45 728-BU 450-YL 452-PU L59 L34 E986-YL L28 614-PU

126-PK

L75

998-BR

126-PK

L85

TRANSMISSION SPEED SENDER 3E-6955

L60

CONN 23

604-OR 251-BK

L65 LOCKUP SOLENOID 7X-1120

NNN

CONN 25

L86 DOWN SHIFT SOLENOID 7X-1120

2 1

A

Q

Q

113-OR

L48

L53

L100

L78

EEE

L58

516-GN 517-BU K985-BR K986-PK

1 4

L30

515-GY-14

201-BK

E750-PU 200-BK

132-PK GAUGE 123-WH 140-BU-14 PRELUBRICATION RELAY CATERPILLAR MON SYS 113-OR AIR DRYER 122-BU FUSES Q Q Q Q 3K-8782

W

L47

L53

L77

L77

L78

L64

1 2

UP SHIFT SOLENOID 7X-1120

4 WAY SOLENOID 9G-9988

14

L52

L78

L78

E750-PU 126-PK 775-BR 773-GY 774-YL 612-GY 604-OR 605-YL 606-GY 614-PU 202-BK 767-WH 770-GN 769-BU 202-BK 202-BK 799-WH 251-BK

799-WH 251-BK 860-PK

L85

E

PROPORTIONAL SOLENOID (R) (L) 3T-0062 S-1 S-2

L24

L53

L28 L43 L34 122-BU

L24

L51

CATERPILLAR MON SERVICE SW 6T-6066 Q 290-BK CATERPILLAR MON CLEAR SW 6T-6066 Q 291-BK

L30

121-YL 126-PK 129-PU 315-GN 176-OR 138-GN 141-PK-14

200-BK 518-OR

L54

Q 2

L32 L30

F717-YL 998-BR F720-GN 308-YL 307-OR 105-BR 727-GN 123-WH

611-PU-14 K985-BR K986-PK F720-GN L43 F717-YL 998-BR 129-PU

L54

L32 BACKUP ALARM TRANS CIGAR LIGHTER START AID ARC PAY MON SPARE TCS

Q

L51

L55

Q

L31

112-PU-12

L79 L44

522-WH-14 200-BK-14 517-BU-14 516-GN-14 518-OR-14 515-GY-14 515-GY-14

L51

L29

308-YL

L36 124-GN-14 521-YL-14

517-BU 516-GN 518-OR 515-GY-14

522-WH-14

5 2 4 3 6 1 RESISTOR 125-9740

2 4 6 8 10 12 13 14 15 16 17 18 19 7 5 1 3 11 9 20 21 22 23 24

L97

RIGHT REAR STRUT SENSOR 124-0328

3 1 2 5 4 6

773-GY 202-BK

L32

BLOWER 112-9565

L31

A

539-BU-18

200-BK-18 663-YL-18 200-BK-18 GAUGE MODULE P 100-4984 LAMPS (2) 7N-5876 P

LEFT TURN

G

411-PK-18 201-BK-18 462-YL-18 200-BK-18 612-GY-18 200-BK-18 539-BU-18 200-BK-18

612-GY-18

G A

200-BK-18 614-PU-18 L21 614-PU-18 727-GN-18

CONN 35 E750-PU 540-WH 611-PU-14 612-GY 411-PK 201-BK 462-YL 539-BU

105-BR 103-YL-14 102-BU-14 539-BU L55 540-WH 610-OR-14

L45

L54 L29

BK PU PU BU

L49

1 2 3

1 2

202-BK 767-WH 767-WH 769-BU 202-BK 770-GN

RD-18 BK-18 WH-18

126-PK E750-PU

Z

15

L54

WH/RD-14

L37

411-PK-18 201-BK-18 462-YL-18

L23

L5

WHEEL SPEED SENSOR 3T-2469

767-WH 202-BK

861-PU 799-WH 799-WH 251-BK 251-BK 860-PK 251-BK

Y

E

767-WH

2 614-PU 3 200-BK 1 129-PU 12 11 4 202-BK 10 716-BU 9 715-GN 8 714-YL 7 713-OR 6 712-WH 5 711-BR ZZ L CONN 19

L57

614-PU 614-PU

102-BU-14

L45

A

BK-000

+V GROUND SIGNAL

X A 767-WH B 202-BK C 770-GN

+V GROUND SIGNAL

3 1 2

RD-18 WH-18 BK-18

AL 605-YL A 614-PU C 200-BK B

L86 SS

WH BK

S T

RD-18 WH-18 BK-18

J CONN 7 X

769-BU 202-BK

A

RH TURN/ TAIL LAMP 130-3453

S T

AL 604-OR A 614-PU C 200-BK B

767-WH

RH STOP/ TAIL LAMP 130-3453

L103

L86

L86 AL 608-GN 200-BK AL

RH BACKUP LAMP 9X-7169

ZZ

L54

L81

J

GN-18 GN-18

200-BK 612-GY

202-BK-18 716-BU-18 715-GN-18 714-YL-18 713-OR-18 712-WH-18 711-BR-18

L58

317-YL F707-WH F710-BR F705-PK

L86

1 2

E 2 1

BK-18 BK-18

200-BK-14

6 126-PK E750-PU 202-BK 605-YL 604-OR 612-GY 614-PU 606-GY 200-BK-14 773-GY 774-YL 775-BR

GN-18 GN-18

AL 608-GN 200-BK AL

BACK-UP ALARM 123-6449

CONN 9

SS 1 799-WH 2 251-BK 3 861-PU

703-BU 202-BK

604-OR 614-PU 200-BK

774-YL

AL A C B

773-GY 775-BR

RD-18 WH-18 BK-18

CONN 12 9 7 5 4 1 3 6 2 8 10 11 E J

202-BK 775-BR 202-BK 774-YL

S T

Y

3 2 4 1

LH STOP/ TAIL LAMP 130-3453

L101 OPERATOR STATION

1 2

L66

202-BK CONN 2 AL E 1 604-OR 2 200-BK 3 612-GY 4 614-PU 5 614-PU 6 605-YL AL E CONN 1 1 604-OR 2 200-BK 3 612-GY 4 614-PU 5 614-PU 6 606-GY

L54

129-PU-18

612-GY

126-PK E750-PU 202-BK-14

1 2 3

L86

RD-18 WH-18 BK-18

AL A 605-YL C 614-PU B 200-BK

RD-18 PK-18 BK-18

L53

L81

L

704-GY 202-BK

+ BATTERY SOLENOID GROUND BODY UP SENSOR 3E-0461

SHIFT LEVER POS SENSOR 126-7896

NEUTRAL GROUND GND VERIFY LEVER 5 LEVER 4 LEVER 3 LEVER 2 LEVER 1

6 7 10 2 1 9 8 5 4 3

L74

L82

L57

MOTOR

L28

L101

202-BK-14 202-BK

S T

SHUTTER CONTROL RELAY 3E-5239

315-GN-12

124-6704

ZZ

614-PU 200-BK

102-BU L37 L45 122-BU 129-PU

CONN 31

L37

L77

ZZ

L58

HEATER GP 118-6383 BK-14

L58

L74 L81

E

WHEEL SPEED SENSOR 3T-2469 LH TURN/ TAIL LAMP 130-3453

87 87a

L58

L58

CONN 18

L73

L101

769-BU 202-BK 767-WH

C B A

85

OIL BURN RESISTOR L101 124-6704 LEFT REAR STRUT SENSOR 124-0328 A 987-WH RD 1 RD-18 +V RD J992-YL 2 BK-18 GROUND WH-18 SIGNAL EXHAUST DIVERTER RESISTOR

X SIGNAL GROUND +V

A 30

A

E729-GN 998-BR F708-YL

893-GN 892-BR 202-BK

N

L77 L51

LEVER POSITION LAMP 110-2079

L53

892-BR 893-GN 892-BR 893-GN 892-BR 893-GN 892-BR 893-GN F975-OR

L39

L36

892-BR 892-BR 892-BR 892-BR 892-BR 892-BR 893-GN 893-GN 893-GN 893-GN 893-GN 893-GN

998-BR

F705-PK 317-YL F710-BR F707-WH

86

RD RD

1 2

N

L75

A

956-BR E986-YL

RD RD

A CONN 17

L51

L53

200-BK-14 515-GY-14

450-YL

L101

L99

L58

L52

L52

L50 L99

892-BR L49 893-GN 892-BR L50 893-GN F975-OR L51

N E793-BU E794-YL

612-GY-14 L75 L74 L84

L99

L44

121-YL

L49

L61

L101 NNN 799-WH E 818-BR D 819-GY C 250-BK B 820-BU A

L46

N

L51

1 24 12 8 3 9 2 15 16 22 14 6 17 4 11 5 25 13 18 21 10 7 23 20 19

START AID RESISTOR 124-6704 A K984-GY-14 1 317-YL 2

PAYLOAD MONITOR CONTROL 9X-6846

893-GN 892-BR

E750-PU

K972-BR 202-BK 227-BK 709-OR 710-GN 721-BR 722-WH 723-OR 724-YL 725-GN 726-BU 705-PK 704-GY 703-BU 219-BK 218-BK 217-BK 280-BK

A

250-BK 818-BR 820-BU 819-GY 799-WH

L84

L87 87 A 87a BACKUP RELAY 3E-5239 315-GN

A

105-BR 201-BK

L67

START AID ON RELAY 86 A 85 3E-5239 A 87 315-GN-12 317-YL-12 A 30 87a

85

N

N

L58 L45 L101 E986-YL

L85

998-BR F710-BR

A 315-GN-12 30 315-GN-12

A

5 250-BK 13 818-BR 14 820-BU 15 819-GY 1 799-WH 20 707-PU 3 635-BU 4 636-GN 6 794-YL 7 859-YL 8 858-GY 9 861-PU 10 860-PK 11 863-BU 12 864-BR 16 891-BU 17 865-GY 18 866-PK 19 867-PU 2 251-BK NNN 799-WH

ARC SUPPLY VALVE 3E-8691

GN GN

A B C D E F G H J

ECAP

UNUSED 31 UNUSED 20 7 UNUSED 3 K988-WH AIR CONTROL VALVE 4 K989-BU AIR SUPPLY VALVE UNUSED 22 UUU UNUSED 23 1 UNUSED 24 3 UNUSED 25 TO RETARDER 2 454-GN 5 454-GN AUTO RETARD LAMP LAMP 202-BK 4 UNUSED 32 33 UNUSED UUU UNUSED 34 202-BK BK-18 2 6 UNUSED BK-18 K991-OR 1 AUTO RETARD PRESS SW 16 K991-OR MANUAL RETARD PRESS SW 21 K992-PU AUTO RETARD UNUSED 27 PRESSURE SW UNUSED 28 111-9563 UNUSED 29 1 K992-PU UNUSED 30 TO MANUAL 2 202-BK UNUSED 35 RETARD PRESS SW CONN 12 UUU UNUSED 13 CONN 11 UUU A UNUSED 12 2 202-BK UNUSED 15 4 892-BR ENGINE SPEED 10 450-YL L53 5 893-GN 176-OR 1 + BATTERY 3 K985-BR AUTO RETARD ON 11 K986-PK 1 176-OR AUTO RETARD OFF 26 7 K985-BR 9 UNUSED L54 8 K986-PK 8 UNUSED 6 450-YL UNUSED 14 L58 6 202-BK 2 202-BK GROUND A215-BK 1 202-BK HARNESS CODE 0 19 ARC A217-BK 3 202-BK HARNESS CODE 2 17 CODE A216-BK 2 202-BK HARNESS CODE 1 18 L78 A218-BK 4 HARNESS CODE 3 37 A231-BK 5 202-BK HARNESS CODE 4 36 UUU VVV ARC CONTROL UUU CONN 13 3E-3663 L78 L78 L82 452-PU L103 450-YL L103

L82 L103

BK-18 GN-18 BK-18 GN-18

87 K984-GY-14 A 87a

86 A 30

956-BR

START AID HOLD RELAY A 3E-5239 85 86

F705-PK

315-GN 315-GN

F707-WH 315-GN

C

LINK GND TX OUT TX KEY OUT RX IN +24V (IN) BED RAISE RED LAMP GREEN LAMP XMSN SPD L FRONT PR R FRONT PR L REAR PR R REAR PR TX LCD OUT LCD CLOCK NEUTRAL LCD LATCH TEST/SET MODE GROUND

ARC CONTROL VALVE 3E-8691

GN GN

UUU K989-BU 1 202-BK 2

893-GN 892-BR UUU

L58 L81

OIL BURN CONTROL 117-9364

K972-BR 321-BR

537-GN

UUU 1 K988-WH 2 202-BK

138-GN

L40

L42

L42 200-BK L44 L39 138-GN 135-BU 126-PK 113-OR

L45

L61

L99

THERMOSTAT 3E-5464

L101

173-YL 315-GN 121-YL-12 J992-YL 121-YL

A

11 LEVER 1 12 LEVER 2 13 LEVER 3 14 LEVER 4 15 LEVER 5 16 GND VERIFY 6 RETARDER 20 BRAKE 29 ENG SPEED 30 T/C OUT SP 27 BODY UP SW 8 31 32 33 34 35 28 7 BED RAISE 2 GROUND 1 + BATTERY 36 ID CODE 4 18 ID CODE 1 19 ID CODE 0 3 UP SOL 4 DOWN SOL 5 LKUP SOL 9 +V 21 GEAR 1 22 GEAR 2 23 GEAR 3 24 GEAR 4 25 GEAR 5 26 GND VERIFY 17 ID CODE 2 37 ID CODE 3 10 XMSN SPEED L XMSN CONTROL 3E-5390

1 2 3 4 5 6 7 8 9 10

BU-18 GN-18 BR-18 RD-18 PU-18 PK-18 WH-18 BK-18 OR-18 YL-18

L81

L45

A

L84

L87

L87

L45

FLASHER 108-0358

LH BACKUP LAMP 9X-7169

126-PK 707-PU E750-PU 891-BU 306-GN 307-OR 892-BR 893-GN K972-BR 321-BR 706-BR 720-PU 452-PU 450-YL

614-PU 129-PU 200-BK 710-GN 202-BK L78

710-GN

A

121-YL 201-BK 408-WH

L92

L91 L87

710-GN 706-BR 126-PK 202-BK 720-PU 129-PU 321-BR K972-BR 200-BK 306-GN 307-OR 450-YL 452-PU 707-PU 891-BU E750-PU 892-BR 893-GN 614-PU 215-BK 987-WH

L78 A B C

BRAKE AIR PRESS SENSOR 9X-5272

B

L82

L74

768-OR 202-BK 213-BK 216-BK

A RD-18 BK-18 YL-18

VS GROUND SIGNAL

173-YL

L

L84

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED DATA LINK + DATA LINK -

L42

L39

CONN 24

123-WH

103-YL-14 103-YL-14

L62

521-YL-14

L77

L77

202-BK 213-BK 216-BK 215-BK 987-WH

FFF

707-PU 202-BK 126-PK 280-BK 218-BK 219-BK 703-BU 704-GY 705-PK 709-OR 721-BR 722-WH 723-OR 724-YL 725-GN 726-BU 217-BK 227-BK 710-GN

START RELAY BU ALARM NEUTRAL EMS NEUTRAL PMC START SW SERVICE CLEAR DRIVE RET. DATA + DATA -

N

200-BK-8

1 3 2 4

BU-18 GN-18 BR-18 RD-18 PU-18 PK-18 WH-18 BK-18 OR-18 YL-18

L42

L54

L25 L24

L25 L24

1

G G G G G G G G G

540-WH-18 200-BK-18 E750-PU-18 123-WH-18 611-PU 200-BK-18 454-GN-18 123-WH-18

E750-PU-18 611-PU

E750-BU L34 E735-PU L33 411-PK 518-OR 124-GN-14 521-YL-14 515-GY-14 L99 516-GN 517-BU 727-GN L34 462-YL 200-BK 612-GY 123-WH 201-BK 308-YL 454-GN 767-WH 700-PK 537-GN 307-OR 614-PU

200-BK 200-BK

L79

201-BK 201-BK

L22

L33

308-YL 308-YL 454-GN 958-YL

L41

L40

L40

138-GN

540-WH-18

L38

L99 L41

L37

L44

522-WH-14 200-BK-14

202-BK 202-BK 202-BK

BK

L77

L81

202-BK 200-BK

1 2 3 4 5 6 7 8 9 10

202-BK 711-BR 712-WH 713-OR 714-YL 715-GN 716-BU 706-BR L97 720-PU 450-YL 452-PU E750-PU

L

CONN 5

L

200-BK-8 251-BK

17 14 18 19 23 20 24 11 6 8 5 7 12 13 1 2 16 9 10 15 21 3 22 4

W/PAYLOAD W/O TRACTION AID USE WIRE AS. FFF

891-BU 307-OR

A

L83

202-BK 202-BK 202-BK 202-BK K972-BR 893-GN 892-BR

A

NNN

767-WH 767-WH 770-GN 769-BU 775-BR 773-GY 774-YL 202-BK-14 202-BK

213-BK 216-BK

306-GN 321-BR

L97

202-BK

CONN 3 R A 1 768-OR 3 202-BK 2 213-BK 4 216-BK L102

215-BK

L77

K972-BR 893-GN 892-BR

13 11 1 5 14 2 8 19 4 6 7 9 10 12 16 15 17 18 3 20 21 22 23 24

769-BU 770-GN 775-BR 774-YL 773-GY

L90

L91 767-WH

L102

ID CODE 1 ID CODE 4

CONN 4 R A 2 215-BK 1 132-PK 3 700-PK 8 772-BR 12 893-GN 5 892-BR 4 767-WH 6 769-BU 7 770-GN 11 775-BR 10 774-YL 9 773-GY

202-BK 202-BK 768-OR 132-PK

+BATT GROUND SOL 1 OUT SW 2 IN SW 1 IN SOL 2 OUT

ID CODE 3

L87

R

34 6 7 8 11 2 17 10 1 14 12 13 19 9 15 29 30 4 3 5 16 37 20 21 18 36 22 23 24 25 26 27 28 35 33 31 32

126-PK 307-OR 306-GN

L83

RD BK OR YL GY BR

D

LEFT SP RIGHT SP RIGHT SOL LEFT SOL PROP SOL

L103

AUTOMATIC ELECTRONIC TRACTION AID (TCS) 128-0869 772-BR 700-PK 892-BR 893-GN

A CAB GND

L49

176-OR 124-GN-14 521-YL-14

522-WH-14 200-BK

1 2

L96 L38

2

L22

L36

612-GY 123-WH

A

3

L43 L28 L35

307-OR L34 L79 L96 L38 L54

L35

L46

L49 L48

L99

129-PU

L50

L48

L103

L90

1 2 3 4 5 6

+10V

SERVICE/RETARDER A BRAKE TEE 767-WH L90 772-BR

315-GN 200-BK

GROUND ID CODE 2 XMSN SP + BATTERY

794-YL 707-PU 891-BU

700-PK 767-WH 767-WH 772-BR

BRAKE TEST

L50

L35

L35

AUTO LUBE

200-BK

L54

L60

L35 L44

L62 L44

L50

4

L28 L35 L33 L36

L33 L36

L40

141-PK-14

L42 L60

L50

202-BK 614-PU 202-BK

202-BK

140-BU-14 L41

1 2

200-BK

L35

L62

200-BK-14

202-BK

6 7 3 4 5 1 2 10 9 8

1 2

L89

L46

202-BK

BK-18 BK-18

113-OR 113-OR

L49

767-WH

E

123-WH 794-YL 202-BK 202-BK 710-GN 768-OR

200-BK 200-BK 200-BK

L93

L35

202-BK 202-BK 202-BK 202-BK

202-BK

L102

GROUND SPEED IN TRACTN AID XMSN SPEED DISTRIBUTOR 3T-5438

SERVICE BRAKE SW 3E-2034

7 1 3 5 2 6 4

612-GY-14

SERVICE BRAKE SW 3E-2034

A

GY-18 WH-18 YL-18 PK-18 BK-18 GN-18 OR-18

L94

L60

L35

L89

L89

L38

231-BK

BK-18 SPEED + BATTERY PYLD MNTR

L91

202-BK 706-BR

L79

201-BK

L38

A

A

L96 201-BK 201-BK 123-WH 105-BR

L60

L93

B GROUND C SIGNAL A +V

A

202-BK

2 1

L42

L42

200-BK

L94

767-WH 700-PK 537-GN

129-PU

BK-18 BK-18

720-PU 202-BK

202-BK

1 2

A

200-BK

BK-18

L42 L79

L60

136-GN 132-PK

L36

L96

L43

L34

1 2

200-BK 102-BU

123-WH

454-GN 200-BK

BK-18 SECONDARY BRAKE SW 3E-2033

F

709-OR 710-GN 721-BR 722-WH 723-OR 724-YL 725-GN 726-BU 705-PK 704-GY 703-BU 202-BK 202-BK 202-BK 202-BK

A

A

201-BK 201-BK 201-BK 201-BK

201-BK 201-BK

CONN 10

1 24 2 7 12 13 14 15 16 17 18 19 11 10 9 6 5 4 8 20 21 22 23 3

1 2

L94

GN-18 GN-18

BK-18

958-YL

L93

L94

614-PU 614-PU 614-PU

E735-PU 411-PK 410-WH

L92

5 E750-PU E750-PU

L24

L41

L25 L79 L96 L38

L79

L96 614-PU 614-PU

L48 L25

L41

L48

L79

A 200-BK

A

728-BU

L38

6

L36

L28

L49

L49 L92 L48

307-OR

L25 L48

L48

7

L43

L48 L41

8

L36

L49 L92

728-BU 454-GN 308-YL 308-YL 958-YL

L94

L25

K972-BR 202-BK

STOP LAMP SW A 2M-9346

L50 L93

L49 L92

L92 L94

705-PK

958-YL RETARDER BRAKE SW 103-4977

200-BK 728-BU 308-YL 308-YL 454-GN 958-YL

200-BK 201-BK 113-OR L50 893-GN 892-BR F975-OR

L49

L28

200-BK WW WW

L79 L38

200-BK 200-BK 200-BK 200-BK 200-BK

308-YL 200-BK

L92

9

L36

612-GY

1 2

L60 L92

10

11

612-GY 604-OR 605-YL 606-GY 614-PU 122-BU 728-BU

ARC SUPPRESSOR 106-8704

A

727-GN 417-GY

408-WH 661-GN 663-YL 662-YL 481-PK 403-GN E735-PU 410-WH 411-PK 417-GY 290-BK 291-BK

403-GN

200-BK 200-BK 200-BK

23 21 24 22 13 15 14 7 6 20 8 9 11 4 5 10 2 3 1 17 16 12 18 19

E750-PU 126-PK

1 2

200-BK 200-BK 200-BK 200-BK 200-BK 200-BK

614-PU 113-OR 200-BK 663-YL 661-GN 662-YL

L92

GN-18 GY-18

200-BK 200-BK 308-YL 728-BU 136-GN 403-GN

2 3 1 6 5 4

LIGHTS ON + BATTERY GROUND GAGE LAMPS TACH LAMP SPEEDO LAMP

L49

MAG SW OPR PANEL

TRAILER STOP LAMP SW 2M-9346 NOTE E WW WW

A

6 3 9 5 8 2 4 1 7

L83

F

GROUND GROUND KEY SW STER SW + BATTERY ALTERNATOR

BR-18 OR-18 PK-18 PU-18 BK-18 YL-18 BU-18 RD-18 WH-18

202-BK 707-PU E750-PU

SUPPLEMENTAL STEERING CONT 3E-5184

A

12

13

14 LIGHT DIMMER 103-5526

202-BK

15