1 2 3 4
POWER SYSTEM MODE STATUS
Harness And Wire Electrical Schematic Symbols
RENR5164-03 August 2011
POWER
Symbols
SYSTEM
(1) POWER - The LED is green. The LED is illuminated when voltage is supplied from the key start switch.
MODE STATUS
14
1
(2) SYSTEM - The LED is green. The LED is illuminated when the internal 5 volt supply is working.
T
Hydrostatic Transmission ECM
Pressure Symbol
(3) MODE - The LED is yellow. The LED will slowly flash when the program is running properly.
Hydrostatic Transmission ECM
(4) STATUS - The LED is red. The LED is illuminated when a diagnostic fault is detected. Refer to table 3 for more information on diagnostics.
Temperature Symbol
Flow Symbol
Circuit Breaker Symbol
Symbols and Definitions
28
15
Level Symbol
Fuse: A component in an electrical circuit that will open the circuit if too much current flows through it.
29
Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it.
42
Connector Pin Orientation.
Ignition Switch
Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.). No circle indicates that the wire cannot be disconnected from the component.
_
+
Ground (Wired): This indicates that the component is connected to a grounded wire. The grounded wire is fastened to the machine. Ground (Case): 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
Diagnostic LED (1)
Potential Cause
-!!!
5 volt power supply is out of tolerance.
Check the wiring. Check the output voltage at the ECM.
--!!
The signal from the position sensor (inching pedal) is incorrect.
Check the wiring. Check the sensor.
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.
!!-!
No signal is detected from the speed sensor during start-up
Check the wiring. Check the sensor.
Magnetic Latch Solenoid: A magnetic latch solenoid is an electrical component that is activated by electricity and held latched 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.
-!-!
The circuit for one of the solenoids is open or shorted.
Check the wiring. Check the solenoid.
!--!
Short circuit in the position sensor (transmission control lever).
Check the wiring.
---!
Speed sensor signal is incorrect
Check the wiring. Check the sensor.
Reverse Solenoid
Hydrostatic Pump
TH210 and TH215 Telehandlers Electrical System
TABLE 3
Hydrostatic Motor
Possible Remedy
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.
CEC1-500 CEG1-500
Harness and Wire Symbols Wire, Cable, or Harness Assembly Identification: Includes Harness Identification Letters and Harness Connector Serialization Codes (see sample).
L-C12 3E-5179
AG-C4 111-7898
Incorrect Hardware
Harness Connector Serialization Code: The "C" stands for "Connector" and the number indicates which connector in the harness (C1, C2, C3, ...).
Part Number: for Connector Receptacle
2 Plug
--!-
L-C12 3E-5179
1
Part Number: for Connector Plug
Engine
Harness Identification Letter(s): (A, B, C, ..., AA, AB, AC, ...)
Replace the ECM
Receptacle Pin or Socket Number
1 2
Deutsch connector: Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.
1 2
Sure-Seal connector: Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.
5A Fuse (5 Amps)
Speed Sensor
+ Two Speed Solenoid (Hydrostatic Motor)
A parameter is not set.
Replace the ECM
Component Location Schematic Location
Machine Location
A/C Unit (Cab)
E-11
25
Sensor Speed
AC Compressor
B-9
7
Solenoid Aux 1A In
Alarm Backup
H-12
22
Solenoid Aux 1B Out
H-12
21
Alternator
B-9
7
Solenoid Aux 2A In
G-12
21
Battery
A-6
45
Solenoid Aux 2B Out
H-12
21
Beacon
H-11
28
Solenoid Circle Steer
C-8
12
Controller Xmsn susmic
D-2
46
Solenoid Crab Steer
C-7
12
10 19
45 44
Component
9
11 16
18
15
13
7
Electric Seat
6
3
17
37
43 38
1
6
35 39
31
27
7
4
5 5
29
1 2 4 22
21
30 33
2
42
46
36 12
24
8 26 7 41 25 47 34
28 23 3
Components
Component
B-11
2
Solenoid Extend
G-12
21
Front Wiper
E-2
36
Solenoid Forward
B-7
18
Fuel Solenoid
A-9
11
Solenoid Motor Displacement
H-1
38
Fuse Alternator
B-7
14
Solenoid Retract
G-12
21
Fuse Main
B-7
14
Solenoid Reverse
B-7
18
Fuse Start Relay
B-7
14
Solenoid Reverse Fan
C-9
6
Heater Unit
G-11
24
Starter
C-8/B-8
13
Inch Pedal
F-6
34
Starter Relay
B-8
14
Internal Power Socket
F-11
7
Switch
G-6/F-6
47
Light LH Cab Rear Working
H-11
3
Switch A/C
E-8
27
I-7
26
Switch Air Filter
A-8
16
E-11
3
Switch Disconnect
A-6
44
Rear Water Pump
A-7
20
Switch Forward Colum
G-6
33
Relay Aux Disable
G-9
25
Switch Heater 3 Speed Fan
E-8
27
Radio
Relay Boom Lamp
G-9
25
Switch Hydraulic Disable
E-6
35
Relay Front Lamp
F-9
25
Switch Hydraulic Filter
A-8
19
Relay Hydraulic Disable
H-9
25
Switch Low Brake Pressure
C-5
43
Relay Main Power
H-6
32
Switch Low Steer Pressure
C-7
17
Relay Rear Lamp
F-9
25
Switch Oil Pressure
A-9
10
Relay Side Lamp
G-8
25
Switch Parking Brake
H-1
39
RH Cab Rear Working Light
D-11
4
Switch Steer Select
E-6
35
RH Cab Speaker
D-11
5
Switch Stop Lamp
H-1
41
Sender Fuel Level
D-6
42
Switch Trinary
G-11
30
Sensor Engine Temp
B-9
9
Switch Trinary
G-11
30
Sensor Front Steer
H-1
37
Thermostat A/C
G-11
5
Sensor Rear Steer
B-12
1
CONN 1
4
CONN 2 CONN 3 CONN 4 CONN 5
CONN 8 CONN 9 CONN 10 CONN 11
1 36
8
26 16
6 37
47 41 12 17 18 25 15 32 46 38 43 6 20 34 39
5
8
7 14 19
5 24
2
28
Schematic Location C-12 I-11 A-11 A-10 D-9 D-9 D-8 A-4 F-2 G-2 H-2 I-2
Machine Location 1 2 3 4 5 5 5 6 7 7 7 8
CONN 12 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.
22
13 42
Wire Color
1
29 Related Electrical Service Manuals Title
HARNESS CONNECTOR AND COMPONENT LOCATIONS
Form Number
LSI System:
RENR5163
Hydrostatic Xmsn ECM:
RENR6712
Printed in U.S.A.
Wire Number
Wire Color
101
RD
Bat (+) (Not Application Specific)
516
GN
Blower Motor (Medium)
105 110
RD
Key Sw
517
BU
Blower Motor (Low)
RD
Aux Ckt
518
OR
Hazard Flasher To SW
112
PU
Main Power Rly Output
522
WH
A/C Clutch To Thermostat SW
113
OR
Opr Mon Panel VMIS B+ Switched
537
GN
Turn Signal SW To Flasher
114
GN
Warning Horn (Forward)
538
BR
Hazard Indicator Aux Hyd - Open
Description
Description Accessory Circuits Cont.
Power Circuits
115
PK
Disable Relay R6
548
GY
116
BR
Fuel Solenoid
549
PK
Aux Hyd - Close
119
PK
Rear Cab Wiper Motor
A513
PK
DC/DC Converter Memory Output
120
PU
Front Wiper Motor
A571
PU
Aux Ckt 1
122
BU
Heater 3 Speed Fan Switch
C509
WH
A/C Thermostat
123
WH
XMSN Mode Switch
124
BU
Cab A/C Unit
603
PK
Rotary Beacon
125
RD
Rear Steer Sensor
604
OR
Stop Lamp
128
PK
Aux Ckt
605
YL
Turn Lamp - Left
130
RD
Radio
606
GY
Turn Lamp - Right
136
GN
Suppl Ster
614
PU
Park/Tail/Dash/Lamp
144
GN
Rear Wiper Washer Switch
615
PK
Cab Flood Lamp/Rops
158
BR
Rear Work Lamp Switch
616
GY
Bucket Flood Lamp/Boom Flood Lamp
159
BR
Aux Ckt
617
BR
Tail/Position Lamp - Left (Road Pkg)/Width
161
PK
Hazard Switch
618
YL
Tail/Position Lamp - Right (Road Pkg)/Width
185
RD
Steer Aligned Lamp
619
GN
Head Lamp Lo
620
YL
Flood Lamp - Front (Eng. Flood Lamp)
Ground Circuits
Lighting Circuits
200
BK
Main Chassis
627
YL
Fog Lamp
216
BK
AETA Coding Pin 20
652
YL
Right Front Flood
217
BK
XMSN Id Code 2
653
YL
Boom Working Lamp
667
OR
Front Floods - Aux
681
OR
Flood Lamp Rear (Atch) Flood Lamp Rear (Atch)
Basic Machine Circuits 303
YL
Key SW ACC Position
304
WH
Starter Relay No. 1 Output
683
PU
306
GN
Starter Relay Coil To Neut Start SW Or Key SW
A607
PK
Light SW to Side Flood Relay
307
WH
Key SW To Neutral Start SW Or VMIS Sensor Module
A625
BR
Crane/Boom Flood Lamp Sw to Relay
308
YL
Main Power Relay Coil
309
GY
Alternator Regulator Term.
752
YL
XMSN Shift Sol No. 2
321
WH
Backup Alarm Lamp Travel Alarm
754
BU
XMSN Shift Sol No. 3 Or 1
322
GY
Warning Horn (Forward)
780
PU
Coupler Disengage Sol
323
WH
Fuel Pump Power
Eng Speed (+)
405
2 3 4
21
30
11
10
Wire Gauge Wire Color
Wire Description Wire Number
Monitoring Circuits
CONN 7
9
21
Solenoid Diverter
CONN 6
7
G-12
20
Machine locations are repeated for components located close together.
3
27
15
29
Connector Number
33
A-8
A-7
Connector Location
44 35
Machine Location
G-11
Connectors 5
Schematic Location
Font Water Pump
Rear Cab Wiper Motor
3
32
45
Harness identification code: This example indicates wire group 325, wire 135 in harness "AG".
(1) ! represents a short on-time. - represents a long on-time. --- represents continuous on-time.
© 2011 Caterpillar, All Rights Reserved
20 14
Component Part Number
325-AG135 PK-14
---Two Speed Rotory Motor
9X-1123
Control Circuits
788
YL
A779
YL
Mechatronics Cont Sol5
A780
GN
Mechatronics Cont Sol6
GY
Opr Mon Oil Press. (Low Setting)
430
BU
Opr Mon Air Filter
G709
WH
Roading SW - Body Inhibit
441
OR
Eng Coolant Temp Gage
G710
GY
Jumper For Roading Relay
447
PK
Fuel Level Gage
G745
PK
Brake Pedal Sensor
450
YL
Tach Sender (+)
G750
BU
XMSN Cont Fwd SW To Gnd
483
BR
Brake Fluid Level
G797
BU
SW To Relay Coil
C450
YL
Steering Oil Pilot Press
H702
PU
Impl Cont Reversing Fan SW (N.O.)
C491
PU
Park Brake Pressure
H731
GY
Forward Output - Shuttle Control
E455
BR
Hydraulic Oil Filter
H750
BR
Steer Input #1
H751
OR
Steer Input #2
500
BR
Wiper - Front (Park)
H764
GY
Rear Steer Position Snsr
501
GN
Wiper - Front (Low)
H765
WH
Front Steer Position Snsr
503
BR
Wiper - Rear (Park)
J764
BR
Switch/Sensor Return #1
Accessory Circuits
(Was D728)
504
YL
Wiper - Rear (Low)
F811
BR
RS232C Tx (Master)
(Slope Finish, HEDC)
506
PU
Washer - Front
F817
GY
RS232C Rx (Master)
(Slope Finish, HEDC)
507
WH
Washer - Rear
F843
YL
Inching Pedal Telescope In Sol
508
PU
Radio Speaker - Left
979
BU
509
WH
Radio Speaker - Left (Commom)
980
BR
Telescope Out Sol
511
BR
Radio Speaker - Right
G985
PU
Seat Switch
512
GN
Radio Speaker - Right (Common)
N904
PU
Forward High Range Solenoid
513
OR
A/C Compressor/Refrigerant Pressure SW
P991
PK
Mode Select Sw
515
GY
Blower Motor (HI)
(Dimensions: 39 inches x 28 inches)
Forward Solenoid
Power Mode Rocker Switch
30 Page,
Inching Pedal Position Switch
F/N/R Position Switch
RENR5164-03
Parking Brake Switch