Cat TH255 Telehandler Electrical Schematic Manual - PDF DOWNLOAD

CAB HARNESS - SHEET 1

S/N TBS00100 thru TBS00626

TH255 Electrical Schematic 31200457 Sheet 1 of 6 October 21, 2011 - K

2

1 2 TO CAB ROOF 3 WORKLIGHT HARNESS 4 5 SHEET3 6

5

6

7

8

Sheet2-[7,D]

Sheet2-[8,D]

Sheet2-[5,D] Sheet2-[5,D]

Sheet2-[8,D]

Sheet2-[7,D]

000-8-25BLK 000-8-24BLK 070-1-17BLU 070-1-18BLU

D

Sheet2-[5,D] Sheet2-[5,D]

051-6BLU 000-8-3BLK 051-7BLU 000-8-2BLK 072-1BLU 000-8-1BLK

SW09

1 2 3 4 5 6 7 8

000-8-20BLK 000-8-21BLK 070-1-13BLU 070-1-14BLU

062-9YEL 072-1BLU

SW15

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 SW11

000-8-18BLK 000-8-19BLK 070-1-11BLU 070-1-12BLU

SWITCH,BEACON

051-4BLU 051-7BLU

1 2 3 4 5 6 7 8 SW10 051-3BLU 051-5BLU

Sheet2-[7,D]

062-3-1YEL 062-3YEL 076-3GRN

SWITCH,REARWORKLIGHTS

000-8-19BLK 000-8-20BLK 070-1-12BLU 070-1-13BLU

SWITCH,FRONTWORKLIGHTS

051-2BLU 051-6BLU

SWITCH,BOOMWORKLIGHTS

1 2 3 4 5 6 000-8-26BLK 7 8 SW08

SW16

13 14 3 15 16 6 12 11 9 10

WH42

1 2

Sheet2-[4,D]

TO CAB 1 GROUND X-CAB STUD

6AWGBLACK

065-4ORG 065-1-1ORG 065-3ORG 065-1-2ORG 065-2ORG 000-8-17BLK 070-1-10BLU 000-8-18BLK 070-1-11BLU

TO FRAME GROUND 1 STUD X87-6 SHEET4

4

SWITCH,F/RAUX.HYD.

065-1ORG 065-1-1ORG

D

3

SWITCH,STEERSELECT

061-2RED 000-8-31BLK

CONNECTOR,POWERSOCKET

1

062-4-5YEL

Sheet2-[8,C]

Sheet2-[1,C]

S06

X22

062-2-5YEL 062-2-3YEL

062-2-2YEL

C TO FRAME 000-5BLK6AWGSGT GROUND 1 STUD X87-3 SHEET4

S05

S48

S171

Sheet2-[3,D]

Sheet2-[4,D] Sheet2-[4,D]

Sheet2-[8,C] Sheet2-[6,B]

Sheet2-[1,B] Sheet2-[1,B]

S168

000-8-1BLK 000-8-2BLK 000-8-3BLK 000-8-4BLK 000-8-5BLK 000-8-6BLK 000-8-7BLK 000-8-31BLK

S07

Sheet2-[4,B]

S172

077-1-2ORG

TO BASE FRAME HARNESS SHEET4

C

Sheet2-[7,B]

000-8-9BLK 000-8-10BLK 000-8-11BLK 000-8-12BLK

Sheet2-[4,A] Sheet2-[4,A] Sheet2-[5,A] Sheet2-[5,A]

Sheet2-[1,C]

065-4-2ORG

Sheet2-[5,D]

065-1-2ORG 062-2-2YEL 070-1-19BLU 062-4-4YEL

1 2 3 4 X21

1. ANSI CABS WITHOUT HEADLIGHT CONNECT TO X21A. 2. ANSI CABS WITH HEADLIGHT CONNECT TO X21B. 3. CE & AUS NO CONNECTION REQUIRED

B

HV93

077-1-1ORG 000-8-4BLK 1 2

SW18

1 2 3 4 5 6

1 2 3 4 5 6 SW18

1 2 3 4

062-2-2YEL 062-2-2YEL 062-4-4YEL 062-4-4YEL X21A

S B F

VALVE,PARKBRAKE

S B F

I

SGRY BRED FORG SW18_S 1 SW18_B 1 SW18_F 1

SW12

IYEL

000-8-15BLK 000-8-16BLK 070-1-8BLU 070-1-9BLU

052-1BLU 061-4RED

2WSTEERLT. CRABSTEERLT.

1 2 3 4 5 6 7 8

GD17

065-4-1ORG 065-2-2ORG

062-4-3YEL 070-1-2BLU 048-6GRY 048-9GRY 000-8-8BLK 048-8GRY 077-2-2ORG 048-5GRY 048-7GRY 065-3-2ORG 048-4-2GRY 078-3WHT HOURMETER FUELGAUGE GND ENG.HIGHCOOLANTTEMP.LT. PARKBRAKELT. BATTERY/ALTERNATORLT. ENG.LOWOILPRESSURELT. 4WSTEERLT. ENG.PRE-HEATLT. LOWSTEERINGPRESSURELT.

SWITCH,FNRLEVER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

SW19

048-2GRY 048-1GRY

007-1ORG 077-1-3ORG 008-1ORG

1 2 3 4 5 6

000-8-6BLK 076-5GRN 000-8-14BLK 070-1-7BLU 000-8-15BLK SW14 070-1-8BLU

062-3-1YEL 076-4GRN

1 2 3 4 5 6 7 8

SWITCH,QUICKCOUPLER

Sheet2-[8,C]

PWR GAUGEBACKLIGHT

SWITCH,PARKBRAKE ANSI

SW13

000-8-14BLK 000-8-13BLK 070-1-6BLU 070-1-7BLU

1 2 3 4 5 6 7 8

077-2-1ORG 077-1ORG 062-2-1YEL 077-2-2ORG

Sheet2-[3,D]

062-1YEL

Sheet2-[5,D] Sheet2-[5,D]

Sheet2-[3,D]

I

Sheet2-[1,C]

SW18_I 1

Sheet2-[4,B]

048-1GRY 061-5RED 048-4GRY

Sheet2-[4,B] S04

B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 X20

S03

000-6BLK10AWG 000-7BLK10AWG S167 000-8BLK8AWGSXL

062-1YEL 061-5RED 061-4RED 062-2YEL 062-3YEL 062-4-1YEL 051-3BLU 051-5BLU 051-2BLU 051-4BLU 062-9YEL 070-1-1BLU 076-3GRN 065-2-1ORG 065-3-1ORG 052-1BLU 048-3GRY 048-4-1GRY 048-9GRY 048-6GRY 048-7GRY 048-8GRY 048-5GRY 007-1ORG 008-1ORG 076-4GRN 076-5GRN 008-2-2BLU 073-7BRN 061-2RED

ANSI

1 2 3 4

062-2-2YEL 062-2-2YEL

X21B

SWITCH,HORN SWITCH,IGNITION

A

A ELEC ASSY, 4IN. GAUGE

CAB HARNESS - SHEET 1

ALL WIRES 16GA. GXL UNLESS NOTED

1

2

3

5

4

S/N TBS00627 & After

6

7

8

TH255 Electrical Schematic 31200457 Sheet 1 of 6 October 21, 2011 - B

CAB HARNESS - SHEET 2

S/N TBS00100 thru TBS00626

TH255 Electrical Schematic 31200457 Sheet 2 of 6 October 21, 2011 - K

A SWITCH,BRAKE PEDAL

1 2 FRONT REAR TANK,DUAL WASHER,PUMPS

3

WIPER,FRONT MOTOR ANSI SWITCH,LSI OVERRIDE INDICATOR,TURN,HIGHBEAM

4

S/N TBS00627 & After

5

LOW GND HI MED

6 HVAC FAN

073-6BRN 073-7BRN

ALL WIRES 16GA. GXL UNLESS NOTED

7

062-14YEL 052-2WHT 000-6-4BLK14AWG 074-8BRN14AWG 074-9BRN14AWG 061-9RED 062-13YEL 000-7-3BLK

000-8-26BLK

C 070-1-19BLU 070-1-2BLU 070-1-1BLU

000-6-8BLK 000-6-2BLK 000-6-3BLK14AWG 000-6-4BLK14AWG

000-7-1BLK14AWG 000-7-2BLK 000-7-4BLK 000-7-3BLK

1 2 3 4 5 6 7 8

SW26

062-15-1YEL 074-7BRN 000-8-23BLK 070-1-16BLU 000-8-24BLK SW35 070-1-17BLU

074-9BRN14AWG 062-16YEL14AWG 074-8BRN14AWG

Sheet1-[3,D]

Sheet1-[6,D]

Sheet1-[7,D]

1 2 3 4 5 17 18 7 8 10

SWITCH,HAZARD

X50B

8 7 6 5 4 3 2 1

Sheet1-[4,B]

062-11YEL 071-13BLU 061-8-3RED 071-5-1BLU 071-4-1BLU 071-5BLU 071-6BLU 071-6-1BLU 070-1-18BLU 000-8-25BLK

PWR LOW MED. HI AC

6

HV31

062-2-4YEL 077-2ORG 077-1-2ORG

B L M H C SW38-F 073-6BRN A 073-5BRN B 000-6-8BLK C SW38-AC

062-18YEL12AWG 073-1BRN14AWG 073-2BRN14AWG 073-3BRN14AWG 073-4BRN

SWITCH,FRONT WASHER

1 2 3

WH39-AC

1 2

Sheet1-[8,C]

073-1BRN14AWG 000-7-1BLK14AWG 073-3BRN14AWG 073-2BRN14AWG

S141

074-6BRN 1 062-15YEL 2 062-15-1YEL 3 074-2-1BRN14AWG 4 074-4BRN14AWG 5 074-5BRN14AWG 6 000-8-22BLK 7 070-1-15BLU 8 000-8-23BLK SW33 070-1-16BLU

SW34

SWITCH,FRONT WIPER

WH39-F

1 2 3 4

071-4BLU 071-6-5BLU

Sheet1-[6,D]

Sheet1-[6,D]

1 2 3 4 5 6 7 8

SWITCH,JOYSTICK LOCKOUT

SW27

1 2 3 4 5 6 7 8

070-1BLU 061-7RED 071-2BLU 071-3BLU 061-8-1RED 071-5-5BLU S140

Sheet1-[4,B]

074-2-1BRN14AWG 074-4BRN14AWG 062-17YEL14AWG 074-1BRN14AWG 074-2BRN14AWG 074-1BRN14AWG 074-3BRN14AWG 000-8-21BLK 070-1-14BLU 000-8-22BLK 070-1-15BLU

1 2 3 4 5 6 7 8 SW36

5

M

SIDELT LIGHTPWR LOWHD HIGHHD FLASHPWR LEFT TURNPWR RIGHT

GD139

2A 2B

Sheet1-[4,B]

Sheet1-[2,D]

Sheet1-[2,D]

Sheet1-[6,B]

Sheet1-[6,B]

Sheet1-[5,B]

Sheet1-[3,C]

Sheet1-[2,D]

076-7GRN 062-2-5YEL 062-2-4YEL 065-1ORG 062-2-3YEL 065-4-2ORG 000-8-16BLK 070-1-9BLU 000-8-17BLK 070-1-10BLU

FC29

31 49 49a C1 C2

4

077-3ORG 000-8-12BLK

071-15BLU 000-8-11BLK

Sheet1-[4,B]

Sheet1-[3,C]

000-7-5BLK 000-7-4BLK 071-13BLU 071-4BLU 071-4-1BLU 071-15BLU

HOLDER,FUSE/RELAY,CAB

1A 1B

GD138

071-14BLU 000-8-10BLK 071-17BLU

Sheet1-[1,B] Sheet1-[2,B] Sheet1-[1,B] Sheet1-[4,B]

Sheet1-[1,B]

Sheet1-[3,B]

Sheet1-[8,C]

S47

FLASHER

1A 1B

071-3-3BLU 000-8-9BLK

000-8-13BLK 000-8-7BLK 070-1-5BLU 070-1-6BLU

062-12-2YEL 062-12YEL 076-9GRN

S51

3

2A 2B

SW32

1 2 3 4 5 6 7 8

WH40

000-6-3BLK14AWG

074-2BRN14AWG 074-3BRN14AWG 074-5BRN14AWG

071-3-1BLU 071-3-3BLU 071-2-1BLU 071-7BLU 071-3BLU 071-8BLU 071-3-1BLU 071-9BLU 071-2BLU 071-10BLU 071-2-1BLU 071-11BLU 071-1-3BLU 071-12BLU 071-1-4BLU 061-7RED 061-6-1RED 061-8RED 061-6-2RED 061-9RED 061-6-3RED 073-5BRN 073-4BRN 077-2ORG 000-7-5BLK 048-3GRY 048-2GRY 077-2-1ORG

F21_A F21_B F22_A F22_B F23_A F23_B F24_A F24_B F25_A F25_B F26_A F26_B F27_A F27_B F28_A F28_B F29_A F29_B F30_A F30_B F31_A F31_B F32_A F32_B F33_A F33_B F34_A F34_B F35_A F35_B F36_A F36_B F37_A F37_B F38_A F38_B F39_A F39_B F40_A F40_B R11_85 R11_86 R11_87 R11_30 R11_87a R12_85 R12_86 R12_87 R12_30 R12_87a X1_31 X1_49 X1_49a X1_C1 X1_C2

2

G

1 2 3 4 5

S169

M

L H P

S45

TO IGNATION RELAY ON FRAME SHEET4

WH41-R

000-7BLK

074-7BRN 000-6-5BLK

S170

1 2

Sheet1-[1,B] 000-6BLK

M

Sheet1-[1,C]

074-6BRN 000-6-2BLK 000-6-5BLK WH41-F

Sheet1-[8,B] Sheet1-[4,B] Sheet1-[8,C]

1 2

1

M

061-8-2RED 071-16BLU

1

SW28

1 2 3 4

S166

D 062-10-2YEL 062-10-4YEL 062-14-1YEL 062-11YEL 062-10-1YEL 062-12YEL 062-10-2YEL 062-13YEL 062-10-3YEL 062-14YEL 062-10-4YEL 062-15YEL 062-10-5YEL 062-16YEL14AWG 062-10-6YEL14AWG 062-17YEL14AWG 062-10-7YEL14AWG 062-18YEL12AWG 062-10-8YEL12AWG

1 7 8

SWITCH,HVAC CONTROL WITH A/C AC

FAN SWITCH,REAR/ROOF WIPER

TO BATTERY FUSEON FRAME SHEET4

061-6RED10AWGSXL

RL68-R

FC65-L1 062-10YEL8AWGSXL

Sheet1-[5,B]

Sheet1-[8,C]

Sheet1-[4,C]

D

Sheet1-[7,D] Sheet1-[7,D]

071-6-1BLU 071-5-1BLU 071-12BLU 071-11BLU 071-10BLU 071-9BLU 071-8BLU 071-7BLU 077-3ORG 071-16BLU

008-2-2BLU 078-3WHT 062-4-5YEL 076-7GRN 076-9GRN 076-8GRN CANSHIELD CANLOBLK CANHIRED 062-14-1YEL 052-2WHT LSIPWRBLU LSI2BLK LSI1RED LSISHIELD 085-1BLU

CANSHIELD 062-12-2YEL 076-8GRN LSISHIELD LSI1RED LSI2BLK LSIPWRBLU CANHIRED CANLOBLK 000-7-2BLK

B 085-1BLU

2 3 4 5 6 7 8 9 10 11 1 12 28 29 TO OPTION FRAME 22 HARNESS 17 SHEET5 16 13 24 25 26 27 19 31 30 18 23 X25

10 1 2 5 6 7 TO CAB ROOF 8 OPTION 11 HARNESS 12 SHEET3 3 4 9 X50A

C

B

TO CAB ROOF OPTION HARNESS SHEET3

AC VALVE,MANUAL PARKBRAKE IF EQUIPPED

A

INDICATOR,TRAILER SWITCH,TURN SIGNAL LEVER

CAB HARNESS - SHEET 2

8

TH255 Electrical Schematic 31200457 October 21, 2011 - B

Sheet 2 of 6

ENCLOSED CAB ROOF HARNESS

S/N TBS00100 thru TBS00626

TH255 Electrical Schematic 31200457 Sheet 3 of 6 October 21, 2011 - K

A

1 2 3 025-2GRN 026-4GRN 070-1-22BLU 014-1GRN 026-5GRN 062-3-3YEL 000-4-13BLK 055-2GRN S148

SWITCH,FRAMER LOADER

4 5

S/N TBS00627 & After

SW145

RADIO, CE-IF EQUIPPED

6

S123

7 051-6-1BLU 000-8-27BLK

X105

1 2

X105

1 2

X106

1 2

1 2 LB105

noneBLU noneBLK

LB106

noneBLU noneBLK

FRONT LEFT LIGHT,WORKLIGHT

S110

S111

X106

1 2

1 2 LB104

noneBLU noneBLK

REAR RIGHT LIGHT,WORKLIGHT

1 2

X104

1 2

6

051-6-2BLU 000-8-28BLK

1 2 X104

REAR LEFT LIGHT,WORKLIGHT

051-7-1BLU 000-8-29BLK

1 2 LB103

noneBLU noneBLK

POWER SOCKET

X103

1 2

LIGHT,BECON

X103

1 2

MS109

1 2

M

M

5

S112

S113

S173 051-7-2BLU 000-8-30BLK

072-1BLU 000-8-1BLK

WH115-G

G 000-6-6BLK14AWG

WH115-P 1

W P

1 WH115-W 074-9BRN14AWG 1

074-8-1BRN14AWG

G

P

W

WIPER,ROOF MOTOR

000-4-15BLK 070-1-22BLU

S121

1 WH114-W 1 WH114-P 000-6-7BLK14AWG 1 WH114-G

074-8-2BRN14AWG

LIGHT,DOME

1 2 3 4 5 6 7 8

LSISHIELD LSI1RED LSI2BLK LSIPWRBLU 085-1BLU CANSHIELD CANHIRED CANLOBLK S119

1 2 LB107 000-7-8BLK 1 LB107-G 062-13-2YEL

4

062-3-3YEL 055-2GRN

058-2BLK MS118-

052-4WHT 1 MS118+ 1

MS117-

LSI PASSIVE

SW120

1 2 3 4 5 6 7 8 9 10

052-3WHT

LB183-

1

1

Lb183+

POWER GROUND CUTOUTOUTPUT LSI1 LSI2 LSIPWR CANH CANL

3

S146

S149

025-2-1GRN 026-4GRN 014-1-2GRN 014-1-1GRN 026-5GRN 025-2-2GRN 000-4-14BLK

1 MS117+ 058-1BLK 1

000-7-10BLK

085-1BLU

1 2 3 4 5 6 7 8 GD158

076-8GRN LSI1RED LSI2BLK LSIPWRBLU CANHIRED CANLOBLK

062-12-2YEL 000-7-6BLK

+

2

X27

1 2 3 4 5 6 7 8

B MS116-BRN

X50A 000-7-3BLK 062-13YEL 061-9RED 074-9BRN14AWG 074-8BRN14AWG 000-6-4BLK14AWG 052-2WHT 062-14YEL 120¹

7 8

062-12-2YEL 076-8GRN 000-7-2BLK GD30+

SPEEDO

062-13-1YEL 000-7-9BLK

061-9RED

1 2 3 4 5 6 7 8 S

GAUGE,SPEEDOMETER

MS116-GRY 1 2 058-2BLK 3 052-4WHT 4 058-1BLK 5 052-3WHT 6

1 2 3 4 5 6 7 8

C 1 2 3 4 5 6 TO OPTION CAB 7 HARNESS 8 SHEET2 9 10 11 12 GD30-S 062-14YEL 1

-

D 1 GD30052-2WHT 1

000-7-7BLK

1 7 8

LSI DISPLAY WIPER,REAR MOTOR FRONT RIGHT LIGHT,WORKLIGHT

D

C

S122 051-6BLU 000-8-3BLK

051-7BLU 000-8-2BLK 072-1BLU 000-8-1BLK

X50B 1 2 3 4 5 6 X22 TO BASE CAB HARNESS SHEET1

SPEAKERS,CE-IF EQUIPPED SPEAKERS,CE-IF EQUIPPED LEFT(DX) RIGHT(LX) SWITCH,AUX DECOMP

B

TO BASEFRAME

A

SHEET4(B8) HARNESS

ALL WIRES 16GA. GXL UNLESS NOTED

ENCLOSED CAB ROOF HARNESS

8

TH255 Electrical Schematic 31200457 October 21, 2011 - B

Sheet 3 of 6

FRAME HARNESS

S/N TBS00100 thru TBS00626

TH255 Electrical Schematic 31200457 Sheet 4 of 6 October 21, 2011 - K

CONTROLLER, HYDRAULIC JOYSTICK

FUNCTION CUTOUT RELAY R1

SENSOR,LEVER, FUEL SENDER FUEL LEVEL

R2

BATTERY,930CCA

F7

F6

F5

F4

F3

F2

F1

F11

F12

F13

F14

F15

F16

1 2 3 JS52

1 2 3 4

048-9GRY

RL159

026-1GRN 079-2GRN 025-1GRN 079-3GRN

080-1YEL 000-4-16BLK

079-1GRN 062-5YEL

4 1 3 2 5

1 AH64-G 000-4-5BLK

1 AH64

VALVE,STEER SELECT

VALVE,DIVERTER,AUX

Name F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 R1 R2

080-1YEL 062-19YEL

Description FUSE,Shifter,Steer,ParkBrake FUSE,F/RAux,QC FUSE,Display FUSE,Joystick FUSE,Fuelvalve,coldstartadvance FUSE,FuelPump FUSE,Back-UpAlarm,ReverseLight FUSE,Beacon FUSE,LSI FUSE,spare FUSE,Key FUSE,Horn FUSE,RearPower FUSE,FrontWorklights FUSE,BoomWorklights FUSE,RearWorklights RELAY,Worklights RELAY,Back-UpAlarm,ReverseLight

055-2GRN 000-3-21BLK

D

1 2 HV144

S147

S46

Rating 15 15 5 5 10 7.5 15 10 15 10 10 15 10 10 10 35N.O. 35N.O.

YEL 2 2 YEL 1 1 1. ANSI MACHINES HAVE 163A JUMPER X163 X163A 2. LSI EQUPPED MACHINES X163 PLUGS INTO X164 ON PAGE 5.

S154

S90

062-1YEL 061-5RED 061-4RED 062-2YEL 062-3YEL 062-4-1YEL 051-3BLU 051-5BLU 051-2BLU 051-4BLU 062-9YEL 070-1-1BLU 076-3GRN 065-2-1ORG 065-3-1ORG 052-1BLU 048-3GRY 048-4-1GRY 048-9GRY 048-6GRY 048-7GRY 048-8GRY 048-5GRY 007-1ORG 008-1ORG 076-4GRN 076-5GRN 008-2-2BLU 073-7BRN 061-2RED

S101

S143

S02

VALVE,AUX DECOMP

051-5BLU 000-4-3BLK

1 1 2 2 X88

051-5-2BLU 000-4-8BLK

051-5BLU 000-4-3BLK

S95 S91

X88

051-5-1BLU 000-4-7BLK

076-4GRN 076-5GRN S153

C

1 2 3 4 5 6 7 8 9 10 11 12 13 TO BASE 14 CAB HARNESS 15 SHEET1 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

052-1BLU

L1 FC65-L1 A10 062-19YEL A9 062-9YEL A8 062-8YEL A7 062-7YEL A6 062-6YEL A5 062-5YEL A4 062-4YEL A3 062-3-2YEL A2 062-2YEL A1 061-5RED C1 061-1-2RED D1 061-4RED C2 061-1-1RED D2 061-2RED C3 061-1-3RED D3 051-2BLU C4 051-1-1BLU D4 051-3BLU C5 051-1-2BLU D5 051-4BLU C6 051-1-3BLU D6 070-1-21BLU B8 003-1-10BLK D7 051-1BLU10AWGGXL D8 061-1RED10AWGGXL B7 C8 008-1-2ORG B10 003-1-11BLK D9 008-2BLU D10 062-8YEL B9 C10 FC65

BUSSBAR2

RL68-R

RL68-Y

1 RL68-B+ 048-3GRY 1 003-1-18BLK 2 RL68 XGRY8AWGSXL 1

1 RL67-R

061-1RED10AWGGXL 061-1-1RED 061-1-2RED 061-1-3RED BUSSBAR1 001-2RED6AWGSGT

1 2 RL67 BUSSBAR2

062-1YEL 003-1-9BLK

BUSSBAR1

RL66-R

1 RL66-Y

XGRY8AWGSXL

1 2 RL66 048-4-1GRY 003-1-17BLK

BUSSBAR1

D

000-1BLK2/0AWG

001-1RED2/0AWG 1 001-2RED6AWGSGT BT75-P

1 BT75-G

87 30 87a 85 86

F8

PWR OUT GND

HORN F10 F9

8

HV71

ELEC ASSY,MAIN FUSEBOX

7

1 2

STARTER RELAY,POWER MODULE,RED

6

076-3GRN 000-4-4BLK

IGNATION RELAY,POWER MODULE,YELLOW

5

1 2 HV76-AW 065-2-1ORG 1 000-3-14BLK 2 HV76-CB

GLOW PLUGS RELAY,POWER MODULE,GREEN

4

065-3-1ORG 000-3-13BLK

3

SN127

2

003-1-12BLK

1

1 2 3 4 X89

BOOM_CABLEYEL BOOM_CABLEGRN BOOM_CABLEWHT BOOM_CABLEBRN

1 2 3 4

1 2 LB73

1 2 LB74

LIGHT,WORKLIGHT BOOM,LEFT

C

LIGHT,WORKLIGHT BOOM,RIGHT

BOOM_CABLEYEL BOOM_CABLEGRN BOOM_CABLEWHT BOOM_CABLEBRN

1 2 HV72 VALVE,QUICK COUPLER

X89

X20

RL205 S92

000-1BLK2/0AWG

S155 000-3-1BLK 000-3-2BLK 000-3-3BLK 000-3-4BLK 000-4-1BLK 000-4-2BLK 000-4-3BLK 000-4-4BLK 000-4-6BLK 000-4-12BLK

ALARM,REVERSE

RELAY,SPDT,12V,20/40AMP

ENGINE COLD START ADVANCE SOLENOID

2

025-2GRN 026-4GRN 070-1-22BLU 014-1GRN 026-5GRN 062-3-3YEL 000-4-13BLK 055-2GRN

RL204 000-4-10BLK 5 026-1-1GRN 2 026-4GRN 3 026-2GRN 1 026-5GRN 4

1 2 3 4 5 6 7 8 X27 TO FRAMER/ LOADER SWITCH PAGE3(B5)

RELAY,SPDT,12V,20/40AMP

1. ANSI MACHINES HAVE X96A CAP 2. CE & AUS MACHINES, X96 PLUGS INTO X70 ON PAGE 5

A

GLOW PLUGS ENGINE

FUEL PUMP ENGINE

ENGINE FUEL SOLENOID(2PIN)

SWITCH, TEMP,WATER

AC COMPRESSOR

VALVE,F/RDRIVE

SWITCH,PRES,OIL

SWITCH,PRES,AC

FRAME HARNESS

ALLWIRES16GA.GXLUNLESSNOTED

1

B

RELAY,SPDT,12V,20/40AMP

86 85 87a 30 87

RL203 000-4-11BLK 5 025-1GRN 2 026-2GRN 3 079-4GRN 1 026-3GRN 4 86 85 87a 30 87

AH135

008-2-1BLU 000-4-2BLK 1 2

HV49-AUX

1 2

055-1GRN 000-3-19BLK

025-2GRN 1 000-3-17BLK 2 HV49-TC 014-1GRN 1 000-3-18BLK 2 X96

3 2 1 X96A

3 2 1

073-8BRN 1

WH99

SN137-2

007-3ORG 008-1-3ORG

X136

1

1 X136 073-7BRN 1

VALVE,FUNCTION SELECT

86 85 87a 30 87

M

W

D+

B+

M

ALTERNATOR ENGINE

STARTER ENGINE

SN137-1 073-8BRN 1

HV77-RV

007-2ORG 000-3-15BLK 1 2

048-6GRY A 062-4-2YEL B 048-7GRY C SN62

048-8GRY

SN59

A B

EC100 000-4-12BLK 2 062-6-1YEL 1

EC55

062-7YEL 000-4-1BLK 1 2

EC56

XGRY8AWGSXL 1

062-6-2YEL EC54

1

EC53-D

001-3RED6AWGSGT 1

EC53-B 048-5GRY 1

HV77-FW 008-1-1ORG 1 000-3-16BLK 2

A

EC57-G

EC57-S 000-2BLK2/0AWG 1

EC57-B-1 XGRY8AWGSXL 1

EC57-B-2 001-1RED2/0AWG 1

1

001-3RED6AWGSGT

S94

073-7BRN

000-4-5BLK

HV49-CT

S21

S86

5 2 3 1 4

S208

S97

S85

S174

B

1 X87-1 FRAME 000-2BLK2/0AWG GROUND 1 STUD X87-2 000-3BLK10AWG 1 000-4BLK10AWG X87-4

000-4-9BLK 026-1-2GRN 055-1GRN 026-3GRN

3

5

4

S/N TBS00627 & After

6

7

8

TH255 Electrical Schematic 31200457 Sheet 4 of 6 October 21, 2011 - B

FRAME OPTIONS HARNESS

S/N TBS00100 thru TBS00626

TH255 Electrical Schematic 31200457 Sheet 5 of 6 October 21, 2011 - K

1 2 3 C B A

MS179-3

ALL WIRES 16GA.GXL UNLESS NOTED

4

S/N TBS00627 & After 120¹

5 FRAME GROUND STUD

S175

HV49-CT

025-2GRN18AWG

000-10BLK10AWG 000-9BLK10AWG

062-23YEL 000-10-5BLK 081-1WHT18AWG 062-22YEL 000-10-6BLK 081-2WHT18AWG

X98 1 2 3 4 5 6

NC A B C

X160 062-23YEL 1 000-10-5BLK 2 081-1WHT 3 062-22YEL 4 000-10-6BLK 5 081-2WHT 6

SN161

LSISHIELD LSI1RED LSIPWRBLU LSI2BLK

1 PWR 2

Vcc Vout GND

SENSOR,SPEED

2 1

X87-5 1

MS179-1

SN79

1 2 3

LB60

1 2

1 MS125-7

1 MS125-6

1 MS125-5

1 MS125-4

062-14-1YEL 052-2WHT 000-9-2BLK

071-12-4BLU 000-10-1BLK

071-12-3BLU

071-16-2BLU

071-11-3BLU

071-6-4BLU

1 MS125-3

1 MS125-2

1 MS125-1

TAIL

BACK

TURN

STOP

TAIL

BACK

TURN

STOP

4

CO176-J2

CANH1RED CANL1BLK 084-1WHT18AWG 084-2WHT18AWG

A B C 000-10-2BLK

071-5-4BLU

LB84

TRAILER CONNECTOR

4 5 6 7 8 9 10 11 12

C B A

CO176-J1 086-1YEL18AWG 1 087-1WHT18AWG 2 088-1BLK18AWG 3

S78

071-16-3BLU 071-5-3BLU 008-2-4BLU 071-12-2BLU 000-10-3BLK14AWG

7 6 5 4 3 2 1

LB83

7 6 5 4 3 2 1

TURN

3

+5V PRSSENSOR AGND N/C N/C N/C N/C N/C CANBUSHIGH CANBUSLOW ANALYZERTRANSMIT ANALYZERRECEIVE

CANL2BLK CANH2RED

062-20YEL18AWG 000-9-13BLK18AWG 076-9GRN18AWG 025-2GRN18AWG 007-3ORG18AWG 081-1WHT18AWG 082-1GRN18AWG 082-2GRN18AWG 083-1GRN18AWG 083-2GRN18AWG 080-1YEL18AWG 085-1BLU18AWG

MS179-2

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

CANSHIELD CANLOBLK CANHIRED

IGNPWR(7-33V) GROUND LSIOVERRIDE TELESCOPECMD DRIVEFORWARD BOOMTELESTATE1 LIFTMODEVALVE LIFTDOWNVALVE TELEOUTVALVE TELEMODEVALVE FUNCTIONLOCKOUT LSIPASSIVELAMP

X180 S129

071-16-1BLU 071-6-3BLU 008-2-3BLU 071-11-2BLU 000-10-4BLK14AWG

Lb82

SIDE

HIGH

LIGHT,TAIL LIGHT,RIGHT

CO162-J2

062-21YEL 062-20YEL18AWG 062-25YEL18AWG 062-24YEL 062-19YEL

CANH2RED CANL2BLK

S128

S131

S130

6 2 3 4 5 1

LOW

TURN

2

6 7 8 9 10 11 12

071-6-1BLU 071-5-1BLU 071-12BLU 071-11BLU 071-10BLU 071-9BLU 071-8BLU 071-7BLU 077-3ORG 071-16BLU 008-2-2BLU CANSHIELD

CO162-J1 1 2 3 089-1WHT 4 089-1WHT 5

062-25YEL18AWG 000-9-14BLK18AWG 081-2WHT18AWG 008-1-3ORG18AWG 076-8GRN18AWG 076-7GRN18AWG

071-9BLU 071-7BLU 071-11-1BLU 071-6-2BLU 000-9-3BLK14AWG

LB81

LIGHT,RIGHT HEADLIGHT

N/C N/C N/C +5V MODULECONFIG N/C N/C N/C CANBUSHIGH CANBUSLOW N/C N/C

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

FOR CE AND AUS 1.X70 PLUGS INTO MACHINES X164 X96 ON SHEET4 PLUGS INTO X163 ON SHEET 4 IGNPWR(7-33V) GROUND BOOMTELESTATE2 DRIVEREVERSE LSICUTOUT JSCUTOUT N/C N/C N/C N/C N/C N/C

A SIDE

HIGH

LOW LIGHT,LEFT HEADLIGHT

X70

8 7 6 5 4 3 2 1

062-24YEL 007-3ORG18AWG 008-1-3ORG18AWG

TO MAIN CAB HARNESS SHEET2

3 2 1

C

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

X164

080-1YEL18AWG 062-19YEL

B

2 1

071-10BLU 071-8BLU 071-12-1BLU 071-5-2BLU 000-9-4BLK14AWG

6 2 3 4 5 1

1 5 6

000-9-5BLK12AWG S80

6

7

000-9-6BLK 000-9-7BLK

076-7GRN18AWG 085-1BLU18AWG CANLOBLK CANHIRED 062-14-1YEL 052-2WHT 078-3WHT 062-4-5YEL LSI1RED LSI2BLK

062-23YEL 062-22YEL

CAN-T

CANH1RED CANL1BLK

I/O MODULE

7

8

LIGHT,TAIL LIGHT,LEFT 062-23YEL 000-10-5BLK 081-1WHT BOOM MID PROX

LIGHT,LICENSE

S102

S134

083-2GRN18AWG 000-9-11BLK

1 2 3 SN178

062-22YEL 000-10-6BLK 081-2WHT

D

078-3WHT 062-4-5YEL

082-1GRN18AWG 000-9-8BLK

S133 082-2GRN18AWG 000-9-9BLK

076-8GRN18AWG 076-9GRN18AWG LSISHIELD LSIPWRBLU

083-1GRN18AWG 000-9-10BLK

X25

000-9-12BLK 084-1WHT18AWG 084-2WHT18AWG 062-21YEL

086-1YEL18AWG 088-1BLK18AWG 087-1WHT18AWG

1 2 3 SN44

1 2 3 SN177

PWR GND SIG

LSI SENSOR BOOM MID PROX PWR GND SIG

D

SWITCH,PRES,STEER

1 2 SN37

1 2 HV69

LIFT MODE VALVE

1 2 HV01

PLUGS INTO HV49-CT ON SHEET4

C

S132

1 2 HV63

LIFT DOWN VALVE

1 2 HV25 TELE OUT VALVE

TELE MODE VALVE

B

4 3 2 1 X165 PRESSURE SENSOR PWR GND SIG

A

VALVE MODULE

FRAME OPTIONS HARNESS

8

TH255 Electrical Schematic 31200457 October 21, 2011 - B

Sheet 5 of 6

1

2

D

LIGHT,BECON

FRONT RIGHT LIGHT,WORKLIGHT

3

FRONT LEFT LIGHT,WORKLIGHT

REAR RIGHT LIGHT,WORKLIGHT

4

5

6

7

8

D

REAR LEFT LIGHT,WORKLIGHT

LB103

072-1BLU 000-8-1BLK

X103

051-7-2BLU 000-8-30BLK

X103

1 2

1 2

X104 X104

051-7-1BLU 000-8-29BLK

1 2

1 2

072-1BLU 000-8-1BLK

MS157

1 2 noneBLU noneBLK

LB104

1 2

1 2

LB106

noneBLU noneBLK

POWER SOCKET

1 2

1 2 MS30

POWER SOCKET

051-6-2BLU 000-8-28BLK

LB105

051-6-1BLU 000-8-27BLK

1 2

LIGHT,BECON

TO BASE CAB HARNESS SHEET1

S151

S126

S150

C S124

C

051-6BLU 000-8-3BLK 051-7BLU 000-8-2BLK 072-1BLU 000-8-1BLK

1 2 3 4 5 6

TO BASE CAB HARNESS SHEET1

X22

1 2 3 4 5 6

072-1BLU 000-8-1BLK X22

B

B

GNDBLK

1

WH99-GND2 1

WH99-GND1

MOUNTED ON THE ENGINE BLOCK FOR THE AC INSTALLATION

A

A

OPEN CAB ROOF HARNESS

1

2

3

5

4

S/N TBS00100 & After

6

7

8

TH255 Electrical Schematic 31200457 Sheet 6 of 6 October 21, 2011 - B