Machine Location C
Component Location Chart Alarm - Action (EMS)
Schematic Location D-3
1
Alarm - Backup
D-14 E-15
21
Sensor - Trans Speed (Speedometer)
F-10
2
Alternator
F-14
25
Shifter - Transmission
F-5
3
Batteries
B-15, F-14
22
Solenoid - Air Conditioner Clutch
C-14
A
Breaker - Blower Motor
C-9
A
Solenoid - Bucket Positioner
B-6
B
Breaker - Main
A-14
23
Solenoid - Engine Shutdown
C-14
B
Breaker - Running Lamp
A-13
A
Solenoid - Lift Positioner
B-6
4
Control - Transmission
E-10
24
Solenoid - Ride Control
B-2, D-1
5
Converter - Voltage
F-6
26
Solenoid - Start Aid
C
Flasher
E-4
19
Solenoids - Transmission
F-9
A
Fuses
C-9
A
Switch - Air Intake Heater
E-9
B
Fuses - Alarm, Horn, Stoplamp, Key
A-13
A
Switch - Beacon
E-7
C
Gauge - Engine Coolant Temp
F-3
C
Switch - Blower
D-4
C
Gauge - Fuel Level
E-3
27
Switch - Brake Oil Press (EMS)
F-8
C
Gauge - Hydraulic Oil Temp
E-3
28
Switch - Bucket Positioner
Component
Machine Location 20
Component Sensor - Engine Speed (Trans)
Schematic Location B-10
12 31
Switch - Disconnect
B-15
6
Ground - Platform
C-5
2
Switch - Engine Coolant Temp (EMS)
F-12
7
Ground - Engine End Frame
A-6, B-6
2
Switch - Engine Coolant Temp (Start Aid)
F-12
5
Ground - Roof
E-6
23
Switch - Engine Oil Press (EMS)
B-14
8
Heater - Air Intake
9
Horn - Forward
C
Lamp - Action (EMS)
D-11
A
Switch - Flood Lamp
D-7
C-2, E-1
25
Switch - Forward Horn
D-5
D-3
A
Switch - Front Intermittent Wiper/Washer
E-6
F-3
A
Switch - Front Wiper/Washer
D-8
E-10
23
Switch - Fuel Press (EMS)
B-14
C
Lamp - Air Intake Heater
10
Lamp - Diagnostic (Trans)
C
Lamp - Neutralizer Override
F-3
A
Switch - Key Start
C
Lamp - Ride Control
F-3
29
Switch - Lift Positioner
A
Meter - Service
E-7
30
Switch - Neutralizer
A-3
C
Meter - Speedometer
F-4
31
Switch - Parking Brake (EMS)
D-10
C
Monitor - Operator (EMS)
E-3
32
Switch - Primary Steering Press (EMS)
A-15
10
3 17
2
5
4
8
4
20 14
22 23
25
32
2
C
B
5
7 10 1
33
6
A
12 Contacts
D-6 C-2, F-1
C-3
A
Switch - Rear Wiper/Washer
D-8
Motor - Front Washer
F-8
17
Switch - Refrigerant Press (AC)
E-12
Motor - Front Wiper
B-4
A
Switch - Ride Control
E-7
12
Motor - Rear Washer
F-8
A
Switch - Running Lamp
D-7
14
Motor - Rear Wiper
E-9
A
Switch - Start Aid
E-9
15
Motor - Starting
F-13
30
Switch - Stop Lamp
A-3
16
Radio
F-7
32
Switch - Supplemental Oil Flow (EMS)
A-15
15
Relay - Air Intake Heater
D-11
A
Switch - Test (EMS)
E-8
B
Relay - Main
A-13
C
Switch - Thermostat
C-3
B
Relay - Start
A-14
19
Switch - Torque Converter Oil Temp (EMS)
B-13
B
Resistor - Alternator
A-13
A
Switch - Transmission Auto/Manual
E-8
11
Resistor - Blower Motor Speed
C-3
33
Switch - Transmission Downshift
B-6
2
Sender - Engine Coolant Temp (Gauge)
F-12
A
Switch - Transmission Neutralizer Override
E-8
17
Sender - Fuel Level (Gauge)
E-12
25
Switch - Turn Signal
F-5
18
Sender - Hydraulic Oil Temp (Gauge)
B-13
C
Timer - Air Intake Heater
D-9
19
Sender - Torque Converter Temp (Gauge)
B-13
25
14 10 4
26
1
5 22
18
2 23
1 4
8
20 B
3 3
C
6
8 21
29
28
12 7
E-3
A -108-1124 B - 4E2846 Standard
A-3
A -108-1124 B - 8R4127 Attachment
A-3 D-2
2
A -108-1124 GGG - 4E8960
A-3
6
B - 8R4127 Attachment Q - 4E4317 Attachment
E-1
A -108-1124 P-102-5889
B-5
D -102-9298 P - 102-5889 Standard
B-9
D -102-9298 FF - 4E0599 Attachment
B-9 C-10
C
P - 102-5889 Transmission Shifter
D-5
P-102-5889 FF - 4E0599 Attachment
B-9 C-9
5
FF - 4E0599 Attachment GG - 4E2908 Attachment
E-10
F -102-5888 Operator Monitor (EMS)
E-3
A
LL - 101-5308 Attachment Wiper Switch Attachment
D-6
A-108-1124 B - 4E2846 Standard
B-3
A
P - 102-5889 SS - 7X6015
C-4
A-108-1124 B - 8R4127 Attachment
B-3 D-2
7
A - 108-1124 D -102-9298
B-9
8
A -108-1124 Positioner Solenoids
B-6
9
B - 8R4127 Attachment K - 4E4371 Attachment
F-1
L - 4E0598 UU -101-9161 Standard
D-9
L - 4E0598 AIH Timer Attachment
D-9
*
2
A-108-1124 C - 4E2307 Standard
D-13
A-108-1124 C - 8R4128 Attachment
D-13 E-14
4
A-108-1124 E-108-1123
C-11
1
A-108-1124 E-108-1123
C-12
3
8 Contacts
7 Contacts
6 Contacts
A 4 Contacts
L - 4E0598 N - 102-5891 Standard
D-9
10
N - 102-5891 Rear Wiper Motor
E-9
L - 4E0598 N - 4E4186 Attachment
D-9 F-7
C
P-102-5889 Front Wiper Motor
B-4
1
L - 4E0598 P -102-5889
C-6
1
L - 4E0598 P - 102-5889
C-6
C
P -102-5889 Transmission Shifter
D-6
918F Wheel Loader Electrical System 3TJ1-UP 2CK1-UP 5DL1-UP
A = Connector is located in right console area. B =Connector is located at breaker box. C =Connector is located in dash area.
9 24
30 27
7
F - 102-5888 Cluster Gauge
* = Connector is located at the component.
13
11
19
15
17
31
10
*
Machine locations are repeated for connectors located close together.
33
A
E-10
1
5
10 Contacts
FF - 4E0599 Attachment Data Link Plug Attachment
B-7
1 16
5
A-108-1124 L - 4E0598
9
6
9 Contacts
Schematic Location
1
29
8
F-5
Harness And/Or Components
A-13
2 16
Machine Location
E-108-1123 G - 8Y7607
28
11
19 26
20 Contacts
24
13
F-102-5888 P -102-5889
Connectors
B
30
21
Schematic Location
E-10
9
7
15 18
Harness And/Or Components
FF - 4E0599 Attachment Transmission Control Attchmnt
1
27
Harness Connector Location Chart
*
24 Contacts
3
3
13
1
1
F-3
12
25 Contacts
C-2, F-1
Gauge - Torque Converter Temp
Motor - Blower
C 40 Contacts
C-14
C
11
Connectors
Machine Location
SENR5775-01 May 1999
6
2
9
32
Machine locations are repeated for components located close together. A = Components located at right console. B = Components located at breaker box. C = Components located in dash area.
C57693P1
Machine Harness Connector And Component Locations Printed in U.S.A.
© 1993 Caterpillar All Rights Reserved
Wire Number
Wire Color
101 102 104 105 108 109 112 113 114 116 118 120 121 124 126 127 128 129 130 135 144 160 164 193
RD BU YL BR BU OR PU OR GN BR GY YL YL GN PK OR PK BU GN BU GN PU WH PU
200 201 202 206 276 277 278 279 280 281
BK BK BK BK BK BK BK BK BK BK
301 304 306 307 308 309 310 311 321 322 326 373
BU WH GN OR YL GY PU WH BR GY PU GN
403 405 406 409 410 411 413 415 416 417 419 428 432 441 442 443 447 449 450
GN GY PU OR WH PK BR GN OR GY YL OR PK OR GY YL PK BU YL
Wire Description Chart Description Power Distribution Circuits BAT HD LMP AUX CKT KEY START SW AUX CKT ALT OUTPUT (+) TERM MAIN POWER RELAY OUTPUT OPR MON PANEL WARNING HORN (FORWARD) AUX CKT AUX CKT AUX CKT BACKUP ALARM TO LAMP A/C XMSN CONT AUX CKT AUX CKT AUX CKT AUX CKT AUX CKT AUX CKT AUX CKT XMSN CONT TO DATA LINK AUX CKT Ground Circuits MAIN CHASSIS OPR MON PANEL XMSN CONT BAT SIDE OF DISCONNECT XMSN CONT IDENT CODE 0 XMSN CONT IDENT CODE 1 XMSN CONT IDENT CODE 2 XMSN CONT IDENT CODE 3 XMSN CONT IDENT CODE 4 XMSN CONT IDENT CODE 5 Basic Machine Circuits STARTER NO. 1 SOL STARTER RELAY NO. 1 OUTPUT STARTER RELAY COIL TO XMSN SHIFTER KEY START SW TO XMSN SHIFTER MAIN POWER RELAY COIL ALTERNATOR REGULATOR TERM START AID SW TO START AID SOL START AID SOL TO TEMP SW BCKP ALARM LAMP TRAVEL ALARM WARNING HORN (FORWARD) KEY START SW C TERM AIH TIMER Monitoring Circuits ALTERNATOR (R) TERM OPR MON OIL PRESS (LO SETTING) OPR MON COOLANT TEMP OPR MON NEUT OPR MON ACTION ALARM OPR MON ACTION LAMP OPR MON FUEL PRESS OPR MON TEST SW SUPPL STER SW PRIMARY STER SW OPR MON PARKING BRAKE OPR MON XMSN OIL TEMP OPR MON BRAKE PRESS (OIL) ENG COOLANT TEMP GAGE HYD SYSTEM TEMP GAGE POWER TRAIN TEMP GAGE FUEL LEVEL GAGE SPDOM SENDER (SIGNAL NO. 1) TACH SENDER (+)
Wire Number
Wire Color
500 501 502 503 504 505 506 507 508 509 511 512 513 515 516 517 521 522 537 538
BR GN OR BR YL BU PU WH PU WH BR GN OR GY GN BU YL WH GN BR
603 604 605 606 608 610 611 614 615 617 619 710 720 751 752 754 755 761 762 900 901 910 921 922 923 924 925 926 944 945 963 964 965 966 967 968 969 970 971 972 973 974 975 976 977 978 987 B757 B758 B766 C920
PK OR YL GY GN OR PU PU YL BR GN GN PU GN YL BU OR GY YL PU WH YL WH BR GY GN YL BU OR BR GN BU WH GY BU BR YL GN YL BU BR PU WH OR YL GN WH WH GN WH GY
Description Accessory Circuits WIPER - FRONT (PARK) WIPER -FRONT (LO) WIPER - FRONT (HI) WIPER - REAR (PARK) WIPER - REAR (LO) WIPER - REAR (HI) WASHER - FRONT WASHER - REAR 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) A/C SW TO REFRIGERANT SW A/C CLUTCH TO THERMOSTAT SW TURN SIGNAL SW TO FLASHER HAZARD INDICATOR Lighting Circuits ROTARY BEACON STOP LAMP TURN LAMP - LEFT TURN LAMP - RIGHT FLOOD LAMP - REAR HEAD LAMP BASIC HEAD LAMP HI PARK/TAIL/DASH LAMP CAB FLOOD LAMP/ROPS TAIL/POSITION LAMP - LEFT (ROAD PKG/WIDTH) HEAD LAMP LO Control Circuits XMSN SPEED PICKUP SIGNAL XMSN BRAKE SW XMSN SHIFT SOL NO. 1 OR 3 XMSN SHIFT SOL NO. 2 XMSN SHIFT SOL NO. 3 OR 1 XMSN SHIFT SOL NO. 4 OR 5 LIFT KICKOUT SOL SW BUCKET POSITIONER SOL SW XMSN SHIFT SOL NO. 5 OR 4 XMSN SHIFT SOL NO. 6 XMSN NEUTIZER OVERRIDE INDICATOR XMSN SOL NO 1 OR 3 RETURN XMSN SOL NO 2 RETURN XMSN SOL NO 3 OR 1 RETURN XMSN SOL NO 4 OR 5 RETURN XMSN SOL NO 5 OR 4 RETURN XMSN SOL NO 6 RETURN CAT DATA LINK + CAT DATA LINK BUCKET/FORK POSITION DETENT COIL FORK POSITION SELECT TRANS SOL 1 SW TO GND TRANS SOL 3 SW TO GND TRANS SOL 1 & SOL 3 SW TO B+ (CST ONLY) TRANS SOL 2 SW TO GND TRANS SOL 3 SW TO B+ TRANS SOL 4 SW TO GND TRANS SOL 5 SW TO GND TRANS SOL 6 SW TO GND XMSN CONTROL - AUTO/MANUAL SW 2 XMSN CONTROL - SLOW MODE SW XMSN CONTROL - SOL RETURN RIDE CONT SOL XMSN CONTROL - AUTO/MANUAL SW 1 XMSN CONTROL - SLOW MODE SW 1 DIVERTER SOL XMSN CONTROL XMSN CONTROL KICKOUTS/DETENT DISABLE SW TO KICKOUTS XMSN CONTROL - DIAGNOSTIC LAMP
Part No. 3E6429 3E6449 3E6450 3E6451 3E6453
4 grams (.14oz) 38 ± 3°C (100 ± 5°F) 1200 kPa MAX (175 psi MAX) 107.0 ± 3.0°C (224.6 ± 6.0°F) 129.0 ± 3.0°C (264.0 ± 6.0°F) 70 kPa MAX (10 psi MAX) 90 ± 21 kPa (13 ± 3.0 psi) 10700 kPa MAX (1550 psi MAX) 213 kPa MAX (31 psi MAX)
Engine Coolant Temperature (Start Aid) Primary Steering Pressure (EMS) Engine Coolant Temperature (EMS) Torque Converter Oil Temperature (EMS) Fuel Pressure (EMS)
3E6455
Engine Oil Pressure (EMS)
9W0549
Actuate
Supplemental Steering Oil Flow
3E6454
3E7693
Off Machine Switch Specifications
Function
Brake Oil Pressure (EMS) A/C Low Pressure
Deactuate
Contact Position
1.5 grams(.05oz)
Normally Open
26.7°C MIN (80°F MIN) 700 ± 100 kPa (100 ± 15 psi) 93.0°C MIN (199.0°F MIN) 118.0°C MIN (244.0°F MIN) 40 ± 20 kPa (6.0 ± 3.0 psi) 70 ± 21 kPa (10 ± 3.0 psi) 8960 ± 345 kPa (1300 ± 50 psi) 172 kPa MIN (25 psi MIN)
Resistor and Solenoid Specifications
Code Flashed 11
Normally Closed A-C, Normally Closed A-B, Normally Open Normally Closed Normally Closed Normally Closed A-B, Normally Open A-C, Normally Closed A-B, Normally Open A-C, Normally Closed Normally Open
12 21
DIAGNOSTIC CODE CONVERSION CID-FMI
NO ACTIVE Not applicable Faults NO INACTIVE Not applicable Faults 368-02 Auto/manual switch signal not correct.
Open
Transmission speed sensor signal not valid.
641-05
Solenoid 1 open circuit.
32
642-05
Solenoid 2 open circuit.
33
643-05
Solenoid 3 open circuit.
34
644-05
Solenoid 4 open circuit.
35
645-05
Solenoid 5 open circuit.
36
646-05
Solenoid 6 open circuit.
41
641-06
Solenoid 1 short to ground.
42
642-06
Solenoid 2 short to ground.
43
643-06
Solenoid 3 short to ground.
44
644-06
Solenoid 4 short to ground.
45
645-06
Solenoid 5 short to ground.
Model
46
646-06
Solenoid 6 short to ground.
918F
51
641-03
Solenoid 1 short to + battery.
52
642-03
Solenoid 2 short to + battery.
6T7864
55
645-03
Solenoid 5 short to + battery.
Resistor - Blower Motor Speed
9G1950
56
646-03
Solenoid 6 short to + battery.
Solenoid - Air Conditioner Clutch
8T8813
39.00 ± 1.95 Overall 2.00 ± 0.10 Tap 1.00 ± 0.05 14.4 ± 0.6
61
660-02
Invalid shift lever input line 12.
Solenoid - Bucket Solenoid - Engine Shutdown Start (Latch) Coil Stop (Unlatch) Coil Solenoid - Lift Positioner
9T5679
108.0 ± 5.5
62
661-02
Invalid shift lever input line 13.
63
662-02
Invalid shift lever input line 14.
64
663-02
Invalid shift lever input line 15.
9T5678
108.0 ± 5.5
65
664-02
Invalid shift lever input line 16.
Solenoid - Ride Control
9X3267
17.8 ± 0.9
66
665-02
Invalid shift lever input line 17.
Solenoid - Start Aid
3E6332
6.0
67
666-02
Invalid shift lever input line 18.
Solenoids - Transmission
3E6269
33.8 ± 1.0
68
667-02
Invalid shift lever input line 19.
69
668-02
Invalid shift lever input.
71
168-00
System voltage above normal.
72
168-01
System voltage below normal.
74
650-02
Invalid harness code.
¹ At room temperature.
Ground²
191-08
Resistor - Alternator
Open
Open
31
Solenoid 4 short to + battery.
Open
Ground²
25
Solenoid 3 short to + battery.
Ground² Open
Engine speed sensor signal not valid.
644-03
Contact 5¹
Open
190-08
643-03
Contact 3¹
To Clear ³
24
54
Contact 1¹
To Scroll INACTIVE Faults
Downshift switch signal not correct.
53
1.55 ± 0.15 10.30 ± 1.03
To Scroll ACTIVE Faults
621-02
Resistance (Ohms)¹
8C3663
Operation
22
Part No.
Component
Electrical Schematic Symbols And Definitions
Activation of Diagnostic Indicator Operation (Quick Reference)
Description
¹ These contact are located in the harness code connector. ² Remove the connection to ground to place the desired information shown during scrolling on-hold. ³ A fault is cleared only while it is on-hold. A fault that is active can not be cleared.
Harness And Wire Electrical Schematic Symbols A
AA
T
Pressure Symbol
Temperature Symbol
Level Symbol
Flow Symbol
Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.
Receptacle
Plug
1 2
1 2
1
2
Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets.
Pin or Socket Number Wire, Cable, or Harness Assembly Identification
Normally open switch that will close with an increase of a specific condition (temp-press-etc.).
Electronic Transmission Harness Code Plug Serial No. 3TJ,2CK,5DL
Component Part Number
Single Wire Connector
Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition.
C
A
A 325-PK-14
Harness Code Plug Part No.
Pin
4E-2908
Normally closed switch that will open with an increase of a specific condition.
AA 1
Wire Color
Socket
2
Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition.
9X-1123 325-PK-14
200-BK-14
Circuit Number Identification
The circle indicates that the component has screw terminals and a wire can be disconnected from it.
Wire Gauge
Electrical Schematic Symbols And Definitions FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it.
No circle indicates that the wire cannot be disconnected from the component.
Related Electronic Service Manuals Title
Form No.
Alternator: K1/N1
SENR3685
Electronic Transmission Control
SENR5751
Monitoring System
SENR2945
Starting Motor: R5.5
SENR3828
This indicates that the component has a wire connected to it that is connected to ground.
This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.
REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.
T
SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.