Beruflich Dokumente
Kultur Dokumente
0412
SM06---047---000.00
2
3
Category
Color
6
Circuit Designation
Example: Wire number 243---A BLU indicates:
Category 2, circuit 43, conductor
A, blue wire.
Figure 1
Wire Number Explanation
Wire Harness
Each wire, in any given wire harness within the electrical system, has a colored insulating coating. This coating is labeled with a wire number. The color and wire
number, when fully understood, will allow the positive
identification of a wire and its specific use in the circuit.
Each wire has four basic identifying elements. Refer to
Figure 1.
Category
The first character of each wire number corresponds to
a general category. Seven basic categories exist and
are described as follows:
1. Category 1: Primary Power (Red or Orange) 100
series numbers are used to identify wires which are
used to provide the originating source of power to
all circuits within the electrical system.
1.
2.
3.
Circuit Breaker
Thermal Switch
Wire Connector
4
4.
5.
6.
Indicator Light
Buzzer
Ground Bolt
Figure 2
Wire Number Suffix Sequence
2. Category 2: Engine and Transmission Control
(Blue) 200 Series numbers are used to identify
wires in circuits used in the operation and control of
the engine and transmission.
3. Category 3: Monitoring Group (Yellow) 300 series
numbers are used to identify wires in circuits used
in monitoring crane operation. Circuits that
contain gauges or instrumentation are included in
this category. (See Category 8 also.)
4. Category 4: Lighting and Horns (Green) 400
Series numbers are used to identify wires in the
interior and exterior lighting circuits of the crane, as
well as the horn and back up alarm circuits.
5. Category 5: Equipment Control (Brown) 500
Series numbers are used to identify wires in circuits
concerned with the operation and control of
functions that are unique to the crane. (See
Category 7 also.)
6. Category 6: Accessories (Violet) 600 series
numbers are used to identify wires in circuits
concerned with the operation and control of
operator accessory equipment such as heaters,
defrosters, windshield wipers, etc.
7. Category 7: Equipment Control (Brown) 700
series numbers are simply an extension of
Category 5. (See Category 5 also.)
8. Category 8: Monitoring Group (Yellow) 800 series
numbers are simply an extension of Category 3.
(See Category 3 also.)
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Color
The color of the wire, like the wire number, has a very
specific meaning. It can be used to identify, as well as,
describe the function of the wire in a given circuit. All
wires are colored according to the category that defines their corresponding circuit, with the following exceptions:
1. Wires which are directly connected to the system
power source, and are at constant battery potential, are colored RED. These wires remain HOT at
all times.
2. Wires that are at battery potential only when the
ignition switch is in the ON position are colored
ORANGE.
Category 1
Primary Power Circuits
Wire Number Description
000
101
Battery Charge
102---110
Battery Distribution
111---119
120---121
122---123
Chassis Ground
124
125
126---127
128---129
Ground
130
Battery Distribution
131
132
Controller Power
133---137
Ground
138
24 Volt Power
139---140
Ground
141---143
144
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3. Wires that are at constant ground potential are colored BLACK.
Circuit Designation
The second and third characters of each wire number
specifically identify the circuit within any given category. See the category listings found later in this document for specific wire number designations.
Note: All wire numbers listed in category listings
are typical and may not necessarily apply to one
given crane.
Jumper Wires
A jumper wire is defined as any wire not included in a
wire harness. These wires are not labeled with a wire
number. They are labeled however, with the actual wire
part number which can be used to order a replacement
wire.
All jumper wires will be colored white with the same exceptions, red, orange and black as described for the
wire harness.
Service Manual
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Category 2
Engine And Transmission Control Circuits
Wire Number Description
201---203
Starter Solenoid
204---205
Starter Motor
206---207
Engine Stop
208---209
210
Throttle Lock
211
Throttle Control
212
213
Fuel Cooler
214
215
Idle Validation
216---229
230
231---240
241---242
243
Ether Control
244
245
246---254
255---256
Speed Limiting
257
Fuel Heater
258---267
268
Throttle Actuator
269
Other Control
270
Throttle Supply
271
272
Other Control
273---276
Transmission Supply
277
278
279
280
281
RPM Limiting
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Category 3
Monitoring Circuits (Also See Category 8)
Wire Number Description
301---302
Instrument Supply
303---304
Fuel Level
305---306
307---308
309
Fuel Pressure
310
Voltmeter
311---312
313
Hourmeter
314
315---316
317---318
319
Speedometer
320---321
322---326
327
328---329
330
331---334
335
336---338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353---356
357
Power ON Indicator
358
Anti-Two Block
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361
362---363
Air Pressure
364
365
366
367
368
369
370
371
372
373
374
375---376
377---378
Free-Fall System
379
380
Light Test
381
Position Indicator
382---383
384---388
389
390
391
392
393---395
396
397---398
399
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Category 4
Lighting And Horn Circuits
Wire Number Description
401
402---403
Headlights
404---405
Clearance Lights
406
407
408
409
Backup Solenoid
410
411---412
413
414
415
416
417
418---422
Exterior Lights
423
424
425---426
Horn
427
Instrument Lights
428
Light Solenoid
429---430
Travel Alarm
431
432
433
Instrument Lights
434
Rotating Beacon
435
Swing Alarm
436
Backup Light
437
Backup Alarm
438
439
440
441
442
443
444
445
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Category 5
Equipment Control Circuits (Also See Category 7)
Wire Number Description
501---502
503---505
506
507
508
509
510
511
512
513
514
515
516---518
519
520
Two-Speed Hoist
521
Free-Fall Valve
522
523
524---525
526
527
Pump Disconnect
528
Oscillation Override
529
530
531
532
Remote Steer Directional & Diverter Valve Supply (Front Winch Up*)
533
Remote Steer Directional & Diverter Valve Supply (Front Winch Down*)
534
535
536
537
538
539---540
541---542
543
Two-Speed Swing
544
Two-Speed Travel
* Alternate description for some cranes with serial number prefixes J8 or R3 only.
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Two-Speed Planetary
549
550---551
Cab Motion
552
553
554
555
556
557
Cab Motion
558
559
560---563
Axle Control
564
565---566
Fairleader Control
567
568
569
570
571
572---573
Drum Bypass
574
Automatic Brake
575
Park Brake
576
577
Two-Speed Hoist
578
Control Override
579
Remote Control
580
581
Boom Hoist
582
Boom Telescope
583
Swing Lock
584---585
586
Swing Auxiliary
587---592
Outrigger Control
593---595
Blocking Valve
596---599
Free-Fall
Equipment Control Circuits Continued As Category 7
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Category 6
Accessories Circuits
Wire Number Description
601---602
Heater
603---604
Defroster
605---607
Windshield Wiper
608---610
Windshield Washer
611
612---613
Air Conditioner
614---615
616
Air Dryer
617
Cigarette Lighter
618---621
Air Conditioner
622
623
624
Heater
625
Seat Control
626
AM/FM Radio
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Category 7
Equipment Control Circuits (Also See Category 5)
Wire Number Description
701
Free-Fall
702
703
Tow Winch - In
704
Load Sensing
705
706
Pump Disconnect
707
708
709
710---712
713
714
715
716
Steer Reversing
717
Park Brake
718
719
720
721
722---723
724
725
726
Steer Lock
727
728
729
730
731
Counterweight Removal
732
733
734
735
736
737
738---744
745---746
* Alternate description for some cranes with serial number prefixes J8 or R3 only.
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748
749
750
751
752
753
754
Auger
755
Boom Hoist Up
756
757
Swing Left
758
Swing Right
759
Front Winch Up
760
761
Rear Winch Up
762
763
Horsepower Dissipation
764
Fly Extend
765
Fly Retract
766
767
768
769
Swing Controller
770
771
Free Swing
772
Greaser
773
774
775
790
791
792
793
794
* Alternate description for some cranes with serial number prefixes J8 or R3 only.
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Category 8
Monitoring Circuits (Also See Category 3)
Wire Number Description
801
Ammeter
802
Pyrometer Temperature
803---804
805
Throttle Indicator
806
807
808
809---810
811
812
813
814
815
816
817
Load Moment Indicator (LMI) Reeling Drum & Anti-Two Block (ATB)
818
819
820
821
822
Anemometer
823
824
825
826
827
Swing Sensor
828
829
830
831
Tilt Sensor
832---833
Display/Monitor Supply
834
USB Port
835
836
Camera System
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Senders
Maintained Contact
Normally Open
Pressure Sensitive
Maintained Contact
Normally Closed
Liquid Level
Momentary Contact
Mechanically Actuated
Thermal Sensitive
Pressure Sensitive
Opens As Pressure Rises
Speedometer
Pressure Sensitive
Closes As Pressure Rises
Momentary Contact
Normally Open
Momentary Contact
Normally Closed
Relays
Heating Element
Coil
Contacts NO
Diode
Coil
Mechanically Linked
Contacts NO
Variable Resistance
With Off Position
Contacts NC
Contacts
Common
Circuit Protectors
Fuse
Circuit Breaker
Audible Signals
Valve Solenoid
Ground
Chassis
Gauge
Lights
Manual Reset
Buzzer
Circuit Breaker
Flasher
Gauge
Thermal Reset
Battery
Horn,
Backup Alarm
Motor
Figure 3
Electrical Symbols Legend
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Shielded/Twisted Wire
Thermostat
Sensor
PNP
NO
Figure 3
Electrical Symbols Legend -- Continued
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