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Component Location

Schematic Machine Schematic Machine KENR7078-01


Component Component
Location Location Location Location
8 11
November 2004
Alarm - Backup D-10 1 Relay- Starter B-9 2
B 28
Alternator A-9 D Resistor - 24V B-10 19 12 14 9
25
Battery 1 & 2 A-9 D Sender - Engine Coolant Temp C-12 19 17
24
Breaker - Alt. A-9 2 Sender - Engine Oil Pressure C-12 20
Breaker - Battery A-9 2 Sender - Hydraulic Temp C-11 21 26 10

Breaker - Glow Plug A-8 2 Sensor - Rear Speed C-10 22 18


5 1
23 2
Breaker - Light D-4 B Switch - 2 Speed A-4 B
Breaker - Throttle B-6 B Switch - Air Compressor I-4 23
Cold Start Timing Unit A-11 3 Switch - Air Distribution I-4 23 21
15 4 C
Flasher C-4 B Switch - Backup A-5 B
Fuse Block F-5, G-5 C Switch - Brake B-4 B
Gauges I-6, I-7 C Switch - Disconnect B-9 11 D
27
Glow Plugs B-8 2 Switch - Hazard C-3 B
A 22 3 19
Horn - Warning F-7 4 Switch - 2 Speed Heavy Weight Option A-5 B
20
Lamp - Indicator G-6 5 Switch - Ignition F-7 5
Lamp - Left Turn/Tail E-10 6 Switch - Light D-3 14 13 16
Lamp - LH GP G-3 7 Switch - Neutral Start A-10 24
6
Lamp - RH GP F-3 8 Switch - Starting Aid G-7 5 7
Lamp - RH Turn/Tail C-9 9 Switch - Throttle H-4 5
Lamp - Working GP D-10 10 Switch - Turn C-4 14
Lamp - Working GP D-10 11 Switch - Warning Horn A-5 25
Lamp - Working GP G-4 12 Switch - Water Spray D-3 B
Lamp - Working GP F-4 13 Switch - Traction Control H-4 4
Meter - Hour I-5 C Switch - Engine Coolant Temp A-11 3
Module - Timer A-7 14 Solenoid - Brake Switch A-10 26
Motor - Front Water Pump
Motor - Starter
G-4
A-9
15
D
Solenoid - Injection Pump
Solenoid - Interlock
B-11
A-11
27
24 PS-150C Pneumatic Compactor
Electrical System
Product Link C-11 16 Solenoid - Throttle Control B-9 18
Relay - Brake #1 A-4 17 Solenoid - Traction Control A-11 28
Relay - Brake #2 A-4 17 Solenoid - Electric Fuel Lift Pump B-10 19
Relay - Glow Plug B-8 18 Solenoid - 2 Speed Switch A-10 24
Relay - Main D-4 18 Valve - Air Compressor I-4 A FPS1-UP
Relay - Neutral Start #1 B-4 17 Valve - Air Distribution #1 I-4 A
Relay- Neutral Start #2 A-4 17 Valve - Air Distribution #2 I-4 A
Machine locations are repeated for components located close together.
A = Located on operator platform.
B = Located inside of right console. C

C = Located inside of instrument console. 5 23


D = Located inside engine compartment.
25 B
14 19
26 3
27
4 17 21 2
D
24
8 18
A 22 20
7 12 1
10
13 15 28
9
11
6
16

© 2004 Caterpillar Printed in U.S.A.


Machine Harness Connector And Component Locations All Rights Reserved

Wire Description Harness And Wire Electrical Schematic Symbols


Wire Wire
Wire Color Description Wire Color Description
Number Number Electrical Schematic Symbols And Definitions
Power Circuits Basic Machine Circuits (Cont.) A AA 1 1
101 RD Bat (+) 324 BU Diff Lock/Switch (Foot) to Diff Lock Valve 1 2 2
105 BR Key Sw 330 YL Neutral Start Switch to Relay #2
Key Sw Glow Plug Relay
Typical representation of a Typical representation of a
105 RD 384 BU
Alt Output (+) Term. Monitoring Circuits
Deutsch connector. The Sure-Seal connector. The
109 RD T
Plug Receptacle plug contains all sockets plugand receptacle contain
110 GN Water Spray 406 PU Hydraulic Temperature Sender Connector Location Pressure Temperature Level Flow and the receptacle contains both pins and sockets.
112 PU Main Power Relay Output 419 YL Parking Brake Pressure Switch
Connector Number
Schematic Machine Symbol Symbol Symbol Symbol 2 all pins.
114 GN Light Breaker 440 BR Air Pressure Valve Location Location
121 YL Backup Alarm/Warning Horn 448 WH Air Pressure Valve CONN 1 Product Link C-11 16
123 WH Gauges 449 WH Speed Tach Gauge CONN 2 R5 & P5 D-8 29
Pin or Socket Wire, Cable, or Harness
128 PK Warning Horn Switch 476 PU Engine Oil Pressure Sender CONN 3 P8 &R8 C-8 29 Component
Start Aid Fuse Accessory Circuits
Number Assembly Identification Part Number
135 BU CONN 4 P9 & R9 B-8 29 Normally open switch that will close with an increase of a specific condition (temp-press-etc.).
148 WH Start Aid 537 GN Turn Switch CONN 5 P1 & R1 E-6 30 Single Wire
155 PK Aux Ckt Lighting Circuits Connector
CONN 6 P3 & R3 E-6 30
170 YL Diff Lock/Lift 605 YL LH Turn Lamps CONN 7 P4 & R4 E-5 30 A AA 9X-1123
C A

KENR7078-01
Normally open switch that is closed due to an applied condition, and will open again with a
172 GN Air Pressure/Joint Cutter 606 GY RH Turn Lamps CONN 8 P2 & R2 E-5 30
specific decrease in that condition. 325-PK-14 1 325-PK-14
173 YL Flasher 608 GN Rear Flood Lamps CONN 9 R34 & P34 B-8, E-5 31
177 RD Main Breaker 614 PU Dash Lamps CONN 10 R16 & P16 E-4 32 Wire
Pin Socket
181 GY Timer Module 619 GN Front Flood Lamps
The connectors shown in this chart are for harness to harness connectors.
Color
185 YL Air Compressor Control Circuits Connectors that join a harness to a component are generally located at or near Normally closed switch that will open with an increase of a specific condition.
Ground Circuits 751 GN Speed Switch to 1st Speed Solenoid the component. See the Component Location Chart.

20 Page, KWG
200 BK Main Chassis 777 PU Speed Switch to 2nd Speed Solenoid 2 200-BK-14
Basic Machine Circuits 810 BR Start Aid Switch
304 WH Starter Relay No. 1 Output 4983 BU Throttle Cont. Solenoid Normally closed switch that is open due to an applied condition, and will close again
Circuit Number Wire
306 GN Starter Relay Coil A919 BU Throttle Cont. Solenoid with a specific decrease in that condition. Identification
Key Switch to Relay #4 Throttle Switch
Gauge
307 OR A982 BR
308 YL Main Power Relay Coil A983 BU Throttle Cont. Solenoid
309 GY Alt. Output [R] Term. To Alternator Lamp C720 BU Neutral Start Relay
The circle indicates that the component has screw terminals and a wire can be disconnected Electrical Schematic Symbols And Definitions
321 BR Backup Alarm to Backup Alarm Pressure Switch C922 BR Water Spray Switch
Warning Horn Forward
from it.
322 GY
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.
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 and Solenoid Specifications SENDER - A component that is used with a temperature or pressure gauge. The sender
This indicates that the component has a wire connected to it that is connected to ground. measures the temperature or pressure. Its resistance changes to give an indication to the
Part No. Component Description Resistance (Ohms)¹
T gauge of the temperature or pressure.
030-2010 Sender- Engine Oil Pressure 10.5 ± 5.5
Engine Coolant Temperature Sender 5806 - 7246 @ 54.4°C
6N-5926 Sender-
Hydraulic Temperature Sender 524 - 586 @ 115.6°C
216-2035 Solenoid- Traction Control 30.3 RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity.
This indicates that the component does not have a wire connected to ground. It is grounded
2 Speed Switch It has a coil that makes an electromagnet when current flows through it. The electromagnet
1G-9759 Solenoid- 27.3 by being fastened to the machine.
Brake Switch can open or close the switch part of the relay.
Pull In: .66
160-7396 Solenoid- Throttle Cont.
Hold: 50
¹ At room temperature unless otherwise noted. 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.
12 11 10 9 8 7 6 5 4 3 2 1

614-PU
HARNESS AS
144-9012
I I

200-BK
200-BK
200-BK
HOUR

123-WH

200-BK

123-WH

200-BK

123-WH

200-BK

123-WH
METER
6T-7337
185-YL
172-GN

2 1
AIR COMPRESSOR
- + - + - + - 200-BK - +
AIR COMPRESSOR
SWITCH
GROUND 8D-2676
ENG HOT 448-WH
SIG ENG SIG SIG SPEED SIG AIR DISTRIBUTION

2 1
SIG
OIL OIL
COOLANT TACH VALVE
PRESSURE TEMP
120-3964
406-PU 172-GN AIR DISTRIBUTION

2 1
440-BR
403-GN VALVE

200-BK
AIR DISTRIBUTOR

449-WH
441-OR SWITCH
1V-6652
200-BK
476-PU

181-GY-18 A982-BR THROTTLE


REAR SWITCH
WORK
LIGHT
(PS360 ONLY)
TRACTION
H CONTROL
H
170-YL 324-BU
608-GN
105-BR 7T-2296
200-BK

HARNESS AS-INSTRUMENT HARNESS AS-FRONT


243-3549 TRACTION CONTROL 128-2048
FUSE

403-GN
112-PU-6 112-PU-6 10 170-YL P15
2 1

112-PU-6
R15
FRONT

172-GN
STARTING KEY GAUGES/ 200-BK-16
AID WATER PUMP
START SPEED SENSOR
SWITCH 115-1914
FUSE FUSE
9D-3721 MOTOR
10 10 123-WH C922-BR

181-GY-18
A982-BR
R810-GN 148-WH

109-RD-6
WARNING 200-BK
FLASHER
HORN
FUSE FUSE LH LIGHT GP
G 200-BK C
G
10 10

109-RD-6
614-PU B
INDICATOR 605-YL A
LAMP
2N-2371/ WATER P10 R10
2V-7807 SPRAY
BRAKE
FUSE 619-GN
FUSE

105-BR
WORKING LAMP GP
10 15
R 200-BK
308-YL

155-PK
308-YL
OFF C
FUEL SPRAY WIRE GROUP COLOR DESCRIPTIONS
ON S STARTING AID FUSE

123-WH
307-OR WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS OFF.
ST B FUSE (PS360 ONLY)

173-YL
105-BR
WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS ON.
15 15 619-GN STARTING CIRCUIT.

110-GN-14
IGNITION

112-PU-6
SWITCH WORKING LAMP GP GROUND CIRCUIT.
9G-7641
BACK-UP ALARM TIRE INFLATION 200-BK STARTING AID CIRCUIT.
FUSE FUSE
GAUGES AND WARNING LIGHTS CIRCUIT.
15 15
WARNING BRAKE CONTROL CIRCUIT.
HORN TURN SIGNAL CIRCUIT.
7T-0969 F
135-BU
F P7 R7
200-BK C
200-BK 614-PU B
322-GY 606-GY A

RH LIGHT GP

R810-GN

C922-BR

619-GN
606-GY
605-YL
614-PU
200-BK
307-OR
308-YL
309-GY

476-PU
441-OR
406-PU

449-WH

614-PU
322-GY

608-GN

112-PU-6

110-GN-14

181-GY-18
403-GN

A982-BR
109-OR-6

121-YL
155-PK
135-BU
128-PK

123-WH

105-BR
173-YL

324-BU
1 2 3 4 5 6 7 8 9 10 11 12 R1 1 2 3 4 5 6 7 8 9 10 11 12 P2
P34 1 2 R16 6 5 4 3 2 1 SYMBOL DESCRIPTION
P3 R4

CONN 5 CONN 6 CONN 7 CONN 8 CONN 10


CONN 9
BLADE, SPADE, RING
R3 P4
OR SCREW TERMINAL E
E 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 R2 P16
9 10 11 12 P1 1 2 3 4 5 6

200-BK CIRCUIT CONNECTED

R810-BR

109-RD-6
112-PU-6

322-GY
606-GY
105-RD
322-GY

128-PK
307-OR
308-YL
309-GY

476-PU
441-OR

449-WH

614-PU
406-PU

619-GN
403-GN

A982-BR
155-PK

181-GY

614-PU
110-GN
200-BK

173-YL
123-WH
4

605-YL

C922-BR
3 614-PU
LEFT TURN/TAIL 2
1
200-BK
605-YL CIRCUIT NOT CONNECTED
R36 P36

WORKING LAMP GP
ELECTRICAL CONNECTION
9X-4381
608-GN TO MACHINE STRUCTURE
HARNESS AS.-ENGINE 200-BK
C922-BR
110-GN

240-1452 BACKUP ALARM 112-PU-6


LIGHT
BREAKER
WATER
SPRAY
INTERNAL ELECTRICAL
D
D
3T-1815 R45
1
P45
321-BR 112-PU-6
SWITCH
8D-2676 CONNECTION TO SURFACE
15
2 608-GN
MAIN
RELAY 112-PU-6
OF COMPONENT
200-BK
101-7740
WORKING LAMP GP CONN 2 P11 B
9X-4381 R5 P5 112-PU-6 1 2 114-GN-12
608-GN
605-YL
1
2
1
2 605-YL
109-RD-6
308-YL
R11 T-D CONNECTOR
614-PU 3 3 614-PU 614-PU
200-BK 4 4 606-GY
606-GY
5 5 321-BR 619-GN
ATCH WIRE, CABLE,
4 321-BR
PRODUCT 3 614-PU
LINK 608-GN 6 6 608-GN 608-GN H
2 200-BK 200-BK-12 406-PU 7 7 406-PU 173-YL
P38 RIGHT TURN/TAIL
COMPONENT
1 606-GY
476-PU 8 8 476-PU 606-GY

200-BK
1 105-RD 9 9 441-OR 605-YL
KENR7078-01

441-OR

112-PU-6
2 200-BK R37 P37 R
403-GN 10 10 403-GN 200-BK
CONN 1 3 308-YL 200-BK 123-WH 11 11 123-WH LIGHT
4 403-GN 449-WH 12 12 449-WH FLASHER SWITCH

CIRCUIT GROUPING
5 8V-2514 3K-1650
20 Page, Color 2, KWG

A 123-WH 3
REAR SPEED TURN
6 SENSOR BK B 200-BK SWITCH
2 1
49 +BATTERY TURN SIGNAL 1
123-0960 WH C 449-WH CONN 3 1V-6652 2
DESIGNATION
C TURN INDICATOR
R30 P30 P8 R8 537-GN 49A SIGNAL LAMPS 4 C
ENGINE OIL 476-PU 403-GN 1 1 30B +BATTERY HAZARD 5
C PRESS. SENDER ° 105-RD 105-RD 2 2 105-RD 31 GROUND
302010
HYD 200-BK 3 3 200-BK C2 TUV INDICATOR HAZARD
TEMP SENDER 777-PU 4 4 777-PU SWITCH
751-GN 5 5 751-GN 3T-4405

SHIELD
6N5926
309-GY 6 6 309-GY
306-GN 7 7 306-GN A982-BR
°T 810-BR 8 8 R810-BR
ENGINE COOLANT 330-YL 9 9 330-YL
TEMP SENDER
6N5926 R43
1
P43
A919-BU
308-YL
A919-BU
10
11
10
11
308-YL
A919-BU
200-BK 200-BK
ABBREV COLOR
112-PU-6

181-GY
A983-BU 12 12 A983-BU
441-OR 2 4983-BU
DISCONNECT SW
°T CONN 4 5 2
476-PU
THROTTLE CONT.
SOLENOID CABLE AS.
7N-0718
177-RD-6 109-RD-6
NEUTRAL RD RED
200-BK

406-PU 160-7396 1 30 87 4 START


200-BK

BK-00
441-OR RELAY #1
WH WHITE
200-BK

P9 R9 87a 3
3E-5239
CABLE AS. 306-GN
CABLE AS.
CABLE AS.
BK-00 324-BU
307-OR
OR ORANGE

200-BK
308-YL RD-00 RD-00 330-YL

POS NEG POS NEG


CONN 9
R34
155-PK
BRAKE
YL YELLOW
751-GN B
B
2
RD-20
BK-20
BATTERY BATTERY
306-GN 384-BU-8
SWITCH
116-5275 PK PINK
3T-5760 3T-5760 122-7344
BK BLACK
200-BK 1 P39 R39 1 2
1 2 116-6565 4
P40 R40 THROTTLE BREAKER
INJECTION BK-20 A 308-YL GLOW
P21 P42 3

GY GRAY
RD-20 B 200-BK STARTER PLUG
6T-6343
3
PUMP C +
24V_RESISTOR RELAY 1 2 1 2 RELAY 2 SPEED
239-5818 R21 R42 155-2269 GLOW PLUGS 181-GY 112-PU-6 -
118-3534 15 SWITCH
WH 1 181-GY 4D-1836 PU PURPLE
CABLE AS.

+16 TO +32 VDC PWR IN NORMALLY

419-YL
RD-00

200-BK-12 2

155-PK
BR BROWN
304-WH-6 +AUX IN BK 200-BK OPEN FOR

200-BK
S

200-BK
330-YL
LOW SPEED
CABLE AS

GND CABLE AS
-PWR GND IN BK 3 A983-BU
6-RD

RD-6

777-PU
FRAME NEUTRAL START BATTERY +OUT 4
RD
GN GREEN
MTR BAT BREAKER A919-BU

321-BR
CABLE AS

STRAP AS
108-1032

60 171-2208 -OUT 5
5Y-1423

177-RD-6
60 A BK A982-BR NEUTRAL
BK-00

177-RD-6
PLUG

B765-BR
N910-GN 308-YL 6
BU BLUE
GLOW PLUG START
MOTOR BREAKER 5 2
101-RD-6

128-PK
T TRACTION CONTROL 2 SPEED BRAKE 171-2208 TIMER MODULE R59 P59 LOW SPEED NORMALLY CLOSED RELAY #2 5 2
200-BK

INTERLOCK

322-GY
216-2035 SWITCH SWITCH 177-RD-6 160-7395 1 30 87 4 3E-5239
ENG COOL. R22 87 4 BRAKE
7V-9275

1G-9759 1G-9759 STARTER 751-GN 1 2 BACKUP C720-BU


1 30
1 2 RELAY #2

200-BK
TEMP. SW 155-PK ALARM 87a 3
CABLE AS.

COLD ST P22 TO MOTOR 3 3E-5239


3 SWITCH 87a
RD-00

TIMING ENGINE 101-8929


UNIT 2 SPEED SWITCH 4D-1836 P6
BLOCK 200-BK
109-RD-6

R35 330-YL ALTERNATOR 1 2


R44 5 2
R20 R19 308-YL 9W-3043 HEAVY WEIGHT OPTION R6
A
THIS SCHEMATIC IS FOR THE A
1 2 1 2 ALT 60
1 2 1 2 TO BRAKE
P35 P44 BREAKER 1 30 87 4
P20 P19 FRAME W 155-PK RELAY #1
PS-150C PNEUMATIC COMPACTOR
9S0174
B+ D+ 309-GY HARNESS AS-MAIN 87a 3 3E-5239
B-

243-3629-01
777-PU

GND
200-BK
751-GN TO 243-3548 WARNING
ENGINE HORN
FRAME BLOCK SWITCH 200-BK
324-BU 3T-2357

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