Wire Description

Wire KENR9563
Wire Color Description
Number
103 YL Key Power
July 2009
110 RD Key Power
111 RD Generator Winding Termination F2
112 RD Key Power to Circuit Board
Related Electrical Service Manuals 115 RD Boost Relay to Lift / Drop Relay to Power Resistors
Title Form Number 116 RD Circuit Board to Boost Relay / Power Resistor / F1 Winding Termination
120 YL Key Power from Disconnect Sw. to Magnet Control Fuse
Systems Operations:
121 BU Power Resistors Jumper
Troubleshooting: KENR9020 151 GN Magnet Control Fuse to Disconnect Switch
Testing and Adjusting: 161 RD Power Stud to Sample Voltage Relay
162 RD Power Stud to Circiut Board
163 WH Monitor to Circuit Board
165 RD Power Stud to Base Fuse
Diagnostic Codes For Magnet Controller 168 GN Magnet Control Fuse to Disconnect Switch
176 YL Generator Control +24v
ECM (SA No. 71)¹
191 WH Magnet Lockout Relay to LH Joystick
For troubleshooting, see the procedure with the
197 GN Generator Enable Switch to Magnet Lockout Relay
same SPN And FMI No.
198 RD Sample Voltage Relay to Voltage Band Monitor
SPN /
Description 199 RD Sample Voltage Relay to Voltage Band Monitor
FMI
SPN 5000 Generator Overheat Status 200 BK Main Chassis / Relay Panel Ground
FMI 11 Other Failure Mode. 201 BK Main Chassis / Relay Panel Ground
SPN 5001 Genset System Output Voltage Range Status 202 BK Valve Group Return
FMI 11 Other Failure Mode. 205 BK Chassis Ground
SPN 5004 Genset Softstart Active 206 BK Ground Stud to Sample Voltage Relay
207 BK Ground Stud to Circiut Board
FMI 3 Voltage above normal.
208 BK Chassis Ground from Disconnect Switch to Magnet Control Fuse
FMI 5 Current below normal.
234 BK CAN Data Link Shield
FMI 6 Current above normal.

M318D MH & M322D MH

299 BK Drop Relay Returns
SPN 5005 Genset Enable Active
A235 BK Machine Control Switch Return
FMI 3 Voltage above normal.
A272 BK Boost Relay / Sample Voltage Relay Return
FMI 5 Current below normal.

Magnet Controller 15kW

307 OR Generator Enable Switch to Magnet Lockout Relay
FMI 6 Current above normal.
415 GN ECM to Voltage Band Monitor
SPN 5006 Voltage Monitor Active
F430 GN Generator Monitor Fault LED

Electrical System
FMI 3 Voltage above normal.
F431 YL Generator Monitor Ground
FMI 6 Current above normal.
F456 PK Drop Time
SPN 5007 Generator Duty Cycle Exceeded Status
F457 BR ECM to Circiut Board Dropover Current Switch
FMI 0 High
F458 GN Drop Time
SPN 5008 Magnet Forward Current
FMI 3 Voltage above normal.
F459
G465
WH
PK
Drop Time
Generator Winding Termination P1
W8R1-UP
SPN 5009 Magnet Reverse Current
FMI 3 Voltage above normal.
H461 WH Generator Hot W2T1-UP
H462 OR Over 75% DC
SPN 5010 Material Lift Switch H463 BU Over / Under +V
FMI 3 Voltage above normal. H464 GY Magnet On
SPN 5011 Material Drop Switch E540 PK Magnet Lockout Relay
FMI 3 Voltage above normal. F711 GN CAN Data Link (+)
SPN 5012 Generator Current Boost Active Status F712 GY CAN Data Link (-)
FMI 3 Voltage above normal. G889 GY ECM to Magnet Drop Relays
FMI 6 Current above normal. G890 PU ECM to Magnet Lift Relay
SPN 5013 Material Lift Active Status H862 GY Generator Solenoid Return
FMI 3 Voltage above normal. N839 GN Magnet Lift Switch
FMI 5 Current below normal. N840 PK Magnet Drop Switch
FMI 6 Current above normal. R807 WH Soft Start Solenoid
SPN 5014 Material Drop Active 944 OR Cat Data Link (+)
FMI 3 Voltage above normal. 945 BR Cat Data Link (-)
FMI 5 Current below normal. C903 BU ECM to Sample Voltage Relay
FMI 6 Current above normal. C905 OR ECM to Circiut Board and Boost Relay
¹ This table pertains only to diagnostic codes with a SA of 71. J984 PK ECM to Curret Transducer 2
J985 GY ECM to Curret Transducer 1
J992 YL Generator Enable Switch (NC)
J995 PU Generator Enable Switch (NO)
K900 YL CAN Data Link (+)
K990 GN CAN Data Link (-)
T976 YL Generator Enable
T979 YL Magnet Drop Switch

© 2009 Caterpillar Printed in U.S.A.

All Rights Reserved

Harness And Wire Electrical Schematic Symbols

DISCONNECT SWITCH
Symbols

SSR Pressure Temperature Level Flow Circuit Breaker

POWER RESISTOR 1 173 Symbol Symbol Symbol Symbol Symbol
POWER RESISTOR 2
Symbols and Definitions
Fuse: A component in an electrical circuit that will open the circuit if too much current flows
through it.

(Dimensions: 39 inches x 28 inches)

SSR
172 Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
COMMUNICATION circle indicates that the component has screw terminals and a wire can be disconnected from it.
J2 FUSE BASE ADAPTER
PORT 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.
POWER RESISTOR 1 POWER RESISTOR 2
SSR Ground (Wired): This indicates that the component is connected to a grounded wire. The
(1.5 ohm) (1.0 ohm) 171

KENR9563
TEE 2 grounded wire is fastened to the machine.

TEE 1 Ground (Case): This indicates that the component does not have a wire connected to ground.
It is grounded by being fastened to the machine.

MAGNET CONTROLLER ECM VOLTAGE Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the
SSR BAND contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.
170 MONITOR
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
T
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
J1 electromagnet can open or close the switch part of the relay.

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
SAMPLE can open or close a valve or move a piece of metal that can do work.
CIRCUIT BOARD VOLTAGE
RELAY 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.

30 Page,
Harness and Wire Symbols
Wire, Cable, or Harness Harness Identification Letter(s):
Assembly Identification: Includes (A, B, C, ..., AA, AB, AC, ...)
Harness Identification Letters and
Harness Connector Serialization Code:
Harness Connector Serialization
The "C" stands for "Connector" and the
Codes (see sample).
number indicates which connector in the
FUSE BASE harness (C1, C2, C3, ...).
AG-C4 L-C12 L-C12
111-7898 3E-5179 3E-5179
POWER STUD CURRENT Part Number: for Connector Plug 1
Part Number: for Connector Receptacle
TRANSDUCER 2 2
BOOST CURRENT
RELAY TRANSDUCER 1 Plug Receptacle
Pin or Socket Number
5A
GROUND STUD 1 Deutsch connector: Typical representation
Component
of a Deutsch connector. The plug contains all Fuse (5 Amps) 9X-1123 Part Number
2 sockets and the receptacle contains all pins.
325-AG135 PK-14
1 Sure-Seal connector: Typical representation Harness identification code:
of a Sure-Seal connector. The plug and receptacle This example indicates wire group 325, Wire Gauge
2 contain both pins and sockets. wire 135 in harness "AG". Wire Color
 12 11 10 9 8 7 6 5 4 3 2 1

OPERATOR CAB MAGNET CONTROL PANEL

M-C13 F-C1 GENERATOR ENABLE SW HEAT SINK
1288950 1254766 1939066
SSR 173 DISCONNECT SW
1 7 FRONT VIEW OF GENERATOR MONITOR 3231152
2 A-C6 1603579
3 1 MAGNET CTRL A4M1 A-C5 DROP RELAY C-C1 CW-C1
2 MAGNET VOLTS OVER 4 5 3045687 J2 1471446 2716530 2 1 1275486 1275485
4 176-F124 YL-16
F 197-M64 GN-16 5 197-F20 GN-16 176-F132 YL-18 3 197-F20 GN-16
ON FAULT 75% DC 3 6
VOLTAGE BOOST RELAY 2 C905-A64 OR-16 299-A72 BK-16 299-A89 BK-16
4 2
205-A70 BK-14 A B 151-C1 GN-10-C 1 168-CW1 GN-10 168-CW3 GN-14-GXL F

OUTPUT
4 2 7 4 3

INPUT
6 5 J992-F50 YL-18 GEN +GND -GND 1 8 MAGNET DROP RELAY 3 G889-A37 GY-16 299-A26 BK-16 299-A73 BK-16 103-A17 YL-14 30A 120-A3 YL-14 151-C1 GN-10-C 168-CW4 GN-14-GXL
A235-M60 BK-18 7 A235-F46 BK-18 A235-F46 BK-18 6 HOT FAULT FAULT DROP TIME RETURN OF PIN 2, 5 4 A272-A19 BK-16 299-A75 BK-16 MAGNET CONTROL
6 5
8 J995-F133 PU-18 SAMPLE VOLTAGE RELAY 5 C903-A12 BU-16 299-A89 BK-16 C FU 101
D 200-C2 BK-10-C
9 MAGNET LIFT RELAY 6 G890-A36 PU-16 G889-A94 GY-16 115-A68 RD-14 205-A18 BK-14 30A 208-A4 BK-14 200-C2 BK-10-C 1 200-CW2 BK-10
10 RETURN OF PIN 3, 6 8 299-A26 BK-16 +3 +1 MAGNET CONTROL C-C2 CW-C2
11 F-C16 K900-A77 YL-18 FU 102
1177898 GENERATOR MONITOR CAN A + 67 E F 1275485 1275486
12 CU-C02 CAN A - 68 K990-A79 GN-18 G889-A37 GY-16 G889-A74 GY-16 112-A29 RD-14 20A 103-A20 YL-14
13 3470570 1552252 CAN A SHIELD 69 234-A91 BK-18 G889-A94 GY-16 SSR 172 FU 108
14 197-F20 GN-16 SWITCH DROP TIME 1 RD 1 F458-CU1 GN-18-GXL 3231152 G H GND FR 3.X
176-M67 YL-18 15 176-F132 YL-18 J992-F50 YL-18 SWITCH DROP TIME 2 BK 2 F459-CU2 WH-18-GXL GENERATOR ENABLE SWITCH 1 307-A100 OR-18 (GND FRAME DISCONNECT-SW)
J995-M69 PU-18 16 J995-F133 PU-18 J995-F133 PU-18 SWITCH DROP TIME 3 WH 3 F456-CU3 PK-18-GXL CAT DATA LINK (+) 10 944-A81 OR-18 DROP RELAY SPARE
17 MAGNET ON - LED RD/BK 4 H464-CU4 GY-18-GXL BATTERY (-) 13 201-A63 BK-16 G890-A36 PU-16 G890-A71 PU-16 4 2
JOYSTICK LH VOLTS FAULT - LED BU 5 H463-CU5 BU-18-GXL CAT DATA LINK (-) 20 945-A82 BR-18 G890-A93 PU-16 299-A75 BK-16 111-A41 RD-14

OUTPUT
6

INPUT
2451472 OVER 75% DC - LED OR H462-CU6 OR-18-GXL BATTERY (-) 23 201-A62 BK-16
J-C1 F-C6 GENERATOR HOT - LED BK/WH 7 H461-CU7 WH-18-GXL RH MAGNET LIFT SWITCH - N/A 24 N839-A42 GN-18
1027964 1211168 1 MONITOR GROUND GN 8 F431-CU8 YL-18-GXL LH MAGNET DROP SWITCH 25 N840-A43 PK-18
1 2 MAGNET OFF +/-GND FAULT - LED WH/BK 9 F430-CU9 GN-18-GXL GENERATOR THERMAL SWITCH 28 G465-A44 PK-18 G889-A74 GY-16 103-A67 YL-14
3 (FRONT BUTTON) N/A OR/BK 10 DROP OVERCURRENT SWITCH 32 F457-A33 BR-18 +3 +1
4 N/A GN/BK 11 DROP TIME SWITCH SETTING 1 33 F458-A50 GN-18 103-A17 YL-14
9 191-M20 WH-18 5 YL N/A BU/BK 12 DROP TIME SWITCH SETTING 2 34 F459-A51 WH-18 103-A111 YL-16 103-A20 YL-14
10 G889-M21 GY-18 6 GY DROP TIME SWITCH SETTING 3 35 F456-A49 PK-18 103-A67 YL-14
176-J94 YL-16 11 176-F124 YL-16 M-C4 FORWARD CURRENT TRANSDUCER 36 J984-A25 PK-18 103-A98 YL-14 Factory Configuration for 230 Volt Generator
12 1552273 REVERSE CURRENT TRANSDUCER 37 J985-A16 GY-18 HEAT SINK
13 BATTERY (+) 38 110-A60 RD-16 Applicable KW Rated Fuse Part

MAGNET CONTROL PANEL

BATTERY (+) 39 110-A59 RD-16 110-A104 RD-16

MAGNET CONTROL PANEL

SSR 171
VOLTAGE BAND MONITOR OUTPUT 40 415-A38 GN-18 3231152 Machine Rating Amps Amps Number
21 JOYSTICK RH BATTERY (+) 46 110-A58 RD-16 110-A30 RD-14 M318D HCR
2451472 BATTERY (+) 47 110-A86 RD-16 110-A58 RD-16 110-A40 RD-18 LIFT RELAY 15 65.2 70 190-9551*
OPERATOR CAB

OPERATOR CAB
GENERATOR SOLENOID 48 T976-A110 YL-16 110-A59 RD-16 110-A103 RD-18 4 2 M322D HCR
1 SOFT START TIMER - N/A 49 R807-A102 WH-16 110-A60 RD-16 110-A105 RD-18 299-A73 BK-16 205-A39 BK-14

OUTPUT
2 CV-C2 CU-C3 * Two adapters (190-9393) are required when

INPUT
191-M20 WH-18 191-M20 WH-18 MAGNET ON RETURN OF PIN 48, 49 50 202-A28 BK-16 110-A86 RD-16
A235-M46 BK-18 A235-M46 BK-18 3 (FRONT BUTTON) 2304011 2304012 BATTERY (-) 56 201-A61 BK-16 using fuse 190-9551.
A771-M45 PU-18 A771-M45 PU-18 4 197-CV1 GN-18-GXL 1 197-CU10 GN-18-GXL GENERATOR HOT LED 58 H461-A45 WH-18
E J992-F50 YL-18 J992-F50 YL-18 A771-M45 PU-18 5
6
YL T979-CV2 YL-18-GXL 2 T979-CU11 YL-18-GXL OVER 75% DUTY CYCLE LED
VOLTS FAULT LED
59 H462-A46 OR-18 G890-A71 PU-16
+3 +1
111-A87 RD-14 E
G889-M21 GY-18 G889-M21 GY-18 A235-M46 BK-18 GY 61 H463-A47 BU-18 111-A69 RD-14 111-A41 RD-14
M-C09 MAGNET ON LED 62 H464-A48 GY-18 111-A96 RD-14 111-A52 RD-14
1552273 BATTERY (-) 70 201-A106 BK-16 111-A87 RD-14
J1 A-C4 SSR 170
1471445 3231152
115-A35 RD-10 115-A68 RD-14 LIFT RELAY
176-J94 YL-16
+24V KEY SWITCH / FUSE 16
"GENERATOR CONTROL"
CV-C1 M-C16 115-A11 RD-10 115-A95 RD-14 4 2
WIRE GROUP COLOR DESCRIPTIONS
176-M67 YL-18 1673542 1636803 299-A72 BK-16 115-A95 RD-14

OUTPUT
1

INPUT
191-M20 WH-18 15A 176-J94 YL-16 168-J136 GN-12 168-J134 GN-14 191-CV3 WH-18-GXL 191-M20 WH-18 GROUND CIRCUIT
197-M64 GN-16 168-J135 GN-14 197-CV4 GN-18-GXL 2 197-M64 GN-16
G889-M21 GY-18 T979-CV2 YL-18-GXL 3 G889-M21 GY-18 116-A66 RD-10 116-A101 RD-14 WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS ON
+24V KEY SWITCH / FUSE 18 E540-CV5 PK-18-GXL 4 E540-M68 PK-18 116-A10 RD-10 G890-A93 PU-16 103-A98 YL-14
"MAGNET CONTROL PANEL" 5 176-M67 YL-18 116-A65 RD-14 +3 +1
GENERATOR POWER
197-CV7 GN-18-GXL 197-CV4 GN-18-GXL 176-CV6 YL-18-GXL
30A 168-J136 GN-12 197-CV1 GN-18-GXL 116-A88 RD-14 MAGNET CONTROLER CIRCUIT
168-J134 GN-14 GENERATOR MONITOR CIRCUIT
168-J135 GN-14
E540-M68 PK-18 176-CV6 YL-18-GXL 201-A24 BK-18 MACHINE CONTROL CIRCUIT
176-J94 YL-16 201-A61 BK-16 201-A108 BK-18
MAGNET LOCKOUT RELAY 191-CV3 WH-18-GXL 201-A62 BK-16 201-A109 BK-18 CAT DATA LINK
1613128 E540-CV5 PK-18-GXL 201-A63 BK-16 201-A113 BK-14
201-A106 BK-16 103-A67 YL-14 CAN DATA LINK A
168-J134 GN-14 103-A98 YL-14 GENERATOR GROUND
168-J135 GN-14 1 176-CV6 YL-18-GXL 176-J94 YL-16 111-A41 RD-14
E540-M68 PK-18 2 E540-CV5 PK-18-GXL 168-J135 GN-14 111-A87 RD-14
3 197-CV7 GN-18-GXL T979-CV2 YL-18-GXL 168-J134 GN-14 115-A68 RD-14 OTHER COLOR DESCRIPTIONS
4 115-A95 RD-14 A-C8
5 191-CV3 WH-18-GXL 205-A39 BK-14 1552267 HIGHWAYS
A771-M45 PU-18 CV-C3 201-A113 BK-14 201-A31 BK-14 205-A70 BK-14 A K900-A78 YL-18
J992-F50 YL-18 1936887 201-A114 BK-14 B K990-A80 GN-18
J995-M69 PU-18 A-C9 A-C12 C 234-A92 BK-18 A-C7
103-A17 YL-14 1552267 1552267 9W1951
103-A20 YL-14 A K900-A21 YL-18 A 110-A105 RD-18 A
CAN BUS RESISTOR
D A235-M46 BK-18
A235-M60 BK-18
A235-M61 BK-18 112-A29
205-A18
RD-14
BK-14 A-C11
B
C
K990-A1 GN-18
234-A57 BK-18
B
C 1743016
201-A85 BK-18
234-A92 BK-18
B
C D
201-A114 BK-14 1552267 (120 OHM) 944-A83 OR-18 D SERVICE TOOL
201-A56 BK-16 201-A7 BK-18 K900-A77 YL-18 A A 945-A84 BR-18 E CONNECTOR
201-A85 BK-18 K990-A79 GN-18 B B K990-A80 GN-18 F
201-A107 BK-18 234-A91 BK-18 C A-C10 C K900-A78 YL-18 G
1552267 H
110-A105 RD-18 A K900-A97 YL-18 TEE 1 J
202-A53 BK-16 201-A85 BK-18 B K990-A2 GN-18 1330970

T979-CU11 YL-18-GXL
H462-CU6 OR-18-GXL
234-A91 BK-18 C 234-A99 BK-18

F458-CU1 GN-18-GXL
F459-CU2 WH-18-GXL
F456-CU3 PK-18-GXL
H464-CU4 GY-18-GXL
H463-CU5 BU-18-GXL
H461-CU7 WH-18-GXL
F431-CU8 YL-18-GXL
F430-CU9 GN-18-GXL
197-CU10 GN-18-GXL
MACHINE CTRL A4M1 234-A99 BK-18
J992-F50 YL-18

A235-M61 BK-18

A771-M45 PU-18

E540-M68 PK-18
J995-M69 PU-18

168-J134 GN-14
168-J135 GN-14
3045682 202-A28 BK-16 202-A53 BK-16 944-A83 OR-18 TEE 2
202-A54 BK-16 945-A84 BR-18 1330970
K900-A77 YL-18
54 GENERATOR ENABLE SWITCH (NO)
55 GENERATOR ENABLE SWITCH (NC)

J 2 MAGNET CONTROL PANEL K900-A97 YL-18 234-A99 BK-18

205-A34 BK-14 K990-A2 GN-18 K900-A97 YL-18
K990-A79 GN-18 K990-A2 GN-18
110-A105 RD-18 110-A105 RD-18
63 SWITCHES RETURN (GND)
13 MAGNET LOCKOUT RELAY

36 RH JS/TRIGGER BUTTON

205-A34 BK-14 205-A18 BK-14 201-A85 BK-18 201-A85 BK-18

205-A55 BK-16 205-A39 BK-14 944-A83 OR-18 944-A83 OR-18
F-C3 M-C14 M-C15 J-C22 CU-C1 205-A112 BK-16 205-A70 BK-14 945-A84 BR-18 945-A84 BR-18
1288951 1211168 1288951 2388245 3E5179 BOARD CIRCUIT
116-A66 RD-10

10
11
12
3082168
10
11
12
13
14
15
16
17
18
19
20
21
1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2

1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9

AK-C6 AK-C7 AK-C8 CX-C2 EA-C2 POWER RESISTOR 1 A272-A8 BK-16 A272-A15 BK-16

115-WA1 RD-10
121-WC1 BU-10
1114815 1027964 1114815 2388246 1552252 1735462 A272-A19 BK-16 COLOR ABBREVIATIONS
(1.5 OHM)
A235-AK10 BK-18
J992-AK46 YL-18

A771-AK23 PU-18

E540-AK15 PK-18
J995-AK49 PU-18
RESISTOR1
116-A66 RD-10 103-A111 YL-16 5K OHM SYMBOL DESCRIPTION ABBREV COLOR
110-A104 RD-16
115-A35 RD-10 111-A69 RD-14 944-A76 OR-18 944-A83 OR-18 A-C3
111-A96 RD-14 944-A81 OR-18 1552252 RESISTOR2
CIRCUIT CONNECTED RD RED
115-A35 RD-10 162-A23 RD-16-KYNAR 1 5K OHM

T979-EA11 YL-18-GXL
F458-EA1 GN-18-GXL
F459-EA2 WH-18-GXL
F456-EA3 PK-18-GXL
H464-EA4 GY-18-GXL
H463-EA5 BU-18-GXL
H462-EA6 OR-18-GXL
H461-EA7 WH-18-GXL
F431-EA8 YL-18-GXL
F430-EA9 GN-18-GXL
197-EA10 GN-18-GXL
168-CX01 GN-14-GXL
168-CX02 GN-14-GXL
116-A65 RD-14 207-A22 BK-16-KYNAR 2 WH WHITE
12
14
15
16

33
34
35
37
38
39

51
52
53

56
57
58
59
60
61
62
64
65

CIRCUIT NOT CONNECTED

115-A35 RD-10 116-A66 RD-10 163-A27 WH-16-KYNAR 3
C K-C2 C
HCR LINKAGE

HCR LINKAGE
115-WA1 RD-10 116-A88 RD-14 945-A82 BR-18 945-A84 BR-18 111-A52 RD-14 4 RESISTOR3 D5 OR ORANGE
1471446 163-A27 WH-16-KYNAR 945-A90 BR-18 112-A29 RD-14 5 5K OHM
ELECTRICAL CONNECTION TO
1 5KE36C MACHINE STRUCTURE
POWER RESISTOR 2
A235-K158 BK-18

201-A56 BK-16 110-A30 RD-14 6

E540-K59 PK-18

J995-K85 PU-18
J992-K86 YL-18
A771-K75 PU-18

1603596 201-A31 BK-14 7

YL YELLOW
202-A53 BK-16 D1 D6 INTERNAL ELECTRICAL CONNECTION
(1 OHM) 202-A54 BK-16 C905-A32 OR-16 8 1 5KE36C TO SURFACE OF COMPONENT
205-A55 BK-16 C905-A9 OR-16 C905-A32 OR-16 F457-A33 BR-18 9 MUR3060PTG PK PINK
205-A112 BK-16 C905-A64 OR-16 10 CONNECTOR
BK BLACK
A235-AK10 BK-18

E540-AK15 PK-18

J995-AK49 PU-18
A771-AK23 PU-18

J992-AK46 YL-18

234-A99 BK-18 205-A34 BK-14 11 D7

307-A100 OR-18 116-A101 RD-14 12 5KP30A
944-A76 OR-18 163-A27 WH-16-KYNAR DROPOVER CURRENT H# CIRCUIT GROUPING DESIGNATION GY GRAY
945-A90 BR-18 234-A91 BK-18 SW1 D2
F456-A49 PK-18 234-A99 BK-18 1 5KE36C ATCH WIRE, CABLE, COMPONENT
PU PURPLE
F458-A50 GN-18 415-A38 GN-18 VBM
F459-A51 WH-18 F457-A33 BR-18 2918372 BR BROWN
G465-A44 PK-18 C903-A12 BU-16 D3 SPLICE
H461-A45 WH-18 J984-A25 PK-18 D4 MUR3060PTG VOLTAGE GN GREEN
CX-C1 H462-A46 OR-18 J985-A16 GY-18 1N5404RLG BAND
AK-C13 EA-C1 H463-A47 BU-18 K900-A77 YL-18 MONITOR
BLADE, SPADE, RING OR SCREW
2144208 2388245 1552252 TERMINAL BU BLUE
H464-A48 GY-18 K900-A97 YL-18 6 5 4 3 2 1
12
13
14
15
16
17
18
19
20

28

51
52
53
54
55
56
57

69
70

10
11
12
1
2

1
2

K900-A97 YL-18 K990-A2 GN-18

1
2
3
4
5
6
7
8
9
K-C15 CW-C3 CY-C2
1471445 2388246 3E5179 K990-A2 GN-18 K990-A79 GN-18
N839-A42 GN-18 IDENT PART NO. SH LOC DESCRIPTION NOTE
A235-K158 BK-18

N840-A43 PK-18 199-A5 RD-16-KYNAR

E540-K59 PK-18

J992-K86 YL-18

J995-K85 PU-18
A771-K75 PU-18

T979-CY11 YL-18-GXL
F458-CY1 GN-18-GXL
F459-CY2 WH-18-GXL
F456-CY3 PK-18-GXL
H464-CY4 GY-18-GXL
H463-CY5 BU-18-GXL
H462-CY6 OR-18-GXL
H461-CY7 WH-18-GXL
F431-CY8 YL-18-GXL
F430-CY9 GN-18-GXL
197-CY10 GN-18-GXL
R807-A102 WH-16 112-A29 RD-14 415-A38 GN-18 HARNESS AS.
168-CW3 GN-14-GXL
168-CW4 GN-14-GXL

T976-A110 YL-16 161-A13 RD-16-KYNAR 201-A7 BK-18 198-A6 RD-16-KYNAR A 288-3749 1 E-8 HARNESS AS (MAIN CONTROL CIRCUIT) A
162-A23 RD-16-KYNAR
206-A14 BK-16-KYNAR C903-A12 BU-16 C 180-7047 1 D-6 HARNESS AS (24VDC POWER CIRCUIT) A
207-A22 BK-16-KYNAR SVR F 252-6614/319-3806 1 F-11 HARNESS AS (CAB - BASIC) B
1603604
161-A13 RD-16-KYNAR J 266-4155/319-3805 1 E-10 HARNESS AS (BASE FUSE & RELAY) B
201-A7 BK-18 161-A13 RD-16-KYNAR 5 1 SAMPLE 13 9 199-A5 RD-16-KYNAR K 278-5283/314-2874 1 C-12 HARNESS AS (CHASSIS ELECTRONIC) B
CY-C1 A-C1 112-A29 RD-14 206-A14 BK-16-KYNAR VOLTAGE
1552252 3E7990 161-A13 RD-16-KYNAR A272-A15 BK-16 206-A14 BK-16-KYNAR 8 4 RELAY 14 12 198-A6 RD-16-KYNAR M 252-6611 1 F-12 HARNESS AS (CONSOLE LH + RH) B
F458-CY1 GN-18-GXL 1 F458-A50 GN-18 162-A23 RD-16-KYNAR 415-A38 GN-18 AK 287-6034 1 C-10 HARNESS AS (ELECTRONIC - HCR LINKAGE) B
B F459-CY2 WH-18-GXL
F456-CY3 PK-18-GXL
2
3
F459-A51 WH-18
F456-A49 PK-18
206-A14 BK-16-KYNAR
207-A22 BK-16-KYNAR
C903-A12 BU-16
CU 329-1266 1 E-9 HARNESS AS (GENERATOR - CAB) C
B
H464-CY4 GY-18-GXL 4 H464-A48 GY-18 A272-A15 BK-16 CV 329-1267 1 D-11 HARNESS AS (GENERATOR - CAB/FUSE & RELAY) C
H463-CY5 BU-18-GXL 5 H463-A47 BU-18
H462-CY6 OR-18-GXL 6 H462-A46 OR-18 CW 329-1271 1 F-1 HARNESS AS (GENERATOR - UPPER FRAME) C
H461-CY7 WH-18-GXL 7 H461-A45 WH-18 307-A100 OR-18 CX 329-1280 1 C-9 HARNESS AS (GENERATOR - HCR LINKAGE) C
F431-CY8 YL-18-GXL 8 205-A55 BK-16 F456-A49 PK-18 110-A103 RD-18
F430-CY9 GN-18-GXL 9 163-A27 WH-16-KYNAR F458-A50 GN-18 201-A109 BK-18 CY 329-1270 1 B-8 HARNESS AS (GENERATOR - UPPER FRAME) C
197-CY10 GN-18-GXL 10 307-A100 OR-18 F459-A51 WH-18 201-A107 BK-18 EA 329-1279 1 C-9 HARNESS AS (GENERATOR - HCR LINKAGE) C
11 N839-A42 GN-18 G465-A44 PK-18 J985-A16 GY-18 CT2 CT1
GENERATOR T979-CY11 YL-18-GXL 12 N840-A43 PK-18 H461-A45 WH-18 3045312 3045304 EF 329-1275 1 A-9 HARNESS AS (GENERATOR) C
1444361 H462-A46 OR-18 (FWD CURRENT TRANSDUCER) (REV CURRENT TRANSDUCER) CABLE AS.
H463-A47 BU-18
H464-A48 GY-18 EG 329-1272 1 A-12 CABLE AS (MAGNET ADAPTER) [240VDC] C
P2-BR18 1 P2-EF1 GN-18-GXL EF-C1 CY-C4 CY-C3 A-C2 N839-A42 GN-18
3E3382 1552273 1726062 1726063 EH 329-1273 1 A-10 CABLE AS (GENERATOR - CONTROL BOX) [240VDC] C
(Dimensions: 39 inches x 28 inches)

N840-A43 PK-18 110-A40 RD-18 110-A40 RD-18 (S +) 1 1 (S +) 110-A103 RD-18

P1-BR18 1 P1-EF2 WH-18-GXL P2-EF1 GN-18-GXL 1 P2-CY12 GN-18-GXL P2-CY12 GN-18-GXL 1 201-A56 BK-16 R807-A102 WH-16 201-A108 BK-18 201-A108 BK-18 (S r) 2 2 (S r) 201-A107 BK-18 EJ 329-1277 1 A-11 CABLE AS (CONTROL BOX - MAGNET) [240VDC] C
P1-EF2 WH-18-GXL 2 P1-CY13 WH-18-GXL P1-CY13 WH-18-GXL 2 G465-A44 PK-18 T976-A110 YL-16 201-A24 BK-18 201-A24 BK-18 (O r) 3 3 (O r) 201-A109 BK-18
GENERATOR CABLE-WIRE CONNECTOR LIFTING DROPPING 3 111-A69 RD-14 J984-A25 PK-18 (O +) 4 4 (O +) J985-A16 GY-18 XG 288-3745 1 A-4 CABLE AS (MAIN FUSE TO POSITIVE STUD) A
F2-BK10 1 F2-EF7 RD-10 F2-EF3 RD-16-GXL F2-CY14 RD-16-GXL F2-CY14 RD-16-GXL 3 J984-A25 PK-18
TERMINAL COLOR TERMINAL POLARITY POLARITY F2-EF7 RD-10 F2-EF4 RD-16-GXL 4 F2-CY15 RD-16-GXL F2-CY15 RD-16-GXL 4 111-A96 RD-14 WIRE AS.
A1 (F1) WHITE (BLUE) FEMALE POSITIVE NEGATIVE F1-BK10 1 F1-EF8 BU-10 F1-EF8 BU-10 F1-EF5 BU-16-GXL 5 F1-CY16 BU-16-GXL F1-CY16 BU-16-GXL 5 116-A65 RD-14 BASE FUSE WA 288-3743 1 C-8 WIRE AS (RESISTOR CROSSOVER 1) A
F1-EF6 BU-16-GXL 6 F1-CY17 BU-16-GXL F1-CY17 BU-16-GXL 6 116-A88 RD-14 C905-A9 OR-16 307-A100 OR-18 1735433
S1 (F2) BLACK (RED) MALE NEGATIVE POSITIVE H862-CY18 GY-18-GXL 7 202-A53 BK-16 A272-A8 BK-16 F456-A49 PK-18 POWER STUD WC 288-3741 1 C-8 WIRE AS (RESISTOR CROSSOVER 2) A
A1-BK10 WH-EH1 1955831 8 R807-A102 WH-16 F458-A50 GN-18 2636556
70
G 9 202-A54 BK-16 F459-A51 WH-18 162-A23 RD-16-KYNAR 165-XG1 RD-2 WH-EH1 1955831 WH-EH1 1955831 BK-EJ2 1955831
A2-BK10 T976-CY19 YL-18-GXL 10 T976-A110 YL-16 G465-A44 PK-18 161-A13 RD-16-KYNAR
S2-BK10 CBL-GENERATOR 2XAWG6
230V GENERATOR SOL CY-C5 F711-CY20 GN-18-GXL 11 K900-A97 YL-18 A B H461-A45 WH-18 WH-EJ1 1955831
S1-BK10 BK-EH2 1955831 3347445 1552269 F712-CY21 GY-18-GXL 12 K990-A2 GN-18 115-A11 RD-10 H462-A46 OR-18 WH-EJ1 1955831 WH-EJ1 1955831 NOTE A: INCLUDED IN MAGNET CONTROL PANEL GROUP
1 T976-CY19 YL-18-GXL 13 103-A111 YL-16 6 4 H463-A47 BU-18
2 H862-CY18 GY-18-GXL 14 205-A112 BK-16 H464-A48 GY-18 GND STUD NOTE B: STANDARD MACHINE HARNESS
BOOST RELAY 2636557
15 944-A76 OR-18 1603603 N839-A42 GN-18 BK-EH2 1955831 NOTE C: ATTACHMENT MACHINE HARNESS
KENR9563

F711-CY20 GN-18-GXL 16 945-A90 BR-18 N840-A43 PK-18 207-A22 BK-16-KYNAR BK-EJ2 1955831 BK-EJ2 1955831
F712-CY21 GY-18-GXL 17 234-A99 BK-18 R807-A102 WH-16 206-A14 BK-16-KYNAR BK-EH2 1955831 BK-EH2 1955831 WH-EH1 1955831
CY-C6 H862-CY18 GY-18-GXL 18 110-A104 RD-16 116-A10 RD-10 T976-A110 YL-16
3E3370
A (CAN BUS) A F711-CY20 GN-18-GXL
T976-CY19 YL-18-GXL A
TO HARNESS B F712-CY21 GY-18-GXL
ENGINE C
E-C04

EG-C1 EJ-C1
CBL-ADAPTER 2XAWG6 3360679 3360678 CBL-MAGNET 2XAWG6
WH-EG1 1955831 1 WH-EJ1 1955831
MAGNET BK-EG2 1955831 2 BK-EJ2 1955831

COMPONENTS ARE SHOWN INSTALLED ON A FULLY OPERABLE

MACHINE WITH KEY SWITCH AND ENGINE OFF

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

DETAILED CIRCUIT SCHEMATIC (INPUTS TO MAGNET CONTROLLER) DETAILED CIRCUIT SCHEMATIC (OUTPUTS FROM MAGNET CONTROLLER)
THIS SCHEMATIC IS FOR THE M318D MH & M322D MH MAGNETIC CONTROLER
PART NUMBER: 329-1282, CHANGE: 00A, VERSION: (EY)
DISCONNECT SWITCH SSR 170 1.0 Ohm
3 4 30A
(LIFT RELAY) (POWER RESISTOR 2) Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
1 2
+24V DC
(KEY SWITCH)
151-GN 120-YL 103-RD 115-RD
F1
GENERATOR MONITOR (CAB) in neutral and with parking brake set.
121-BU
SSR 172 OUTPUTS 6
OVER 75% DUTY CYCLE Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
30 Page,

200-BK (DROP RELAY) 1K

5 6 115-RD 1.5 Ohm GENERATOR
1 2 7
(POWER RESISTOR 1) WINDINGS 304-5687 GEN HOT
116-RD 1K
116-RD GENERATOR ENABLE SWITCH 1 4
SSR 173 CAT DATA LINK (+) 10 944-OR MAGNET ON
(DROP RELAY) F2 13 1K
BATTERY (-)
2 1 4 6 CAT DATA LINK (-) 20 945-BR 5
BATTERY (-) 23 OVER/UNDER VOLTAGE
SWB 2 24 1K
30A
208-BK 205-BK 111-RD SWB 3 25
SSR 171 BOOST RELAY SWG 3 28
(LIFT RELAY) CONTACT 116-RD SWG 4 32
SWG 5 33 944-OR
2 1 SWG 6 34
205-BK 111-RD 35
SWG 7
4 12 ANALOG ACTIVE 1 36
ANALOG ACTIVE 2 37 945-BR
111-RD BATTERY (+) 38 110-RD 110-RD
BATTERY (+) 39
SWG 8 40 GENERATOR ENABLE
BATTERY (+) 46 202-BK SOLENOID
BATTERY (+) 47
PWM DRIVER + 1 48 T976-YL SOFT START SOLENOID
PCB (PWM DRIVER + 2) N/A 49 R807-WH (OUTPUT NOT USED)
F457-BR PWM DRIVER RETURN 1-4 50 202-BK
11 BATTERY (-) 56 201-BK
D1 PWM DRIVER + 5 58 H461-WH
PWM DRIVER + 6 59 H462-OR C905-OR
5 6 PWM DRIVER + 7 61 H463-BU
112-RD 110-RD 62
PWM DRIVER + 8 H464-GY BOOST RELAY
111-RD D7 205-BK 20A BATTERY (-) 70
PCB B A
9 A272-BK
SW1
201-BK
D2 205-BK
GENERATOR ENABLE SWITCH
307-OR INPUTS 2A ON/OFF STD 1 2
2A ON/OFF FAST 2 3
LOAD RETURN 1 4
C905-OR
G889-GY
A272-BK
G889-GY
D3 2A ON/OFF STD 3 5 C903-BU SAMPLE VOLTAGE
8 304-5687 2A ON/OFF STD 4 6 G890-PU RELAY
201-BK LOAD RETURN 2 8 299-BK 14 13
307-OR 1 GENERATOR ENABLE SWITCH
D4 10 CAT DATA LINK (+) CAN A+ 67 K900-YL
7 201-BK 13 BATTERY (-) CAN A- 68 K990-GN
20 CAT DATA LINK (-) CAN A SHIELD 69 234-BK C903-BU
(MAGNET LIFT INPUT NOT USED, SIGNAL TRANSMITTED VIA CAN)
23 BATTERY (-) G890-PU
RH JOYSTICK/MAGNET LIFT SW N839-GN N839-GN 24 N/A (SWB 2)
N840-PK 25 SWB 3 SSR 170
LH JOYSTICK/MAGNET DROP SW N840-PK G465-PK 28 SWG 3 LIFT RELAY
4 3
F457-BR 32 SWG 4
PCB F458-GN 33 SWG 5
F459-WH 34 SWG 6
THERMOSTAT P1 G465-PK F456-PK 35 SWG 7
SWITCH J984-PK 36 ANALOG ACTIVE 1 299-BK G890-PU
P2 201-BK
J985-GY 37 ANALOG ACTIVE 2
GENERATOR A1 A1 110-RD 38 BATTERY (+) SSR 171
STATOR S1 S1 39 BATTERY (+) LIFT RELAY
415-GN 40 SWG 8 4 3
198-RD 46 BATTERY (+)
199-RD 110-RD 47 BATTERY (+)
48 PWM DRIVER + 1
1 49 PWM DRIVER + 2 299-BK G889-GY
2 50 PWM DRIVER RETURN 1-4
56 BATTERY (-) SSR 172
VOLTAGE BAND 3 201-BK 58 PWM DRIVER + 5 DROP RELAY
MONITOR 4 415-GN 59 PWM DRIVER + 6 4 3 110-RD
5 61 PWM DRIVER + 7
62 PWM DRIVER + 8
6 201-BK 70 BATTERY (-) 201-BK
299-BK
REV CURRENT K900-YL
TRANSDUCER (CT1) 944-OR
C905-OR 2 2A ON/OFF STD 1 SSR 173
1 110-RD 3 2A ON/OFF FAST 2 K990-GN DROP RELAY
2 201-BK 4 LOAD RETURN 1 4 3 945-BR
3 201-BK 5 2A ON/OFF STD 3
6 2A ON/OFF STD 4 234-BK
4 J985-GY 8 LOAD RETURN 2
FWD CURRENT 67 CAN A+ A
TRANSDUCER (CT2) 68 CAN A- B
69 CAN A SHIELD C
1 110-RD
D SERVICE TOOL
2 201-BK E
3 201-BK F CONNECTOR
4 J984-PK G
H
J
GENERATOR MONITOR (CAB)

9 1 F458-GN
163-WH GROUND FAULT+ Dial 2 F459-WH
SW
3 F456-PK
GROUND FAULT-
A1
S1

C905-OR

162-RD

3 PCB 1 1
9 70A
5K 161-RD 165-RD
SAMPLE VOLTAGE 5
12w RELAY CONTACT 1 POWER STUD
5K
12w

4
5K
12 GROUND STUD
12w 206-BK
SAMPLE VOLTAGE 8
RELAY CONTACT 2
2
207-BK