Cat.dcs.Sis.controller

RENR9516-01 February 2007

A2

F2 A1

W I RE GROUP COLOR DESCR I PTIONS WI RES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY

SWI TCH I S ON

WI RES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY

SWI TCH I S ON.

AND CONTROL MAI N SWI TCH ON.

GROUND CI RCUI T. MACHI NE CONTROL CI RCUI T. GENERATOR 240V.

Wheeled Excavator Magnetic Controller Electrical System

GENERATOR C ONNECTI NG P OI NTS

M318C: BEB2001-UP BOX_GP_GE NERATOR 2330968 GROUND

GND

GROUND

BK-16

1 4 6 - A 15

G Y- 1 6

13

CURRENTMONITORING

4 3 9 - A0 6

1 4 7 - A 13

PU-16

1 4 3 - A 11

BR-16

2 0 0 - A0 3

BK-16

1 4 5 - A 10

BU-16

1 4 3 - A1 1

BR-16

H 4 17 - A 0 7

O R- 1 8

H 4 17 - A 0 7

7

I NDUCTOR VOLTAGE

+ 24

2 0 0 - A 03 8

14

CURRENTMONITORING

YL-18 O R- 1 8

4 3 9 - A0 6

YL-18

H 4 17 - A 0 7

O R- 1 8

12 5

CONTROL-LAMP 11

VOLTAGEMONITORING

4

I NDUCTOR VOLTAGE

CONTROL LAMP +

1 4 3 - A 11

BR-16

1 4 3 - A 12

BR-16

1 4 4 - A 14

G N- 1 6

3

4 3 9 - A 06

YL-18

2

191-A04

WH-18

1

1 9 0 - A 05

PK-18

NOT CONNECTED

10

FAULT ALARM BUTTONON/OFF

M-C03 1552273

GND_FR AME

A-C01 3E3364

M-C06 1552269

1

BR

2

BK

3

BU

4

GN

191-A04

WH-18

1

191- M13 W H-18

5

YL

1 9 0 - A0 5

PK-18

2

283-M14 BK-18

6

GY

1 9 7 - A0 1

G N- 1 6

1 4 3 - A1 2

BR-16

1 4 5 - A1 0

BU-16

1 4 6 - A1 5

G Y- 1 6

1 4 7 - A1 3

PU-16

1 4 4 - A1 4

G N- 1 6

SWI NG BRAKE (REAR-RH) HORN FWD ( REAR-LH) MAGNET ON/OFF ( FRONT)

9

FAULT ALARM BUTTONON/OFF X1

1 9 7 - A 01

BREAKER F1 ( 10A)

G N- 1 6

M322C MH: H2F128-UP H2G163-UP

J OYSTI CK_LH 2412488

6

VDC OUT PUT

VOLTAGEMONITORING

M322C: BDK2001-UP BDY2001-UP H2E247-UP

CONTROL_L AMP 2421974

For Machines with the 12.5kW Generator © ©2007 Caterpillar All Rights Reserved

GENERATOR 2354352

Printed in U.S.A.

Electrical Schematic Symbols And Definitions

BR

F1

1 4 4 - A 14

G N- 1 6

1 4 4 - A1 4

G N- 1 6

BR

F2

1 4 7 - A 13

PU-16

1 4 7 - A1 3

PU-16

BR

A2

1 4 6 - A 15

G Y- 1 6

1 4 6 - A1 5

G Y- 1 6

1 4 5 - A 10

BU-16

1 4 5 - A1 0

BU-16

BU-C03

C B L _0 5

1 4 3 - A1 2

BR-16

BR-C04

C B L _0 5

1 9 7 - A0 1

G N- 1 6

G

BR

A1

240V

BR

B2

1 4 3 - A 12

3

3 4

1

4

5

T

2

Pressure Symbol

5

Temperature Symbol

BR-16

B K 1- C 0 1

C B L _0 5

B K 2- C 0 2

C B L _0 5

G N- 1 6

Level Symbol

Circuit Breaker Symbol

Flow Symbol

Symbols And Definitions CBL_MAGNET B K 1- C 0 1 B K 2- C 0 2

1 9 7 - A 01

Symbols 1 2

C B L _0 5

B K 1- C 0 1

C B L _0 5

1

C B L _0 5

B K 2- C 0 2

C B L _0 5

2

BU-C03

C B L _0 5

3

BR-C04

C B L _0 5

4

BU-C03

CBL_05

BR-C04

CBL_05

Fuse - A component in an electrical circuit that will open the circuit if too much current flows through it. Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it.

MAGNET

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.

5 Ground (Wired): This indicates that the component is connected to a grounded wire. The grounded wire is fastened to the machine.

240VDC_CONNECTOR 2339606

GENERATOR_SOL 1957747

A-C02 3E3370

A-C03 1552269

E 9 8 4 - A0 8

1

E 9 8 4 - A0 8

BU-18

H804-A09

2

H 8 04 - A 0 9

G N- 1 8

1 9 7 - A 01

J 992-F07

A

GN-18

B

G N- 1 6

C

F-C04 1552252

7 5

A 23 5 - F 3 8

BK-18

6 1 2

J 9 92 92 - F0 7

3 197-F125

E 9 8 4 - K5 6

BU-18

25

GENERATOR_SOL

H 8 04 - K 1 2 0

G N- 1 8

13

SOLENOI D_GROUND

A 23 5 - K 1 3

BK-18

9

J 9 9 2 - K 26

YL-18

29

YL -1 -1 8

G N- 1 6

F-C22 1117898

K-C08 3E5179

K-C12 1552252

J1

GENERATOR_ SWI TCH

2 4 3 - 55 9 1

CHG- LEVEL

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 i ndication to the gauge of the temperature or pressure.

T

0A

DATE

Relay (Magnetic Switch):A 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.

27. 07. 04

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.

TO FUSE " 4-07"

MAGNETICLATCHSOLENOID - 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.

1 2

3

3

4

4

A

2 43 43 - 55 93 93

5

5

C

2 33 - 9 6 0 8

C- 4 C-

6

6

F

2 4 1 - 87 87 2 0

A- 5

7

7

J 9 92 92 - K2 6

YL -1 YL -1 8

YL-16

9

1 7 6 - K 20 0

YL-16

197-F125

G N- 1 6

10

1 9 7 - K 19 9

G N- 1 6

A 23 5 - F 3 8

BK-18

A 23 5 - K 1 3

BK-18

12

1 7 66- J 5 5

( 15A)

2

Y L- 1 6

I DENT

PART NO.

LOC D- 5

J

2 41 41 - 87 40 40

B-2

8

K

X XX - XX XX

B-3

9

M

2 41 -8 -8 71 8

F- 2

DESCRI PTI ON

HARNE SS SS AS ( GE NE RATOR) CAB LE ( B ULK) HARNES S AS ( CAB ) HARNE SS SS AS ( B OX- J U NC TI ON) H AR NE S S AS ( C HAS S I S - E LE LE CT CTR ONI C ) HARNES S AS ( CONS OLE LH)

10

11 YL-16

J -C05 3E5179

1

8 176-F122

176-F122

P ART NO.

SWI TCH_GR OUND

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.

SCHEMATI C FOR 12, 5 KW GENERATOR S ET

J2

G N- 1 6

YL-18

GENERATOR_SW 1939066

4

1 9 7 - K 19 9

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

MACHI NE_CONTROL_MODUL_ ( MCM) 1890077

K-C37 1552267

BU-18

11 1 7 6 - K 20 0

YL-16

NOTE

Harness And Wire Symbols

B B A

Pn i

S oc ke t

WireColor

Wire, Cable, or Harness Assembly Identification

A

A

325-PK-14

A/ C A

NOTE B:

ATTACHMENT

NOTE C: M313C FCR-M322C FCR = 241-8746 M318C HCR/M322C HCR = 241-8738 M3 1 3C 3C - M3 1 8C 8C = 2 4 11- 8 7 3 0 M3 2 2 C = 2 4 1 - 87 87 3 4

Component PartNumber

105-9344 Receptacle

SingleWire Connector

CircuitNumber Identification

Wire Gauge Plug

NOTE A: S TANDARD

12

Fuse

AA 1

GroundConnection

1 2

Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.

2

200-BK-14 Pin or Socket Number

1 2

Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.

) s e h c n i 4 2 x s e h c n i 4 3 : s n o i s n e m i D ( , e g a P 6 1

1 0 6 1 5 9 R N E R

R1

R2 L 10

9

8

7

6

5

4

3

2

R3

R2M

1

CONTROL BOX 2330968

H

3

1 2

K7

K4

SCALE 1-6

SCALE 1-3

H

R1 2425576

K2 ADJ USTED TO 250-260VDC AT THE POWER CONNECTOR WI THOUT LOAD

A1 2425904

K6

014 RD-16

K3

013 RD-16

017 RD-16

G

SCALE 1-6

G K7 2425586

K6 1

5

2

6

3

7

4

2425586

8

K3

K4 1

5

2

6

3

7

4

2421309

8

1

5

2

6

3

7

4

K2

2476937

8

1

5

4

K1

2425581

8

1

5

4

13

9

10

11

12

14

13

9

10

11

12

14

13

9

10

11

12

13

14

9

12

13

14

9

12

13

240VAC

019 RD-16

2425581

8

1

5

4

8

1

2 14

K1

9

14

1

R2L 2425575 2. 2 OHM

2

1

R2M 2425575 2.2 OH M

2

R3 2425577 1 0 . 0 OH M

12 020 RD-16

S1

015 RD-16 018 RD-16

R4

1

016 RD-16

A

2

3

4

5

6 7

8

013 RD-16

B

014 RD-16

C

F1

9 10

1 1 12 13 13 1 4

9 10

1 1 1 2 13 1 4

015 RD-16

C1

D

F

D N G

F

016 RD-16

E

V4

K 01

K8

K9

K10

K11

017 RD-16

F

018 RD-16

V2

1

V1

2

3

4

5

6 7

8

V3

E

E 12

11

6 1 K B 2 1 0

6 1 U B 0 1 0

D

) s e h c n i 4 2 x s e h c n i 4 3 : s n o i s n e m i D ( , e g a P 6 1

1 0 6 1 5 9 R N E R

C

6 1 U P 5 2 0

6 6 6 6 1 1 1 1 - - - Y U U U G B P P 9 6 7 8 0 2 2 2 0 0 0 0

6 1 U B 0 1 0

1 B

A 0 1 1 5 F 8 5 5 2 4 2

A

9

6 1 Y G 1 2 0

6 1 U B 3 0 0

2

3

10

F F 1 M O A 4 R / L 5 A N 3 L O A 4 A N I 5 N 2 T O M L T R U T E T A U F B 1 X 9

1

F F M O B 1 4 R / L 5 A N 3 L O A 4 A N I 5 N 2 T O M L T R U T E T A U F B 1 X 10

2

6 1 K B 1 1 0

1 C 4 L 5 3 A 4 N I 5 2 M R E E E T R F 1 X

+ P M A L L O R T N O C

3

6 1 K B 4 0 0

6 1 K B 2 1 0

4

6 1 Y G 5 0 0

6 1 R B 2 2 0

5

6 6 1 1 - U U P B 8 6 2 0 0 0

6 1 R B 3 2 0

6

11

12

13

14

G N I R O T I N

G N I R O T T I U 1 N P F 4 O T L 5 M U 3 O A 4 T N I 5 N C 2 M E D R V R R 4 E T U 2 C + 1 X 13

G N I R O T I N

P 1 M E 4 O A L 5 M L 3 A 4 E L N I 5 G O 2 A R M R T T E L N T O O V C 1 X 12

4

5

6

6 1 K B 7 0 0

6 6 1 1 - Y Y G G 9 0 2 3 0 0

7

G N I E R G O A T T I L 1 N O D 4 O V L 5 M 3 R A 4 E O N I 5 G T 2 M A C T U R L D E T O N V I 1 X 11

10

6 1 K B 1 1 0

7

8

7

6 1 Y G 8 0 0

6 1 K B 7 0 0

4

3

6 1 K B

6 1 U B

4 0 0

3 0 0

2

1 6 1 U B 1 0 0

6 1 Y G 2 0 0

008 GY-16 007 BK-16

027 PU-16

006 BU-16

021 GY-16

005 GY-16

003 BU-16

004 BK-16

004 BK-16

003 BU-16

027 PU-16

005 GY-16

021 GY-16

030 GY-16

022 BR-16

022 BR-16

021 GY-16

006 BU-16

023 BR-16

022 BR-16

023 BR-16

025 PU-16

023 BR-16

007 BK-16

027 PU-16

043 BU-16

029 GY-16

030 GY-16

030 GY-16

026 BU-16

008 GY-16

029 GY-16

(A1) MAIN BOARD 6 1 U P 5 2 0

R2L

4

1

6 1 Y G 1 3 0

6 6 1 1 - Y Y G G

6 6 1 1 - Y Y G G

2 9 3 2 0 0

6 6 1 1 - Y Y G G

4 4 2 3 0 0

6 1 Y G

6 5 3 3 0 0

4 3 0

K8 1

A2

2

3

6 1 Y G 5 3 0

6 6 1 1 - Y Y G G 6 4 3 4 0 0

6 1 Y G

6 6 1 1 - U U B B

2 0 0

7 8 3 3 0 0

K9

2476931

3

2

4

7

5

6

2476931

3

2

4

7

5

6 6 1 1 - Y Y G G

K10 2476931

6

3

6 1 Y G

9 0 3 4 0 0

2

4

1 3 0

7

5

6 6 1 1 - U U B B

6 1 U B

8 6 3 2 0 0

1 0 0

K11 2476931

6

3

6 1 Y G

6 6 1 1 - U U B B

9 3 0

3 1 4 4 0 0

2

4

7

5

V3

1 7 4 3 0 0

S1 2361460

6

2

B

5

K4

12

9

14

13

B

6 6 1 1 - Y Y G G 2 3 3 3 0 0

6 1 Y G 4 4 0

8

1

8

1

8

1

8

1

6 1 R B 3 2 0

6 1 R B 2 2 0

6 1 U B 3 4 0

6 1 Y G 4 2 0

6 1 Y G 1 2 0

6 6 1 1 - Y Y G G 3 2 3 4 0 0

6 1 Y G 0 4 0

6 1 Y G 2 4 0

K6

1

4

5

8

9

B 6 1 Y G 0 3 0

021 GY-16

F

K1

E

7 2 0

4

D

K2

K7

6 1 U P

GND 8

C

1

8 6 6 1 1 - U U B B

R3

R2M

A

C

6 1 Y G 8 0 0

D N U O R G

R1

D DOOR 025 PU-16

K01 2 4 2 5 5 8 3 A1

1 X

5 6 1 Y G 5 0 0

026 BU-16

8

2 H 4 L 5 3 A 4 N I 5 D 2 N M U R O E T R G

6 6 1 U B 6 0 0

025 PU-16

GND

E G A T L 1 O G 4 O V L 5 M 3 R A 4 T O N I 5 N T 2 E C M R R U E R D T U N C I 1 X 14

9 6 1 Y G 9 0 0

V2 10

9

12

11

V1

C1 V4

8

12

7

6

5

4

3

2

13 14

K3

043 BU-16

R4

022 BR-16 023 BR-16 GNDCONTROLBOX

N AM E A1 C 1 F1 W I RE GROUP COLO R DESCRIPTI ONS

A

WI RES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY S WI T CH I S ON AND CONTROL MAI N SWI T CH ON.

GROUND CI RCUI T. GENERATOR 240V.

10

9

8

7

6

P ART NO. CHG- L EVEL

5

A

SCHEMATI C FOR 12. 5kW GENERATOR CONTROL BOX

WI RES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY S WI T CH I S ON.

4

3

2 33- 09 68 02A

2

1

F UN CT O I N Main Printed Circuit Board Fi el dA bs or pt oi nC ap ac ti or M ain B reaker

P AR T N O.

S TA ND AR D S ET TI NG

242-5904

-

242-5585

-

2 4 2- 5 58 3 2 42 -5 58 1

-

242-5581 2 4 7- 6 93 7

-

K01 K1

M a gn e tO n O / f fS w ti c hi n gR e al y F ei d l M ag ne it zni g R el ay

K2 K3

Drop R elay Dr V o tl a ge M o ni t or i ng R e al y ( N ot U s ed )

K4

D ro p T m i er R el ay

2 42 -1 30 9

K6 K7

TimeDelay Warning Relay (Not Used) B oo st T m i er R el ay

242-5586 2 42 -5 58 6

6 S (X1/S)/ SCALE 0-6 2 S ( X1 /S ) / S CA L E0 -6

K8

C ur re nt M on ti or n i g R eal y

2 47 -6 93 1

-

1 ,5 S ( X 1/ S) / S C AL E 0 -3

K9

C u r e nt O v er l oa d P r ot e ct i on R e al y

K10 K 11 R1

S y set m A c it v at i on S a e f t yR e al y R es et C on tr ol S a ef ty R el ay Excitation Voltage Variable Resistor

2 4 7- 6 93 1 2 47 -6 93 1 242-5576

Adjusted AfterMachine Installation

R 2L

Dr op R es si ot r- 1 Dr

2 42 5 - 57 5

-

R 2M R3

Dr op R es si ot r- 2

2 4 7- 6 93 1

2 42 5 - 57 5

-

-

F ei d l Ds i c ha rg e R es s i to r

2 42 -5 57 7

S1

Main S witc h

236-1460

-

V1 V2

Diode Diode

-

-

-

V3

Diode

-

-

V4

Diode

-

-

1

Cat.dcs.Sis.controller

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