RENR9516-01 February 2007

A2 A1

F2
WIRE GROUP COLOR DESCRIPTIONS
WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS ON AND CONTROL MAIN SWITCH ON. WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS ON. GROUND CIRCUIT. MACHINE CONTROL CIRCUIT. GENERATOR 240V.

GENERATOR CONNECTING POINTS

Wheeled Excavator Magnetic Controller Electrical System

M318C: BEB2001-UP
CONTROL_LAMP 2421974

BOX_GP_GENERATOR 2330968
GROUND GROUND CURRENT MONITORING INDUCTOR VOLTAGE CURRENT MONITORING + 24 VDC OUTPUT VOLTAGE MONITORING CONTROL-LAMP VOLTAGE MONITORING INDUCTOR VOLTAGE NOT CONNECTED CONTROL LAMP + FAULT ALARM BUTTON ON/OFF FAULT ALARM BUTTON ON/OFF X1 BREAKER F1 (10A) 9 1 10 2 3 11 4 12 5 13 6 14 7 GND 8

M322C: BDK2001-UP BDY2001-UP H2E247-UP

M322C MH: H2F128-UP H2G163-UP

200-A03 146-A15 147-A13 143-A11 145-A10 H417-A07 143-A11 143-A12 144-A14 439-A06 191-A04 190-A05 197-A01

BK-16 GY-16 PU-16 BR-16 BU-16 OR-18 BR-16 BR-16 GN-16 YL-18 WH-18 PK-18 GN-16

439-A06 H417-A07

YL-18 OR-18

439-A06 H417-A07

YL-18 OR-18

200-A03 143-A11

BK-16 BR-16 GND_FRAME M-C03 1552273 1 2 3 4 5 6

JOYSTICK_LH 2412488 SWING BRAKE (REAR-RH) HORN FWD (REAR-LH) MAGNET ON/OFF (FRONT)

A-C01 3E3364 191-A04 190-A05 WH-18 PK-18 1 2

M-C06 1552269 191-M13 WH-18 283-M14 BK-18

BR BK BU GN YL GY

For Machines with the 12.5kW Generator

2007 Caterpillar All Rights Reserved

Printed in U.S.A.

197-A01 143-A12 145-A10 146-A15 147-A13 144-A14

GN-16 BR-16 BU-16 GY-16 PU-16 GN-16

GENERATOR 2354352
BR BR BR F1 F2 A2

Electrical Schematic Symbols And Definitions

144-A14 147-A13 146-A15 145-A10 BU-C03 BR-C04 143-A12 BK1-C01 BK2-C02 GN-16 PU-16 GY-16 BU-16 CBL_05 CBL_05 BR-16 CBL_05 CBL_05 144-A14 147-A13 146-A15 145-A10 143-A12 197-A01 GN-16 PU-16 GY-16 BU-16 BR-16 GN-16 CBL_MAGNET

Symbols
1 2 5 3 4 3 4 5 1 2
T

240V

BR

B2

Symbols And Definitions

BK1-C01 CBL_05 BK2-C02 CBL_05 BU-C03 CBL_05 BR-C04 CBL_05 BK1-C01 BK2-C02 BU-C03 BR-C04 CBL_05 CBL_05 CBL_05 CBL_05 240VDC_CONNECTOR 2339606 1 2 3 4 5
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. 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. Ground (Wired): This indicates that the component is connected to a grounded wire. The grounded wire is fastened to the machine. Ground (Case): 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. 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. 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.

MAGNET

197-A01

GN-16

GENERATOR_SOL 1957747 1 2

A-C03 1552269 E984-A08 H804-A09 BU-18 GN-18

A-C02 3E3370 E984-A08 H804-A09 197-A01 BU-18 GN-18 GN-16 A B C

K-C37 1552267 E984-K56 H804-K120 197-K199 GN-16 A235-K13 J992-K26 BK-18 YL-18 BU-18 GN-18

MACHINE_CONTROL_MODUL_(MCM) 1890077 25 13 9 29 GENERATOR_SOL SOLENOID_GROUND SWITCH_GROUND GENERATOR_SWITCH

J2 J1

SCHEMATIC FOR 12,5 KW GENERATOR SET

PART NO. CHG-LEVEL DATE 243-5591 0A 27.07.04
T

J992-F07

YL-18 F-C04 1552252 1 2 3 4 5 6 7 8 9 10 11 12 K-C08 3E5179 K-C12 1552252 1 2 3 4 5 6 7 8 9 10 11 12 J-C05 3E5179

GENERATOR_SW 1939066 7 4 5 6 1 2 3 J992-F07 197-F125 GN-16 176-F122 197-F125 176-F122 YL-16 A235-F38 A235-F38 BK-18

TO FUSE "4-07" (15A) 176-J55 YL-16

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.

IDENT
A C F J K M

PART NO.
243-5593 233-9608 241-8720 241-8740 XXX-XXXX 241-8718

LOC
D-5 C-4 A-5 B-2 B-3 F-2

DESCRIPTION
HARNESS AS (GENERATOR) CABLE (BULK) HARNESS AS (CAB) HARNESS AS (BOX-JUNCTION) HARNESS AS (CHASSIS-ELECTRONIC) HARNESS AS (CONSOLE LH) NOTE C: M313C FCR-M322C FCR = 241-8746 M318C HCR/M322C HCR = 241-8738 M313C-M318C = 241-8730 M322C = 241-8734

NOTE
B B A A A/C A

Harness And Wire Symbols

Wire, Cable, or Harness Assembly Identification Pin Socket Wire Color Fuse Component Part Number

YL-18 YL-16 GN-16 BK-18

J992-K26 176-K200 197-K199 A235-K13

YL-18 YL-16 GN-16 BK-18 176-K200 YL-16

A
325-PK-14
Single Wire Connector Circuit Number Identification Wire Gauge Plug

AA 1
Receptacle

105-9344

F-C22 1117898

NOTE A: STANDARD NOTE B: ATTACHMENT

2
Ground Connection

200-BK-14
Pin or Socket Number

1 2

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

1 2

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

16 Page, (Dimensions: 34 inches x 24 inches)

BR

A1

Pressure Symbol

Temperature Symbol

Level Symbol

Flow Symbol

Circuit Breaker Symbol

RENR9516-01

R1

R2L

R2M

R3

10
CONTROL BOX 2330968

R1 2425576
1 A1 2425904 2 3 ADJUSTED TO 250-260VDC AT THE POWER CONNECTOR WITHOUT LOAD

K7

K4 K2 K1

SCALE 1-6 K6

SCALE 1-3

014 RD-16 013 RD-16 017 RD-16

K3

G
K7 2425586 1 5 2 6 3 7 4 8 K6 2425586 1 5 2 6 3 7 4 8 K4 2421309 1 5 2 6 3 7 4 8 K3 2476937 1 5 4 8 K2 2425581 1 5 4 8 K1 2425581 1 5 4 8 1 1 019 RD-16 1

SCALE 1-6

240VAC

2 14 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 14 9 12

R2L 2425575 2.2 OHM

R2M 2425575 2.2 OHM

R3 2425577 10.0 OHM

020 RD-16 015 RD-16 018 RD-16

S1 1 2 3 4 5 6 7 F1 9 10 11 12 13 14 GND 8

A
R4 C1

016 RD-16 013 RD-16 014 RD-16 015 RD-16 016 RD-16 017 RD-16 018 RD-16

B C

F
V4 V2 V1 V3

D E F

F
9 10 11 12 13 14

K01

K8

K9

K10

K11

1 2 3 4 5 6 7

E
12
012 BK-16 011 BK-16

E
11
010 BU-16

10
009 GY-16

9
008 GY-16

8
007 BK-16

7
006 BU-16

6
005 GY-16

5
004 BK-16

4
003 BU-16

3
002 GY-16

2
001 BU-16

025 PU-16

008 GY-16 007 BK-16 006 BU-16 005 GY-16 004 BK-16 003 BU-16 021 GY-16 022 BR-16 023 BR-16 025 PU-16 027 PU-16 030 GY-16 026 BU-16 029 GY-16 025 PU-16 027 PU-16 030 GY-16 021 GY-16 022 BR-16 023 BR-16 025 PU-16 043 BU-16 DOOR

026 BU-16 027 PU-16 021 GY-16 003 BU-16 004 BK-16 005 GY-16

R1

16 Page, (Dimensions: 34 inches x 24 inches)

022 BR-16 006 BU-16 023 BR-16 007 BK-16 029 GY-16 030 GY-16

(A1) MAIN BOARD

R2L R2M R3
C
1

GY-16 BU-16 PU-16 PU-16

010 BU-16

028 PU-16 006 BU-16

025 PU-16

021 GY-16

003 BU-16

011 BK-16

004 BK-16

012 BK-16

005 GY-16

022 BR-16

023 BR-16

007 BK-16

029 GY-16 030 GY-16

RENR9516-01

008 GY-16

008 GY-16

A 4 8 V3 1 5 9 13 K4

009 026 027 028

031 GY-16

037 BU-16 038 BU-16

024 GY-16 034 GY-16

036 GY-16 035 GY-16

043 BU-16 041 BU-16

032 GY-16 029 GY-16

035 GY-16

036 GY-16 044 GY-16

002 GY-16

039 GY-16 040 GY-16

031 GY-16

038 BU-16 026 BU-16

001 BU-16

039 GY-16

034 GY-16

041 BU-16 037 BU-16

1 B 9 10

3 11 VOLTAGE MONITORING

4 12 VOLTAGE MONITORING INDUCTOR VOLTAGE

5 13 CURRENT MONITORING

6 14 CURRENT MONITORING

7 GND INDUCTOR VOLTAGE

S1 2361460

12 K7 14

K2

K1

CONTROL LAMP +

CONTROL LAMP -

BUTTON ON/OFF

BUTTON ON/OFF

+24VDC OUTPUT

027 PU-16

K01 2425583 A1 X1 TERMINAL H 2543542

K8 1 3 2476931 3 2 4 7 5 6

K9 2476931 3 2 4 7 5 6

K10 2476931

K11 2476931

X1 TERMINAL A 2543541

X1 TERMINAL B 2543541

X1 TERMINAL C 2543541

X1 TERMINAL E 2543541

X1 TERMINAL F 2543541

X1 TERMINAL D 2543541

X1 TERMINAL G 2543541

FAULT ALARM

FAULT ALARM

10A

E 1 5 K6 4 8 12 12 11 10 9 V2 8 7 6 5 C1 V4 4 3 2 1 V1

GROUND

F1 2425585

GROUND

FREE

A2

8 023 BR-16

1 022 BR-16

8 043 BU-16

1 024 GY-16

8 021 GY-16

1 033 GY-16 042 GY-16

8 040 GY-16

1 042 GY-16

9 1

10 2

11 4

12 5

13 6

14 7

GND 032 GY-16 033 GY-16 8 044 GY-16

B
030 GY-16

13 14 K3 R4

021 GY-16 043 BU-16 022 BR-16 023 BR-16

GND CONTROL BOX

WIRE GROUP COLOR DESCRIPTIONS

WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS ON AND CONTROL MAIN SWITCH ON. WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS ON. GROUND CIRCUIT. GENERATOR 240V.

SCHEMATIC FOR 12.5kW GENERATOR CONTROL BOX

PART NO. CHG-LEVEL 233-0968 02A
2 1

10

NAME A1 C1 F1 K01 K1 K2 K3 K4 K6 K7 K8 K9 K10 K11 R1 R2L R2M R3 S1 V1 V2 V3 V4

FUNCTION Main Printed Circuit Board Field Absorption Capacitor Main Breaker Magnet On/Off Switching Relay Field Magnetizing Relay Drop Relay Voltage Monitoring Relay (Not Used) Drop Timer Relay Time Delay Warning Relay (Not Used) Boost Timer Relay Current Monitoring Relay Current Overload Protection Relay System Activation Safety Relay Reset Control Safety Relay Excitation Voltage Variable Resistor Drop Resistor-1 Drop Resistor-2 Field Discharge Resistor Main Switch Diode Diode Diode Diode

PART NO. 242-5904 242-5585 242-5583 242-5581 242-5581 247-6937 242-1309 242-5586 242-5586 247-6931 247-6931 247-6931 247-6931 242-5576 242-5575 242-5575 242-5577 236-1460 -

STANDARD SETTING 1,5 S (X1/S) / SCALE 0-3 6 S (X1/S) / SCALE 0-6 2 S (X1/S) / SCALE 0-6 Adjusted After Machine Installation -