539 KNUCKLEBOOM LOADER ELECTRICAL SCHEMATIC | CAT Machines Electrical Troubleshooting

1999 Caterpillar

RENR3075

June 1999

539 Knuckleboom Loader

Electrical System

1PZ1-UP (Machine)

Printed in U.S.A.

Component Location

Component

Schematic

Location

Machine

Location

Component

Schematic

Location

Machine

Location

Arc Suppressor - RH Rear Solenoid A-12 19 Motor - Oil Cooler Fan I-11 11

Alarm - Horn B-9 8 Motor - Starter D-12 14

Alternator E-11 14 Motor - Washer F-4 7

Arc - Suppressor - LH Rear Solenoid I-12 16 Relay - AIH C-11 6

Arc - Suppressor - LH Rear Solenoid I-12 16 Relay - Condenser B-11 3

Arc Suppressor D-12 5 Relay - Delimber Close I-10 12

Arc Suppressor A-2 A Relay - Delimber Open I-7 12

Arc Suppressor D-9 17 Relay - Extra Lights I-10 12

Arc Suppressor - Lower Press Solenoid I-4 20 Relay - Ground Saw Down I-10 12

Arc Suppressor G-9 12 Relay - Ground Saw Up I-8 12

Arc Suppressor G-4 1 Relay - Horn I-8 12

Arc Suppressor - Start Oil Lower Sol I-4 7 Relay - Hyd Interlock H-7 12

Arc Suppressor - RH Rear Solenoid A-12 19 Relay - Lights I-8 12

Arc Suppressor - Delimber Arms G-2 1 Relay - Live Heel Extend H-8 12

Arc Suppressor - Delimber Arms G-2 1 Relay - Live Heel Retract I-9 12

Arc Suppressor - Ground Saw G-2 1 Relay - Main G-9 12

Arc Suppressor - Ground Saw G-2 1 Relay - Neutral Start I-9 12

Arc Suppressor - LH Front Stabilizer Sol I-2 15 Relay - Saw Down I-10 12

Arc Suppressor - LH Front Stabilizer Sol I-2 15 Relay - Saw Up I-8 12

Arc Suppressor - RH Front Stabilizer Sol D-1 18 Relay - Start G-9 12

Arc Suppressor - RH Front Stabilizer Sol D-1 18 Resistor H-9 12

Arc Suppressor - Saw Sol H-2 1 Sender - Eng Oil Press C-12 14

Arc Suppressor - Saw Sol H-2 1 Sender - Hyd Oil Temp F-11 13

Batteries D-1 2 Sensor - AIH Coolant Temp D-11 6

Block - Diode H-8 12 Sensor - Coolant Temp D-11 14

Breaker - Alternator H-9 12 Sensor - Fuel Level F-12 13

Breaker - Main H-9 12 Solenoid - A/C Clutch E-12 5

Condenser B-11 3 Solenoid - Eng Shutdown D-12 5

Control Group - LH Switches D-5 C Solenoid - LH Front Stabilizer I-1 15

Control Group - RH Switches B-6 B Solenoid - LH Rear Stabilizer I-12 16

Converter - 24V to 12V E-3 4 Solenoid - Lockout Dumpback D-8 17

Eng Gov Actuator C-12 5 Solenoid - RH Front Stabilizer D-1 18

Fuses C-6,7,8 C Solenoid - RH Rear Stabilizer A-11 19

Gauge - Coolant Temp B-2 A Solenoid Valve - Lower Press I-3 20

Gauge - Engine Oil Press C-2 A Solenoid Valve - Start Oil Lower I-3 7

Gauge - Fuel Level C-2 A Switch - A/C Refrigerant E-12 5

Gauge - Hyd Temp C-2 A Switch - Condenser Fan E-7 C

Ground - Cab A-2 22 Switch - Delimber Guide Bar Cntrl D-7 C

Ground - Chassis 1 A-2 7 Switch - Disconnect C-1 21

Ground - Chassis 2 A-2 7 Switch - Eng Oil Press C-12 5

Ground - Frame C-12 14 Switch - Horn E-7 C

Ground - Frame C-1 21 Switch - HVAC Blower E-6 C

Ground - Panel G-8 12 Switch - Key Start B-6 B

Heater - Air Inlet C-11 6 Switch - LH Front Stabilizer B-8 B

Heater Control Unit H-9 12 Switch - LH Rear Stabilizer B-8 B

Horn H-4 7 Switch - Neut Start/ Hyd Interloc Limit E-6 C

HVAC Unit B-9 8 Switch - RH Front Stabilizer B-7 B

Meter - Service B-2 A Switch - RH Rear Stabilizer B-7 B

Motor - Blower B-11 8 Switch - Throttle Control A-6 B

Motor - Blower B-11 8 Switch - Wiper Washer D-3 D

Motor - Defroster Fan E-2 9 Voltmeter B-2 A

Motor - Front Wiper D-3 10

Machine locations are repeated for components that are located close together.

A = Components located on Gauge Panel

B = Components located on Right Console.

C = Components located on Left Console.

D = Components located in Headliner.

E = Components located on Relay/Fuse Panel.

Off Machine Switch Specification

Part No. Function Actuate Deactuate Contact Position

114-5333 Refrigerant Pressure (AC) 275 to 1750 kPa¹ -- Normally ²

40 to 255 psi -- Open

166-7721 Eng Oil Press 113kPa 70±20kPa Normally

Closed

¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed

condition can be maintained down to 170 kpa (25 psi).

² Contact position at the contacts of the harness connector.

Resistor, Sender, and Solenoid Specifications

Part No. Component Resistance (Ohms)¹

7Y-8242 Resistor 47.0 ± 4.7

9X-1124 Sender - Eng Oil Pressure 240 ± 13 @ 0kPa (0 psi)

153 ± 9.5 @ 138kPa (20psi)

33.5 ± 12 @ 552kPa (80psi)

106-5122 Solenoid - A/C Clutch 17.6 ± 0.6

121-1491 Solenoid - Lockout Dumpback 32.0 ± 3.2

147-1223 Solenoid - Lower Pressure Valve 34.3 ± 1.7

155-4652 Solenoid - Eng Shutdown Latch - 1.55 ± 10%

Unlatch - 10.3 ± 10%

¹ At room temperature.

Wire Description Chart

Wire

Number

Wire

Color

Description

Wire

Number

Wire

Color

Description

Power Distribution Circuits

508 PU Radio Speaker - Left

101 RD Bat (+) 509 WH Radio Speaker - Left (Common)

103 RD Aux Ckt

Accessory Circuits (cont'd)

104 YL Aux Ckt 511 BR Radio Speaker - Right

105 RD Key Sw 512 GN Radio Speaker - Right (Common)

108 BU Aux Ckt 513 OR A/C Compressor/Refrigerant Pressure SW

109 RD Alt Output (+) Term. 515 GY Blower Motor (HI)

112 PU Main Power Rly Output 516 GN Blower Motor (Medium)

113 OR Opr Mon Panel VMIS B+ Switched 517 BU Blower Motor (Low)

114 RD Warning Horn (Forward) 521 YL A/C SW To Refrigerant SW

115 PK Aux Ckt 522 WH A/C Clutch To Thermostat SW

116 BR Aux Ckt 567 WH A/C SW Jumper

119 PK Aux Ckt 592 BU DC/DC Converter Power Output

122 BU Aux Ckt A513 PK DC/DC Converter Memory Output

123 WH Aux Ckt A579 OR Wiper Motor +

124 GN A/C A588 GN Safety Sol Relay To Sol

141 PK Aux Ckt

Lighting Circuits

147 RD Aux Ckt 607 PK Flood Lamp - Front

149 PU Aux Ckt 616 BU Bucket Flood Lamp/Boom Flood Lamp

150 OR Bat (+) 629 PK Aux Head Lamp

151 GN Aux Ckt

Control Circuits

154 WH Aux Ckt A718 PU Start Aid Coolant Sensor Signal

158 BR Aux Ckt F773 OR Governor Accel

177 RD Main Brkr F774 WH Governor Decel

185 YL Aux Ckt 877 YL Glow Plug Magnetic SW To Glow Plug

Ground Circuit

H869 GN Right Front Outrigger Up Solenoid

200 BK Main Chassis H870 BU Right Front Outrigger Down Solenoid

Basic Machine Circuits

H871 OR Right Rear Outrigger Up Solenoid

301 BU Starter No. 1 Sol H872 WH Right Rear Outrigger Down Solenoid

304 WH Starter Relay No. 1 Output H873 YL Left Front Outrigger Up Solenoid

306 GN Starter Relay Coil To Neut Start SW Or Key SW H874 GY Left Front Outrigger Down Solenoid

307 OR Key SW To Neutral Start SW H875 PU Left Rear Outrigger Up Solenoid

308 YL Main Power Relay Coil H876 PK Left Rear Outrigger Down Solenoid

309 GY Alternator Regulator Term. R928 YL Outrigger Manifold Valve (Diode Block to Sol)

310 PU Start Aid SW To Start Aid Sol R929 WH Saw Up (Relay to Sol)

320 OR Horn Relay Coil To SW R930 BU Saw Up (Sw to Relay)

322 GY Warning Horn (Forward) R931 PK Saw Down (Relay to Sol)

326 RD Key SW "C" Term. R932 OR Saw Down (Sw to Relay)

Monitoring Circuits

R933 GY Delimber Arms Open (Relay to Sol)

403 GN Alternator (R) Term. R934 PU Delimber Arms Open (Sw to Relay)

410 WH Opr Mon Fault Alarm R935 YL Delimber Arms Closed (Relay to Sol)

441 OR Eng Coolant Temp Gauge R936 GN Delimber Arms Closed (Sw to Relay)

442 GY Hyd System Temp Gauge R937 OR Delimber Guide Bar Up (Sw to Sol)

447 PK Fuel Level Gauge R943 OR Ground Saw Up (Sw To Relay)

A476 PU Eng Oil Press Gauge To Sender - Eng #1 R944 BU Ground Saw Up (Relay to Sol)

H415 BR Alarm to Warning Pressure Switch R945 BR Ground Saw Down (Sw to Relay)

Accessory Circuits

R946 GY Ground Saw Down (Relay to Sol)

500 BR Wiper - Front (Park) R947 WH Live Heel Extend (Sw to Relay)

501 GN Wiper - Front (Low) R948 PU Live Heel Extend (Relay to Sol)

502 OR Wiper - Front (HI) R949 YL Live Heel Retract (Sw to Relay

506 PU Washer - Front R950 OR Live Heel Retract (Relay to Sol)

Connector Location¹

Connector Number

Schematic

Location

Machine

Location

CONN 1 E-11 9

CONN 2 A-9 1

CONN 3 B-9 1

CONN 4 C-9 2

CONN 5 C-9 2

CONN 6 D-9 2

CONN 7 D-9 2

CONN 8 G-6 3

CONN 9 H-6 3

CONN 10 I-6 3

CONN 11 A-4 4

CONN 12 B-4 4

CONN 13 B-4 4

CONN 14 I-4 5

CONN 15 G-3 6

¹The connectors shown in this chart are harness to harness and special

use connectors. Connectors which join a harness to a component are

generally located at on near the component. See the component location

chart.

Related Electrical Service Manuals

Title Form Number

Alternator: (132-2156) SENR4757

Starter Motor: (104-7040)

Consist: 6V-5720 SENR3581

Consist: 106-8557 SENR3859

Machine Harness Connector And Component Locations

E88908

FUSE - A component in an electrical circuit that will open the circuit if too much

current flows through it.

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.

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.

325-L25 PK-14

200-L32 BK-14

325-A135 PK-14

AG-C4

111-7898

L-C12

3E-5179

AG-C4

111-7898

L-C12

3E-5179

C-C4

130-6795

Harness And Wire Electrical Schematic Symbols

Electrical Schematic Symbols And Definitions

9X-1123

Part Numbers For

Connector Assembly

Component

Part Number

Wire, Cable, or Harness

Assembly Identification

Circuit Number

Identification

Wire

Color

Single Wire

Connector

Wire

Gauge

Socket

Pin or Socket

Number

Plug

Receptacle

Typical representation of a

Sure-Seal connector. The plug

and receptacle contain

both pins and sockets.

Typical representation of

a Deutsch connector. The

plug contains all sockets

and the receptacle contains

all pins.

AG-C3

130-6795

Harness identification letter(s) and a

serializing code. The "C" stands for

connector and the number indicates

which connector in the harness.

Harness identification code

This example indicates wire

32 in harness "L'.

Normally open switch that will close with an increase of a specific condition (temp-press-etc.).

Normally open switch that is closed due to an applied condition, and will open again with a

specific decrease in that condition.

Normally closed switch that will open with an increase of a specific condition.

Normally closed switch that is open due to an applied condition, and will close again

with a specific decrease in that condition.

The circle indicates that the component has screw terminals and a wire can be disconnected

from it.

No circle indicates that the wire cannot be disconnected from the component.

This indicates that the component has a wire connected to it that is connected to ground.

This indicates that the component does not have a wire connected to ground. It is grounded

by being fastened to the machine.

Electrical Schematic Symbols And Definitions

Pressure

Symbol

Temperature

Symbol

Level

Symbol

Flow

Symbol

OPERATOR STATION

RELAY PANEL

326-EE1 RD-18

200-EE2 BK-16

A476-EE3 PU-16

522-EE4 WH-18

200-EE5 BK-16

200-EE6 BK-16

522-EE4 WH-18

513-EE9 OR-18

513-EE8 OR-18

513-EE7 OR-18

513-EE8 OR-18

513-EE7 OR-18

200-EE10 BK-10

H415-EE11 BR-18

301-EE12 BU-10

200-EE17 BK-4

200-E9 BK-18

200-E17 BK-4

616-L1 BU-16

616-L2 BU-16

616-L3 BU-16

200-L4 BK-16

200-L5 BK-16

200-L6 BK-16

113-R36 OR-18

113-R37 OR-18

113-R38 OR-18

508-C11 PU-18

509-C10 WH-18

512-C12 GN-18

511-C13 BR-18

592-C17 BU-18

A513-C18 PK-18

113-P9 OR-18

113-P10 OR-18

113-P11 OR-18

113-P12 OR-18

185-R44 YL-16

200-R45 BK-16

(LIVE HEEL EXTEND)

(LIVE HEEL RETRACT)

(EXTRA-LIGHTS)

H873-M1 YL-18

H873-M2 YL-18

H874-M3 GY-18

H874-M4 GY-18

200-M5 BK-18

200-M6 BK-18

200-M7 BK-18

200-M8 BK-18

200-M9 BK-14

200-M10 BK-18

F773-EE13 OR-16

F774-EE14 WH-16

7V9275 STRAP

H873-M11 YL-18

H874-M12 GY-18

H875-M13 PU-18

H876-M14 PK-18

H875-M15 PU-18

H876-M16 PK-18

200-M18 BK-18

200-M17 BK-18

200-M19 BK-18

200-M20 BK-18

H871-M24 OR-18

H872-M25 WH-18

H871-M26 OR-18

H872-M27 WH-18

200-M28 BK-18

200-M29 BK-18

200-M30 BK-18

200-M31 BK-18

R929-M46 WH-18

R931-M47 PK-18

R929-M48 WH-18

R931-M49 PK-18

200-M54 BK-18

200-M55 BK-18

200-M52 BK-18

200-M53 BK-18

200-M57 BK-18

200-M56 BK-18

R929-M50 WH-18

R931-M51 PK-18

R935-M59 YL-18

R933-M60 GY-18

R933-M63 GY-18

R935-M62 YL-18

200-M64 BK-18

200-M65 BK-18

200-M67 BK-18

200-M66 BK-18

200-M68 BK-18

R944-M69 BU-18

R946-M70 GY-18

R944-M73 BU-18

R946-M74 GY-18

200-M75 BK-18

200-M76 BK-18

R935-M61 YL-18

200-M77 BK-18

200-M78 BK-18

200-M79 BK-18

R944-M71 BU-18R944-M71 BU-18

R946-M72 GY-18

R937-M80 OR-18

R937-M81 OR-18

200-M83 BK-18

200-M84 BK-18

200-M85 BK-18 200-M85 BK-18

R937-M82 OR-18

CBL-GG1 RD-00

CBL-JJ1 BK-00

COMPONENTS ARE SHOWN INSTALLED ON A FULLY OPERABLE MACHINE

IDENT PART NO. CHG LOC

HARNESS AS.

172-6096E 00 E-12

A 172-6092 00 G-6

C 172-6093 00 A-4

I-300164-3206

164-3212 03 G-3

P 172-6097 00 D-9

R 172-6098 00 B-9

V 172-6099 00 F-6

EE 172-6100 00 D-11

CABLE AS.

7Y-8298HH 02 C-12

AA 173-8625 00 D-1

CC 173-8624 00 C-1

JJ 110-5991 00 C-1

8X-6645 GROUND STRAP

HH BK-00

200-EE15 BK-16

111-8867GG 01 D-1

513-EE16 OR-18

877-EE18 YL-4

101-EE19 RD-4

513-E45 OR-18

410-E53 WH-18

410-E55 WH-18

R928-F23 YL-18

200-F25 BK-18

200-E46 BK-14

200-E2 BK-18

410-E55 WH-18

513-E45 OR-18

200-E2 BK-18

200-E17 BK-4

R928-F27 YL-18

R928-F28 YL-18

200-E46 BK-14

200-EE31 BK-18

310-EE30 PU-18

113-R39 OR-18

200-F1 BK-14

H873-F2 YL-18

H874-F3 GY-18

H869-F4 GN-18

H870-F5 BU-18

H875-F6 PU-18

H876-F7 PK-18

H871-F8 OR-18

H872-F9 WH-18

R929-F10 WH-18

R931-F11 PK-18

R933-F12 GY-18

R935-F13 YL-18

R944-F14 BU-18

R946-F15 GY-18

R937-F16 OR-18

200-F33 BK-14

616-F32 BU-14

R928-F17 YL-18

200-F18 BK-18

322-F34 GY-18

R928-F24 YL-18

R928-F20 YL-18

200-F21 BK-18

200-F22 BK-18

200-F29 BK-18

200-F30 BK-18

200-F26 BK-18

R928-F19 YL-18

200-F31 BK-18

310-E6 PU-18

A476-E3 PU-18

522-E4 WH-18

F774-E8 WH-18

H415-E18 BR-18

326-E1 RD-18

F773-E7 OR-18

CONN 1

F773-E7 OR-18

410-E54 WH-18

442-E60 GY-18

447-E61 PK-18

200-E401 BK-14

108-E400 BU-14

158-E47 BR-14

304-E13 WH-8

109-E19 RD-4

101-E14 RD-4

309-E16 GY-18

403-E15 GN-18

A718-E11 PU-18

441-E12 OR-18

200-E48 BK-10

H871-V29 OR-18

H871-V31 OR-18

H871-V30 OR-18

112-P49 PU-14

112-P31 PU-14

112-P34 PU-14

112-P32 PU-14

112-P33 PU-14

112-P35 PU-14

112-P50 PU-14

177-P30 RD-14

177-P28 RD-14

521-P20 YL-14

R937-P25 OR-18

320-P15 OR-16

200-P16 BK-16

567-P18 WH-14

123-P26 WH-18

124-P19 GN-14

515-P23 GY-14

516-P22 GN-14

517-P21 BU-14

154-P1 WH-18

CONN 2

CONN 3

CONN 4

CONN 5

151-P2 GN-18

151-P2 GN-18151-P2 GN-18

113-P13 OR-18

113-P14 OR-18

R934-P5 PU-18

R936-P6 GN-18

R947-P7 WH-18

R947-P7 WH-18 R949-P8 YL-18

R949-P8 YL-18

119-P37 PK-18

116-P36 BR-18

158-P24 BR-14

105-P27 RD-18

114-P42 RD-18

149-P41 PU-14

104-P46 YL-18

147-P40 RD-14

122-P39 BU-18

115-P38 PK-18

141-P45 PK-18

A579-P44 OR-18

103-P43 RD-18

185-P48 YL-18

108-P47 BU-18

123-P26 WH-18

124-P19 GN-14

200-R17 BK-14

CONN 6

CONN 7

200-R17 BK-14

200-R18 BK-18

200-R22 BK-18

200-R20 BK-18

200-R19 BK-18

200-R21 BK-18

200-R46 BK-16

200-R23 BK-18

200-R47 BK-18

104-R24 YL-16 104-R24 YL-16

104-R28 YL-16

104-R26 YL-16

104-R27 YL-16

104-R25 YL-16

616-R29 BU-18

616-R34 BU-18

616-R32 BU-18

616-R33 BU-18

616-R31 BU-18

616-R30 BU-18

308-R1 YL-18

326-R2 RD-18

307-R3 OR-18

105-R4 RD-16

H876-R16 PK-18

H875-R15 PU-18

H874-R14 GY-18

H873-R13 YL-18

H872-R12 WH-18

H871-R11 OR-18

H870-R10 BU-18

H869-R9 GN-18

607-R8 PK-18

113-R35 OR-18

R932-R40 OR-18

R930-R41 BU-18

R943-R42 OR-18

R945-R43 BR-18

185-R7 YL-16

F773-R5 OR-16

F774-R6 WH-16

200-F1 BK-14

200-F18 BK-18

200-F33 BK-14

200-F31 BK-18

616-C1 BU-14

616-C1 BU-14 616-C19 BU-14

616-C19 BU-14

616-C20 BU-14

616-C61 BU-18

616-C56 BU-18

616-C58 BU-18

616-C60 BU-18

616-C59 BU-18

616-C57 BU-18

103-C14 RD-18

103-C15 RD-18

103-C15 RD-18 103-C16 RD-18

103-C16 RD-18

200-C24 BK-18

200-C31 BK-16

506-C32 PU-16

200-C6 BK-16

200-C21 BK-16

200-C5 BK-16

200-C3 BK-16

200-C4 BK-14

200-C2 BK-14

200-C7 BK-16

200-C8 BK-16

200-C7 BK-16

200-C3 BK-16

113-C37 OR-18

113-C37 OR-18 113-C55 OR-18

113-C55 OR-18

113-C36 OR-18

113-C36 OR-18 113-C39 OR-18

113-C40 OR-18

113-C38 OR-18

113-C41 OR-18

113-C42 OR-18

A579-C35 OR-16

A579-C45 OR-16

A579-C46 OR-16

A579-C47 OR-16

A579-C68 OR-16

200-C66 BK-16

200-C25 BK-18

200-C22 BK-18

200-C26 BK-18

200-C30 BK-18

200-C27 BK-18

200-C29 BK-18

113-C41 OR-18

200-C22 BK-18

200-C26 BK-18

200-C30 BK-18

113-C40 OR-18

200-C27 BK-18

113-C38 OR-18

113-C39 OR-18

200-C29 BK-18

113-C42 OR-18

141-C9 PK-16

410-C53 WH-18

410-C53 WH-18 410-C54 WH-18

410-C54 WH-18

410-C52 WH-18

H415-C65 BR-18

403-C23 GN-18

441-C48 OR-18

A476-C49 PU-18

A476-C49 PU-18A476-C49 PU-18

A476-C49 PU-18

447-C44 PK-18

442-C43 GY-18

502-C34 OR-16

501-C33 GN-16

500-C50 BR-16

200-C67 BK-16

501-C33 GN-16

500-C50 BR-16

502-C34 OR-16

NOTE B: ATTATCH TERMINAL TO STUD

NOTE B

H871-V29 OR-18

515-V66 GY-14

516-V65 GN-14

517-V64 BU-14

521-V63 YL-14

113-V9 OR-18

113-V9 OR-18113-V11 OR-18

113-V11 OR-18

113-V8 OR-18

H871-V30 OR-18

113-V10 OR-18

200-V2 BK-14

200-V4 BK-12

200-V4 BK-12 200-V1 BK-14200-V1 BK-14

200-V5 BK-16

H415-V88 BR-18

H415-V88 BR-18 H415-V118 BR-18

H415-V118 BR-18

H415-V103 BR-18

200-V3 BK-18

200-V107 BK-18200-V108 BK-18

A588-V105 GN-18A588-V106 GN-18

104-V6 YL-16

105-V7 RD-16

185-V12 YL-16

307-V13 OR-18

CONN 10

308-V14 YL-18

326-V15 RD-18

616-V16 BU-18

616-V18 BU-14

616-V17 BU-14

607-V20 PK-18

H869-V21 GN-18

H869-V23 GN-18

H870-V25 BU-18

H870-V25 BU-18H870-V26 BU-18

H870-V26 BU-18

H872-V32 WH-18

H872-V32 WH-18H872-V34 WH-18

H872-V34 WH-18

H872-V33 WH-18H872-V33 WH-18

H872-V33 WH-18

H873-V35 YL-18

H873-V35 YL-18H873-V37 YL-18

H873-V37 YL-18

H873-V36 YL-18

H874-V38 GY-18

H874-V38 GY-18H874-V40 GY-18

H874-V40 GY-18

H874-V39 GY-18

H875-V41 PU-18

H875-V41 PU-18H875-V43 PU-18

H875-V43 PU-18

H875-V42 PU-18

H876-V44 PK-18

H876-V44 PK-18H876-V46 PK-18H876-V46 PK-18

H876-V46 PK-18

H876-V45 PK-18

R930-V47 BU-18

R932-V48 OR-18

R943-V49 OR-18

R945-V50 BR-18

F773-V51 OR-16

F774-V52 WH-16

154-V53 WH-18

151-V54 GN-18

150-V55 OR-18

R934-V56 PU-18

R936-V57 GN-18

R947-V58 WH-18

R949-V59 YL-18

320-V60 OR-16

119-V61 PK-18

116-V62 BR-18

158-V67 BR-14

R937-V68 OR-18

112-V70 PU-14

112-V71 PU-14

112-V72 PU-14

112-V73 PU-14

112-V74 PU-14

112-V69 PU-14

112-V75 PU-14

177-V76 RD-14

CONN 9

CONN 8

177-V77 RD-14

114-V78 RD-18

149-V79 PU-14

147-V80 RD-14

122-V81 BU-18

115-V82 PK-18

141-V83 PK-16

A579-V84 OR-16

103-V85 RD-18

108-V86 BU-14

410-V94 WH-18

403-V90 GN-18

A476-V89 PU-18

441-V95 OR-18

447-V92 PK-18

442-V93 GY-18

R929-V97 WH-18

R931-V98 PK-18

R933-V99 GY-18

R935-V100 YL-18

R944-V101 BU-18

R946-V102 GY-18

616-V19 BU-14

322-V87 GY-18

322-V87 GY-18322-V87 GY-18

522-V91 WH-18

H869-V22 GN-18

H869-M35 GN-18

H869-M44 GN-18

H870-M36 BU-18

H870-M45 BU-18

H870-V28 BU-18

200-M42 BK-18

200-M43 BK-18

200-M39 BK-18

200-M40

BK-18

H871-M33 OR-18

H872-M34 WH-18

200-M32 BK-18

200-E2 BK-18

158-E47 BR-14

513-E45 OR-18

H871-M33 OR-18

200-M32 BK-18

H872-M34 WH-18

H876-M22 PK-18

H875-M21 PU-18

NOTE B

326-A164 RD-18

158-A158 BR-14

441-A152 OR-18

410-A154 WH-18

442-A153 GY-18

447-A155 PK-18

F773-A156 OR-18

F774-A157 WH-18

108-A160 BU-14

522-A161 WH-18

403-A163 GN-18

A476-A162 PU-18

H415-A159 BR-18

R928-A26 YL-18

R946-A45 GY-18

R946-A108 GY-18

R946-A44 GY-18

R935-A35 YL-18

R935-A35 YL-18R935-A9 YL-18R935-A9 YL-18

R935-A9 YL-18

R935-A74 YL-18

R929-A41 WH-18

R929-A41 WH-18R929-A25 WH-18

R929-A25 WH-18

R929-A40 WH-18

R933-A37 GY-18

R933-A37 GY-18R933-A12 GY-18

R933-A12 GY-18

R933-A36 GY-18

114-A59 RD-18

114-A59 RD-18114-A58 RD-18

114-A58 RD-18

114-A131 RD-18

122-A84 BU-18

122-A84 BU-18122-A83 BU-18

122-A83 BU-18

122-A110 BU-18

115-A76 PK-18

115-A76 PK-18115-A5 PK-18

115-A5 PK-18

115-A75 PK-18

R931-A39 PK-18

R931-A39 PK-18R931-A46 PK-18

R931-A46 PK-18

R931-A38 PK-18

116-A66 BR-18

116-A66 BR-18116-A47 BR-18

116-A47 BR-18

116-A65 BR-18

119-A71 PK-18119-A71 PK-18119-A70 PK-18

119-A70 PK-18

119-A107 PK-18

R944-A43 BU-18

R944-A43 BU-18R944-A106 BU-18

R944-A106 BU-18

R944-A42 BU-18

147-A102 RD-14

147-A100 RD-14

147-A130 RD-14

147-A62 RD-14

607-A61 PK-18

607-A109 PK-18

607-A4 PK-18

306-A49 GN-18

306-A48 GN-18

306-A50 GN-18

308-A8 YL-18

308-A98 YL-18

308-A6 YL-18

308-A97 YL-18

200-A95 BK-18

200-A11 BK-18

200-A99 BK-18

200-A23 BK-18

200-A95 BK-18

200-A24 BK-18

200-A15 BK-18

200-A18 BK-18

200-A96 BK-18 200-A17 BK-18200-A17 BK-18

200-A17 BK-18

200-A14 BK-18

200-A103 BK-14

200-A20 BK-18

200-A19 BK-18

200-A21 BK-18

200-A16 BK-18200-A16 BK-18

200-A16 BK-18

200-A22 BK-18

200-A105 BK-10

200-A104 BK-14

629-A101 PK-14

177-A88 RD-4

177-A87 RD-8

177-A86 RD-14

177-A85 RD-14

304-A92 WH-8

109-A91 RD-4

112-A89 PU-14

112-A200 PU-14

112-A10 PU-14

112-A201 PU-14

112-A202 PU-14

112-A203 PU-14

112-A204 PU-14

308-A7 YL-18

309-A3 GY-18

309-A1 GY-18

A718-A2 PU-18

310-A13 PU-18

H872-A34 WH-18

H876-A33 PK-18

H870-A32 BU-18

H874-A31 GY-18

H871-A30 OR-18

H875-A29 PU-18

H869-A28 GN-18

H873-A27 YL-18

R947-A82 WH-18

R948-A81 PU-18

150-A55 OR-18

150-A55 OR-18 150-A55 OR-18

150-A55 OR-18

151-A54 GN-18

151-A54 GN-18 151-A54 GN-18

151-A54 GN-18

A588-A53 GN-18

R945-A72 BR-18

149-A63 PU-14

616-A60 BU-14

R932-A67 OR-18

R936-A73 GN-18

R949-A79 YL-18

R950-A78 OR-18

307-A52 OR-18

154-A51 WH-18

320-A57 OR-18

322-A56 GY-18

R930-A64 BU-18

R943-A69 OR-18

R934-A68 PU-18

177-A88 RD-4

177-A87 RD-8

308-A7 YL-18

309-A3 GY-18

101-A90 RD-4

NOTE B

CABLE AS. 9U-8746

200-C66 BK-16

200-C31 BK-16

CBL-AA1 RD-00

CBL-CC1 BK-00

F 172-6101 00 B-4

H869-M37 GN-18

H870-M38 BU-18

200-M41 BK-18

A588-V104 GN-18

R928-V24 YL-18

200-M23 BK-18

150-P3 OR-18

150-P4 OR-18

NOTES

ELECTRIC PANEL

CAB

ENGINE AREA

BOOM

LOWER FRAME

LH CONSOLE

RH CONSOLE

CHASSIS

ON ENGINE

FRONT

150-P3 OR-18

L14

L16

L7L7

L10

L11

L10 L10

L11

L13

L12 L12

L12

L15

L17

L18

L19

L20

L21

L21 L21

L22

F774-EE14 WH-16

F773-EE13 OR-16

KK BK-6

447-E61 PK-18

442-E60 GY-18

108-E400 BU-14

200-E401 BK-14

185-R7 YL-16

200-R46 BK-16

KK 9Y-8241 00 C-12

R933-M58 GY-18

200-M64 BK-18

200-M56 BK-18

ANTENA

RADIO

3E-7140

LEFT SPKR +

RIGHT SPKR +

+B (12V)YL

GY,VI

WH/BK,GN/BK

WH,GN

RIGHT SPKR -

LEFT SPKR -

+B MEMORY

GROUND

GY/BK,VI/BK

GN-14

BU-14

GN-14

GY-14

BN-14

HVAC BLOWER SW

110-7890

MAIN RELAY

167-0138

BK-16

IGN

SEND

GRD

173-7098

IGN

SEND

GRD

4W-0483

IGN

SEND

GRD

3E-9341

IGN

SEND

GRD

VOLTMETER

105-1457

OFF

KEY START SW

9G-7641

BK-18

WH-18

RD-18

DOME LAMP

3E-6389

MOTOR

WASHER

7T-8890

GND

NEGPOS

BATTERY 2

3T-5760

HORN SW

3T-2357

HORN

7T0969

LH CAB FLOODLAMP

112-9378

WH-18

BK-18

RH CAB FLOODLAMP

112-9378

WH-18

BK-18

LH STICK LAMP

112-9378

WH-18

BK-18

RH STICK LAMP

112-9378

WH-18

BK-18

80A

MAIN BREAKER

9S-4693

80A

ALTERNATOR BREAKER

9S-4693

NEGPOS

BATTERY 1

3T-5760

DISCONNECT SW

7N-0718

RD-14

RD-18

BK-18

WH-14

YL-14

BU-14

BR-18

UNUSED

WASH

PARK

LOW

HIGH

GROUND

WASHER B+

WIPER B+

WIPER WASHER SW

3E-0155

BK-18

BU-18

LH FRONT STABILIZER SW

161-7449

WH-18

RD-18

YL-18

BK-18

BU-18

LH REAR STABILIZER SW

161-7449

WH-18

RD-18

YL-18

BK-18

BU-18

RH REAR STABILIZER SW

161-7517

WH-18

RD-18

YL-18

BK-18

RD-18

LIGHT SW

121-1118

WH-18

YL-18

BK-18

BU-18

RH FRONT STABILIZER SW

161-7517

WH-18

RD-18

YL-18

NEUT START/HYD INTERLOC LIMIT SW

111-4799

RD-18

WH-18

BK-18

INDICATOR LAMP

123-5182

SERVICE METER

161-3932

+ -

SIG

+24 V BATTERY IN

+24 V SWITCHED IN

GROUND

24V TO 12V CONVERTER

119-1733

+12 V MEMORY OUT

+12 V SWITCHED OUT

GROUND

G S

MTR BAT

MOTOR

STARTER MOTOR

104-7040

ENG SHUTDOWN SOL

155-4652

BK-18

AC REFRIGERANT SW

114-5333

NOTE A

EE-C2

3E3361

A/C CLUTCH SOL

106-5122

GN-14

EE-C4

3E3361

EE-C3

3E3361

CONDENSER FAN SW

8D-2676

DELIMBER GUIDE BAR CNTRL SW

8D-2676

START OIL LOWER SOL VALVE

152-8345

GN-18

LOWER PRESS SOL VALVE

147-1223

GN-18

DEFROSTER FAN

3E-7835

RESISTOR

OR/GY

OR/DKBU

MOTOR

MOTOR AS

9W-0605

SWITCH AS

1V-6652

MOTOR

CONDENSER

103-9527

MOTOR

BLOWER

106-2721

BLOWER

106-2721

RELAY

3E-5239

BK-14

WH/RD-14

200-BK-14

593-GN-14

200-BK-14

513-OR-14

158-BR-14

200-BK-14

593-GN-14

87a

HEATER CONT UNIT

104-3204

TEMP

KEY SW (START)

REGULATOR

RELAY

GND

KEY SW (0N)

CHECK TERM

RH FRONT STABILIZER SOL

162-4190

DOWN

LH FRONT STABILIZER SOL

162-4190

DOWN

RH REAR STABILIZER SOL

162-4190

DOWN

LH REAR STABILIZER SOL

162-4190

DOWN

RH SPEAKER

124-6046

LH SPEAKER

124-6046

RETRACT (SLOWER)

EXTEND (FASTER)YL-18

RD-18

ENG GOV ACTUATOR

162-8241

EE-C6

3E3361

AIH COOLANT TEMP SENSOR

125-4812

E-C3

3E3361

FRAME GROUND 2

L-C1

3E3364

CONN 14

L-C2

3E3361

L-C3

3E3361

BK-16

ELECTRIC SWIVEL

161-8167

GN-16

BK-16

GN-16

BK-16 BK-16

BK-16

BK-16BK-16

ARC SUPPRESSOR

106-8704

M-C3

3E3361

ARC SUPPRESSOR C0

106-8704

ARC SUPPRESSOR C1

106-8704

ARC SUPPRESSOR C2

106-8704

ARC SUPPRESSOR C3

106-8704

ARC SUPPRESSOR C4

106-8704

ARC SUPPRESSOR C5

106-8704

ARC SUPPRESSOR C6

106-8704

ARC SUPPRESSOR C9

106-8704

ARC SUPPRESSOR C10

106-8704

ARC SUPPRESSOR C11

106-8704

ARC SUPPRESSOR C12

106-8704

ARC SUPPRESSOR C13

106-8704

HORN ALARM

3E-6328

RD-16

BK-16

AIR INLET HEATER

107-9652

AIH RELAY

118-3534

BK-18

START RELAY

125-1302

BK-18

RESISTOR

7Y8242

ANTENNA

8E1118

HVAC UNIT

161-8434

MOTOR

LOW SPEED

MED SPEED

HIGH SPEED

CONDENSER

ON/OFF TOGGLE

GND

MOTOR

OIL COOLER FAN

156-7921

R-C1

3E5176

R-C2

3E5179

R-C7

1160087

R-C3

1160087

R-C4

1160087

R-C5

1160087

R-C6

1160087

C-C3

3E3361

CAB GND

C-C4

3E3361

C-C5

3E3384

C-C6

3E3378

C-C7

3E3385

C-C8

3E3367

BK-16

WH-16

HYD OIL TEMP SENDER

104-3008

E-C7

3E3361

C-C1

3E5176

CONN 13

CONN 12

CONN 11

LOCKOUT DUMPBACK SOL

121-1491

GN-18

ARC SUPPRESSOR C7

106-8704

C-C9

7T5957

ARC SUPPRESSOR C8

106-8704

C-C10

3E3361

ARC SUPPRESSOR C14

106-8704

A-C3

1046573

A-C6

3E3364

PANEL GND

A-C7

3E3361

A-C9

7X6222

DIODE BLOCK AS

164-0344

A-C11

3E3361

P-C1

3E3367

P-C2

3E5176

P-C4

3E5179

P-C6

3E3378

D+

B+

B-

132-2156

ALTERNATOR

BK-16

WH-16

COOLANT TEMP SNSR(WATER)

164-3534

A-C12

3E3361

THROTTLE CONTROL SW

7N-8008

INCREASE RPM

DECREASE RPM

V-C4

3E5179

V-C6

3E5176

V-C8

3E5179

V-C9

3E5176

V-C10

3E5179

F-C5

3E3361

F-C4

3E3385

F-C3

3E3388

V-C14

3E3367

E-C10

3E3366

P-C5

3E3385

V-C7

3E3388

P-C3

3E3388

V-C5

3E3385

E-C11

1237615

FUEL LEVEL SENSOR

162-8208

PK-18

BK-18

RH CONTROL GP

165-5187

SAW DOWN

(LEFT UPPER SW)

SAW UP

(RIGHT UPPER SW)

GROUND SAW UP

(REAR SW)

GROUND SAW DOWN

(FRONT SW)

LH CONTROL GP

165-5188

OPEN CUTTING BLADES

(LEFT UPPER SW)

CLOSE CUTTING BLADES

(RIGHT UPPER SW)

LIVE HEEL UP

(REAR SW)

LIVE HEEL DOWN

(FRONT SW)

E-C6

3E3361

E-C9

3E3361

V-C19

3E3361

V-C25

3E3361

V-C24

3E3361

F-C6

3E3361

F-C7

3E3361

F-C9

3E3361

F-C8

3E3361

CHASSIS GND 1

ARC SUPPRESSOR C15

106-8704

ARC SUPPRESSOR C16

106-8704

SAW SOL

DOWN

ARC SUPPRESSOR C17

106-8704

ARC SUPPRESSOR C18

106-8704

DELIMBER ARMS SOL

OPEN

GROUND SAW SOL

DOWN

ARC SUPPRESSOR C19

106-8704

GUIDE BAR ENABLE SOL

M-C1

1072870

M-C4

3E3361

M-C5

1072870

M-C7

3E3361

M-C8

3E3361

M-C9

1072870

M-C11

3E3361

M-C12

3E3361

M-C13

1072870

M-C15

3E3361

M-C16

3E3361

M-C17

3E3361

M-C18

3E3361

M-C19

3E3361

M-C20

3E3361

M-C21

3E3361

M-C22

3E3361

M-C23

3E3361

M-C24

3E3361

M-C25

3E3361

M-C26

3E3361

M-C27

3E3361

M-C28

3E3361

M-C29

3E3361

M-C30

3E3361

M-C31

3E3379

M-C32

3E3382

M-C33

3E3376

87a

HYD INTERLOCK RELAY

3E-5239

87a

HORN RELAY

3E-5239

87a

NEUTRAL START RELAY

3E-5239

87a

LIVE HEEL EXTEND RELAY

3E-5239

87a

LIVE HEEL RETRACT RELAY

3E-5239

87a

DELIMBER OPEN RELAY

3E-5239

87a

DELIMBER CLOSE RELAY

3E-5239

87a

SAW UP RELAY

3E-5239

87a

SAW DOWN RELAY

3E-5239

87a

LIGHTS RELAY

3E-5239

87a

GROUND SAW UP RELAY

3E-5239

87a

EXTRA LIGHTS RELAY

3E-5239

87a

GROUND SAW DOWN RELAY

3E-5239

P-C7

111-4812

FUSE BASE

15A

20A

10A

15A

10A

HVAC

LIVE HEEL

A/C CONDENSER

WASHER/WIPER/RADIO

DEFROST FAN

DELIMBER GUIDE BAR

STABILIZERS

HORN

RADIO MEM/DOME LAMP

KEY SWITCH

CAB/STICK FLOOD LAMPS

SAW

DELIMBER ARMS

NEUTRAL START/HYDRAULIC INTER LOCK

HYD OIL COOLER FAN

GND SAW

FUSE

10A 9W-1442

15A 9W-1441

20A 9W-1446

REMOVAL TOOL

7Y-5493

10A

EXTRA EXTERIOR LIGHTS

10A

THROTTLE SW

IGN

SEND

GRD

163-7317

EE-C1

3E3388

E-C1

3E3385

CIRCUIT GROUPING

DESIGNATION

ATCH WIRE, CABLE,

COMPONENT

CIRCUIT NOT CONNECTED

BLUE

GREEN

BLADE, SPADE, RING,

OR SCREW TERMINAL

INTERNAL ELECTRICAL

CONNECTION TO SURFACE

OF COMPONENT

ELECTRICAL CONNECTION

TO MACHINE STRUCTURE

CONNECTOR

SYMBOL DESCRIPTION

BROWN

PURPLE

GRAY

BLACK

COLORABBREV

PINK

YELLOW

ORANGE

WHITE

RED

SPLICE

CHASSIS GND 2

FRAME GROUND 1

ENG OIL PRESS SENDER

9X-1124

EE-C5

3E3361

M-C6

1072868

M-C2

1072868

M-C10

1072868

M-C14

1072868

ENG OIL PRESSURE SW

166-7721

BK-18

A-C26

3E3364

M-C34

3E3364

M-C35

3E3364

M-C37

3E3364

M-C36

3E3364

M-C38

3E3364

M-C39

3E3364

M-C40

3E3364

CONN 15

GND

B+

MOTOR

BR-16

GY-16

BK-16

OR-16

GN-16

FRONT WIPER MOTOR

147-7977

C-C15

3E3378

A-C13

9X1054

A-C14

9X1054

A-C15

9X1054

A-C16

9X1054

A-C17

9X1054

A-C18

9X1054

A-C25

9X1054

A-C24

9X1054

A-C23

9X1054

A-C22

9X1054

A-C21

9X1054

A-C20

9X1054

A-C19

9X1054

A-C5

8N1517

E-C2

8N1518

V-C1

9X0141

A-C4

9X1343

V-C13

7X6222

A-C1

9X0145

EE-C7

3E3361

V-C27

3E5176

F-C1

3E5176

V-C28

3E5179

F-C2

3E5179

LAMP 1

5D-0019

C-C16

8D1313

LAMP 2

7X-2085

C-C14

9G7069

LAMP 3

7X-2085

C-C13

9G7069

LAMP 4

7X-2085

C-C12

9G7069

LAMP 5

7X-2058

C-C11

9G7069

C-S9

M-S12

M-S13

F-S5

ENGINE GROUND

THIS DIAGRAM IS FOR THE 539 KNUCKLEBOOM LOG LOADER

NOTE A: NORMALLY OPEN BEFORE REFRIGERANT CHARGE

ENGINE OIL PRESS GAUGE

COOLANT TEMP GAUGE

HYD TEMP GAUGE

GAUGES/CONTROL HANDLES

FUEL LEVEL GAUGE

(173-2387 CHG 00).

SAME IDENT. NUMBER, COLOR AND GAUGE.

WITH THE KEY AND ENGINE OFF.

UNLESS OTHERWISE SPECIFIED, ALL WIRES IN A SPLICE ARE THE

E89262

123456789101112

WIRES THAT HAVE BATTERY VOLTAGE

WHEN THE KEY SWITCH IS OFF.

WIRES THAT HAVE BATTERY VOLTAGE

WHEN THE KEY SWITCH IS ON.

STARTING CIRCUIT.

GAUGE CIRCUIT.

PANEL LAMP CIRCUIT.

WASHER/WIPER CIRCUIT.

HEATER AND AIR CONDITIONER CIRCUIT.

GROUND CIRCUIT.

AIR INLET HEATER CIRCUIT.

ALL DASHED LINES ARE ATTACHMENTS.