SENR8208
January 1990
D40D, D400D
Articulated Dump Trucks
Electrical System
2JJ1-UP
8TF1-UP
©
1990 Caterpillar
All Rights Reserved
Printed in U.S.A.
Circuit Number Chart
Circuit
Number
Color Description
Circuit
Number
Color Description
POWER DISTRIBUTION CIRCUITS MONITORING CIRCUITS
101 RD BATTERY 469 GN FUEL LEVEL SENDER
102 BU HEAD LAMP 472 OR SERVICE BRAKE INDICATOR LAMP
103 YL DOME/DASH/PARK/TAIL LAMP 477 YL SPEEDO PROBE
105 BR KEY SWITCH 488 WH AIR PRESS. SW. LINK
107 WH ENGINE SHUTDOWN CONTROL 490 GN LOCK UP INDICATOR LAMP
109 OR ALTERNATOR OUTPUT (+) TERM. 498 WH DIFF LOCK INDICATOR LAMP
110 GN WINDSHIELD WIPER SW. (REAR) ACCESSORY CIRCUITS
112 PU MAIN POWER RELAY OUTPUT 500 BR WIPER - FRONT (PARK)
113 OR OPERATOR MONITOR PANEL 501 GN WIPER - FRONT (LOW)
114 GN WARNING HORN (FORWARD) 502 OR WIPER - FRONT (HIGH)
118 GY WINDSHIELD WIPER SW. (FRONT) 503 BR WIPER - REAR (PARK)
119 PK WINDSHIELD WIPER SW. (REAR) 504 YL WIPER - REAR (LOW)
121 YL BACK UP ALARM/LAMP 505 BU WIPER - REAR (HIGH)
122 BU AIR DRYER 506 PU WASHER-FRONT
123 WH GAUGES 507 WH WASHER-REAR
124 GN HEATER/AIR CONDITIONER SW. 513 OR AIR CONDITIONER COMPRESSOR
125 OR SUSPENSION FUSE TO SUSPENSION 515 GY BLOWER MOTOR (HIGH)
130 GN INDICATOR LAMPS 516 GN BLOWER MOTOR (MEDIUM)
140 BU LOCK UP FUSE TO CONTROL 517 BU BLOWER MOTOR (LOW)
165 YL START AID FEED 521 YL AIR COND. SW. TO REFRIGERANT SW.
173 YL WORK/STOP LAMP 522 WH AIR COND. COMPR. TO THERMO. SW.
GROUND CIRCUITS 537 GN TURN SIGNAL SW TO FLASHER
200 BK MAIN CHASSIS 539 BU TURN SIGNAL INDICATOR BASIC/RIGHT
201 BK OPERATOR MONITOR PANEL 540 WH TURN SIGNAL INDICATOR BASIC/LEFT
202 BK TRANSMISSION CONTROL 572 PU RETARDER SOL. TO GROUND SW.
203 BK CHASSIS DIAGNOSTIC 573 GN LOCK UP SW. TO RETARDER SW.
207 BK STARTER DIAGNOSTIC 589 GN PRESS. SW. TO AIR COND. CLUTCH
MACHINE BASIC CIRCUITS LIGHTING CIRCUITS
301 BU STARTER NO.1 SOL. TO RESISTOR 602 WH DOME LAMP
302 OR STARTER NO.1 TO DIAGNOSTIC/ 604 OR STOP LAMP
RESISTOR TO DIAGNOSTIC 605 YL TURN LAMP - LEFT
304 WH STARTER RELAY TO NO.1 OUTPUT 606 GY TURN LAMP - RIGHT
306 GN START RELAY TO NEUTRAL START SW. 610 OR HEAD LAMP BASIC
308 YL MAIN POWER RELAY COIL 611 PU HEAD LAMP HIGH
310 PU START AID SW. TO START AID SOL. 614 PU PARK/TAIL/DASH LAMP
311 WH START AID SOL. TO TEMP SW. 619 GN HEADLAMP - LOW
321 BR BACK UP ALARM/LAMP 624 YL WORK LAMP
322 GY WARNING HORN (FORWARD) CONTROL CIRCUITS
326 PU KEY SWITCH "C" TERMINAL 705 PK TRANSMISSION LOCK UP CLUTCH
327 PK SHUT DOWN SOL. SOL. BASIC
MONITORING CIRCUITS 706 BR TRANSMISSION RETARDER SW.
403 GN ALTERNATOR (R) TERMINAL 709 OR TRANSMISSION PICK UP POWER
405 GY OPERATOR MON PANEL OIL PRESS. 710 GN TRANSMISSION SPEED PICK UP
406 PU OPERATOR MON PANEL COOLANT SIGNAL
TEMP. 790 WH PARK BRAKE & SUSPENSION CONTROL
407 PK OPERATOR MON PANEL CONV/RET 791 OR FRONT SUSPENSION
OIL TEMP. 792 BU FRONT SUSPENSION
408 WH OPERATOR MON PANEL BRAKE PRESS. 793 YL REAR SUSPENSION
409 OR OPERATOR MON PANEL NEUTRAL 794 GN REAR SUSPENSION
410 WH OPERATOR MON PANEL FAULT ALARM 815 GN TRANSMISSION PRESSURE SENSOR
411 PK OPERATOR MON PANEL MASTER 821 YL TRANSMISSION PRESSURE SENSOR
FAULT LAMP A789 PK SERVICE BRAKE TO PARK BRAKE
413 BR OPERATOR MON. PANEL FUEL PRESS. INHIBIT SW.
415 GN OPERATOR MON PANEL TEST SW. A790 WH SUSPENSION GROUND TO PARK
419 YL OPERATOR MON PANEL PARK BRAKE BRAKE INHIBIT
443 YL POWER TRAIN TEMP GAUGE A791 OR DOWN SOL. FRONT
446 PU BRAKE OIL TEMP SENDER A792 BU UP SOL. FRONT
449 BU SPEEDO SENDER A793 YL DOWN SOL. REAR
450 YL TACHOMETER SENDER(+) A794 GN UP SOL. REAR
451 BR TACHOMETER SENDER(-) A982 BR RETARDER SOL. TO THROTTLE SW.
454 GN RETARDER INDICATOR LAMP B958 GN LOCK UP CLUTCH CONTROL TO
PRESS. SW.
47
48
49
50
45
46
47
48
49
50
45
47
47
48
49
46
47
48
48
47
49
48
41
43
29
42
37
35
33
34
36
38
39
40
44
30
31
32
Engine and Transmission - Left Side
Engine and Transmission - Right Side
D40D Trailer
D400D Trailer
C32112P1
C32111P1
3
4
5
6
8
9
10
11
12
16
1
2
20
21
23
24
25
26
27
28
7
A
4
6
8
9
10
12
14
15
13
16
17
18
19
20
21
22
23
24
26
28
7
11
C32110P1
Tractor (Except Engine and Transmission)
FOR USE IN SERVICE MANUALS:
D40D, D400D ARTICULATED DUMP
TRUCKS, SENR 8200
Machine locations are repeated for components located close together.
A = Components located at right console.
B = Components located at breaker box.
C = Components located in dash area.
Component Locations
A - COMPONENTS IN OPERATOR COMPARTMENT
Ident Schematic Components Location Ident Schematic Components Location
49
ALARM - BACK UP (D40D)
A-11
21
METER - SERVICE HOUR
E-5
49
ALARM - BACK UP (D400D)
A-12
21
METER - TACHO
E-5
8
ALARM - FAULT
C-5
A
MOTOR - BLOWER
B-4
41
ALTERNATOR
A-2
A
MOTOR - FRONT WASHER
D-11
23
AUXILIARY START RECEPTACLE
A-5
A
MOTOR - FRONT WIPER
B-6
16
BATTERIES
A-5
A
MOTOR - REAR WASHER
D-10
20
BREAKER - AIR CONDITIONER
D-4
A
MOTOR - REAR WIPER
C-7
20
BREAKER - ALTERNATOR
E-9
38
MOTOR - STARTER
A-6
20
BREAKER - ENGINE SHUTDOWN
E-4
21
PANEL - OPERATOR MONITOR
F-1
20
BREAKER - HEADLAMP
D-4
42
PICK - UP - SPEEDOMETER
E-11
20
BREAKER - KEY
D-9
40
PICK - UP - TACHOMETER
A-3
20
BREAKER - TURN/PARK
D-4
43
PICK - UP - TRANSMISSION SPEED
D-11
21
CONTROL - ENGINE SHUTDOWN
E-1
20
RELAY - START
D-9
46
CONTROL - REAR SUSPENSION
B-10
21
RELAY - MAIN POWER
D-4
5
CONTROL - FRONT SUSPENSION
F-12
A
RESISTOR - AIR CONDITIONER
B-5
21
CONTROL - LOCKUP
D-1
39
RESISTOR
A-6
21
CONNECTOR - DIAGNOSTIC
F-9
50
SENDER - BRAKE OIL (D40D ONLY)
B-10
26
DRYER - AIR
E-11
32
SENDER - CONVERTER TEMPERATURE
C-11
21
FLASHER
D-3
44
SOLENOID - AIR CONDITIONER CLUTCH
B-3
20
FUSE - AIR DRYER
E-5
28
SOLENOID - FRONT SUSPENSION
F-12
20
FUSE - BACK UP ALARM
D-7
34
SOLENOID - ENGINE SHUTDOWN
A-2
20
FUSE - DOME LIGHT
E-7
36
SOLENOID - LOCK - UP CLUTCH
D-11
20
FUSE - FRONT WIPER
E-5
25
SOLENOID - RETARDER
F-11
20
FUSE - HORN
D-7
28
SOLENOID - REAR SUSPENSION
F-12
20
FUSE - GAUGES
E-7
A
SOLENOID - START AID
B-2
20
FUSE - INDICATOR LAMP
E-5
1
SWITCH - BACK - UP ALARM
C-3
20
FUSE - RETARDER SOLENOID
E-5
21
SWITCH - BLOWER
B-5
20
FUSE - OPERATOR MONITOR
E-7
17
SWITCH - BRAKE AIR PRESSURE
B-2
20
FUSE - REAR WIPER
E-5
17
SWITCH - BRAKE AIR PRESSURE
C-2
20
FUSE - START AID
D-7
21
SWITCH - CAB LAMP
F-7
20
FUSE - SUSPENSION CONTROL
E-7
2
SWITCH - CONVERTER LOCK INDICATOR
D-10
21
GAUGE - BRAKE OIL TEMPERATURE (D40D)
E-6
31
SWITCH - CONVERTER TEMPERATURE
E-11
21
GAUGE - CONVERTER TEMPERATURE
F-3
29
SWITCH - COOLANT TEMPERATURE
A-4
21
GROUND - DASH PANEL
D-2
35
SWITCH - COOLANT TEMPERATURE
10
HORN - WARNING
B-1
(ETHER INHIBIT)
A-4
21
INDICATOR - DIFFERENTIAL LOCK
F-4
37
SWITCH - DIFF LOCK
D-11
21
INDICATOR - HIGH BEAM
F-5
9
SWITCH - DIMMER
C-2
21
INDICATOR - LEFT TURN
F-6
12
SWITCH - DISCONNECT
A-4
21
INDICATOR - RETARDER
F-5
4
SWITCH - DOME LAMP
B-7
21
INDICATOR - RIGHT TURN
F-4
30
SWITCH - ENGINE OIL PRESSURE
A-3
21
INDICATOR - SERVICE BRAKE
F-5
24
SWITCH - FRONT BRAKE OVERSTROKE
E-10
21
INDICATOR - TORQUE CONVERTER LOCK
F-6
21
SWITCH - FRONT WIPER
E-8
21
LAMP - BRAKE AIR PRESSURE GAUGE
E-6
33
SWITCH - FUEL
A-2
21
LAMP - BRAKE AIR PRESSURE GAUGE
F-6
3
SWITCH - FUEL LEVEL
A-2
13
LAMP - CAB
B-8
21
SWITCH - HORN
F-8
7
LAMP DOME
B-7
21
SWITCH - KEY START
E-3
11
LAMP - HIGH BEAM HEAD RH
B-1
6
SWITCH - LOCK UP INDICATOR
D-11
11
LAMP - HIGH BEAM HEAD LH
C-1
15
SWITCH - LOCK UP CONTROL PRESSURE
D-1
11
LAMP - LOW BEAM HEAD RH
A-1
21
SWITCH - OPERATOR MONITOR TEST
F-3
11
LAMP - LOW BEAM HEAD LH
C-1
27
SWITCH - PARK BRAKE INDICATOR
F-10
21
LAMP - MASTER FAULT
19
47
LAMP - BACK UP (D40D)
45
47
LAMP - BACK UP (D400D)
45
48
LAMP - STOP/TAIL/TURN RH (D40D REAR)
21
48
LAMP - STOP/TAIL/TURN LH (D40D REAR)
21
48
LAMP - STOP/TAIL/TURN RH (D400D REAR)
14
48
LAMP - STOP/TAIL/TURN LH (D400D REAR)
21
11
LAMP - TURN/PARK RH (FRONT)
22
11
LAMP - TURN/PARK LH (FRONT)
21
21
METER - SPEEDO
18
A
SWITCH - BRAKE OVERSTROKE (D400D)
SWITCH - BRAKE OVERSTROKE (D40D)
SWITCH - REAR WIPER
SWITCH - REFRIGERANT
SWITCH - RETARDER INDICATOR
SWITCH - RUNNING LAMP
SWITCH - TURN SIGNAL
SWITCH - START AID
SWITCH - STOP LAMP
THERMOSTAT
SWITCH - SERVICE BRAKE INHIBIT
C-2
B-12
B-11
F-7
B-2
E-10
F-8
E-2
F-3
C-2
B-5
24
SWITCH - PARK BRAKE INHIBIT
C-2
F-2
A-11
A-12
A-11
B-11
A-12
B-12
A-1
C-1
E-4
CHG
124-GN-14
614-PU
103-YL
200-BK-14
110-GN
503-BR
504-YL
505-BU
624-YL
HARNESS AS.
LOCPART NO.IDENT
200-BK-14
124-GN-14
200-BK-14
539-BU
103-YL
DF
2
1
PARK BRAKE
CONV TEMP
FUEL PR
FUEL LEVEL
ENG OILPR
COOLTEMP
ALARM
NEUTRAL
BRAKE AIR
+BATTERY
LAMP
TEST SWITCH
ALTERNATOR
GROUND
7
3
403-GN
302-OR
203-BK
207-BK
322-G
Y
327-PK-14
311-WH
310-PU
121-YL
539-BU
540-WH
D
F
F
610-OR-14
2
1
4
8
1
9
7
2 110-GN
103-YL
539-BU
200-BK-14
124-GN-14
9
8
H
3
118-GY
502-OR
501-GN
3
500-BR
10
5
4
6
103-YL-14
540-WH
202-BK
125-OR
122-BU
BRAKEOIL
TEMP SENDER
6N5926
207-BK
203-BK
302-OR
311-WH
310-PU
D
2
1
4
3
7
6
5
310-PU4
3
6
9
8
1
7
2
10
419-YL
407-PK
413-BR
469-GN
405-GY
406-PU
410-WH
409-OR
408-WH
113-OR
411-PK
415-GN
403-GN
201-BK
201-BK
201-BK
201-BK
201-BK
201-BK
8
201-BK
200-BK-14
614-PU
8
7
201-BK
200-BK-14
202-BK
DF
573-GN
573-GN
200-BK-14
201-BK
140-BU
6
403-GN
113-OR
411-PK
415-GN
4
6
AUX START
RECEPTACLE
4N6579
5
8
E
E
E
D
B
C
5
4
3
2
CABLE AS.
WIRE AS.
1
+BATTERY
GROUND
UP SOLENOID
DOWN SOLENOID
1
5
4
3
U
9
2
3
4
5
1
10
FRAME
GROUND
P
NSQ
12V BATTERY
9G4232
12V BATTERY
9G4232
BK-00
BK-00BK-00
NEGPOSNEGPOS
200-BK-14
109-OR-6
513-OR-14
521-YL-14
BK-18
RD-18
BU-18
LOCK UP CONTROL
PRESSURE SW
6T1546
+ BATTERY
GROUND
PRESSURE
MAG PICKUP
SOLENOID
PRESSURE
PRESSURE
GROUND
CONTROL
2
469-GN
201-BK 6
F
F
F
D
200-BK
L1L1
L39
327-PK-14
200-BK
L30
112-PU
L32
L34
L33
101-RD-14
L31
RESISTOR
6T2217
L30
L19
F
H
F
H
L33
BU-18
RD-18
BK-18
BR-18
GY-18
PU-18
RD-18
OR-18
YL-18
GN-18
BU-18
F
L30
308-YL
112-PU
L34
L30
L33
L34
L1
110-GN
F
406-PU
201-B
K
BK
BK
F
G
G
H
H
H
H
H
H
502-OR
501-GN
101-RD-6
304-WH-10
605-YL
472-OR
321-BR
J
J
JDJ
J
D
D
J
J
FUSES ARE 3K8782. FUSE HOLDERS ARE 4K5122. INDICATORLAMPS
ARE 2U4791. GAGELAMPS ARE 2U4806.
T
V
JK
D
L24
L10
200-BK
490-GN
J
200-BK-14
L28
DG
G
RETARDER SWITCH
6T1546
DGG
L23
D
140-BU
610-OR-14
L7
540-WH
WH-18
BK-18
JT
L23
L23
V
D
D
C
C
DISCONNECT SW
7N0718
NOTE
3
2
4
1
J
2
4
1
3
2
J
1
K
6
U
D30D REARCHASSISHARNESSD25D AND D350D
REAR CHASSISHARNESS
2
5
1
J
K
K
L
200-BK-14
4
+BATTERY
GROUND
UP SOLENOID
DOWN SOLENOID
200-BK-14
REAR SUSPENSION
CONTROL
7U6062
446-PU
321-BR1
RH STOP/TAIL/TURN
LAMP
6U4358
LH STOP/TAIL/TURN
LAMP
6U4358
605-YL
604-OR
614-PU
604-OR
614-PU
200-BK
321-BR
321-BR
REVERSE
ALARM
3T1815
200-BK
200-BK
200-BK
200-BK
2
8
6
7
2
5
4
3
1
605-YL
472-OR
614-PU
604-OR
606-GY
200-BK-14
125-OR
A790-WH
A793-YL
A794-GN
REVERSE
LAMP
5U5915
REAR BRAKE
OVERSTROKESW
5U1452
472-OR
BU-18
RD-18
BK-18
BU-18
605-YL
472-OR
200-BK-14
614-PU
604-OR
606-G
Y
446-PU
321-BR
RD-18
606-GY
L19
1
3
4
5
2
202-BK
7
606-GY
6
8
PARK
BRAKE SW
6T1546
RETARDER
SOLENOID
7U2065
200-BK
200-BK
200-BK
200-BK
200-BK
200-BK
2
L9
710-GN
202-BK
705-PK
202-BK
3
4
200-BK
449-BU
477-YL
SPEEDOMETER
SPEED PICKUP
9X5393
2
709-OR
821-YL
815-GN
F
E
D
200-BK
C
B
A
L51
L51
TORQUE
CONVERTER
LOCK
INDICATOR SW
6T1546
709-OR
821-YL
815-GN
710-GN
705-PK
202-BK
506-PU
443-YL
507-WH
200-BK-14
L52
200-BK
498-WH
DIFF
LOCK SW
3T3133
122-BU
AIRDRYER
8V0769
L52
L53
L53
J
L51
J
L50
L50
J
446-PU
605-YL
606-GY
477-YL
449-BU
D
201-BK
419-YL
140-BU
572-PU
200-BK-14
R
L1
J
1
J
L44
STARTER
6N1889
L44
L43 L43 L43
472-OR
L38
446-PU
200-BK
CONVERTER
TEMPSW
6T4044
A790-WH
A789-PK
FRONT
SUSPENSION
CONTROL
7U6062
BK-00
109-OR-6
308-YL
125-OR
A790-WH
A792-BU
A791-OR
A790-WH
A791-OR
A790-WH
A792-BU
A790-WH
A794-GN
A790-WH
A793-YL
FRONT SUSPENSION
SOLENOID
7U0985
REAR SUSPENSION
SOLENOID
7U0985
NOTE A
BK-00
GS
MTR BAT
MOTOR
9
7
1
8
3
10
5
2
6
4
3
4
5
7
1
9
6
2
8
8
7
3
2
6
5
4
1
2
3
L1
112-PU
3
2
BK-18
BK-18
1
1
2
3
4
3
3
2
1
1
T
T
507-WH
506-PU
1
2
L42
A
L42
L42
L35
614-PU
L26
606-GY
L35
604-OR
614-PU
F
L26
L13
L38
F
L38
F
FL39
F
200-BK-14
F
L31
F
L30
F
F
L28
101-RD-14
446-PU200-BK
173-YL
L30
130-GN
F
R
T
L17
L12
L19
L17
L23
L19
W
L41
L29
L41
L21
L41
L21
L27
F
L18
L18
L41
L25
L18
L40
L40
F
L39
U
540-WH
F
310-PU
F
K
F
L21
H
L21
H
L13
L38
D
L38
F
200-BK
454-GN
H
200-BK-14
F
H
10
1
2
3
9
F
F
F
F
F
F
101-RD
H
H
H
H
H
F
443-YL
H
L6
F
L6
H
F
1
L54
H
L54
H
L54L54
M
F
H
L54
F
L8
L38
112-PU-14
200-BK-14
619-GN-14
611-PU-14
540-WH
207-BK
203-BK
200-BK-14
614-PU
322-GY
200-BK-14
L38
L48
L31
H
200-BK
200-BK-14
200-BK
L48
L19
L18
L15
L37
L37
L37
L5
L17
H
L16
F
F
L16
L37
L47
L15
L37
L47L47
F
L15
L37
L35
L34
L14
L14
L5
L25
L33
F
L13
L5
L25
L34
4
7
6
5
9
8
3
2
1
L5
F
101-RD
F
L5
112-PU-14
L24
L4
L2
200-BK
L19
C
L3
200-BK
200-BK
200-BK
446-PU
200-BK
C
140-BU
L31
C
L3
614-PU
F
L7
614-PU
L22
L34
L31
L22
F
L33
201-BK
101-OR-6
200-BK
200-BK-14
302-OR
327-PK-14
L32
614-PU
F
200-BK
F
F
F
L19
D
L32
L31
L13
L31
L10
610-OR-14
L9
200-BK
124-GN-14
L33
L9
173-YL
L8
F
140-BU
L8
L10
201-BK
L7
L7
L6
L10
L2
L2
L6
201-BK
L12
G
L2
L29
L31
L4
L29
L19
L3
L36
L5
L2
R
419-YL
407-PK
140-BU
573-GN
R
L28
202-BK
573-GN
L36
1
2
3
2
L10
1
L24
125-OR
A790-WH
A793-YL
A794-GN
L
200-BK-14
K
200-BK-14
H
L9
L10
10
4
3
2
6
9
8
7
5
1
472-OR
490-GN
498-WH
454-GN
539-BU
322-GY
327-PK-14
121-YL
311-WH
302-OR
203-BK
207-BK
BK-18
L7
L48
L3
310-PU
310-PU
419-YL
140-BU
572-PU
604-OR
614-PU
472-OR
606-GY
605-YL
446-PU
321-BR
407-PK
A789-PK
122-BU
125-OR
490-GN
201-BK
498-WH
477-YL
449-BU
5
L32
614-PU
614-PU
614-PU
D
614-PU
614-PU
114-GN
101-RD
200-BK
165-YL
113-OR
123-WH
173-YL
125-OR
HORN
BACKUP ALARM
START AID
OPERATORMONITOR
101-RD
DIAGNOSTIC
CONNECTOR
310-PU
311-WH
302-OR
203-BK
207-BK
454-GN
498-WH
490-GN
472-OR
F
624-YL
322-GY
614-PU
20
102-BU-14
19
18
17
16
614-PU
322-GY
624-YL
507-WH
503-BR
504-YL
505-BU
327-PK-14
121-YL
15
14
13
118-GY
110-GN
12
10
9
173-YL624-YL
114-GN
8
322-GY
1
614-PU
6 610-OR-14
5
500-BR
506-PU
4
118-GY
118-GY
7
3
2
11
GAGES
506-PU
614-PU
614-PU
121-YL
CAB LAMP
101-RD
101-RD
112-PU-14
112-PU
112-PU
112-PU
SUSPENSION CONTROL
311-WH
302-OR
203-BK
207-BK
304-WH
105-BR
306-GN
101-RD
308-YL
109-OR
310-PU
112-PU
109-OR-6
109-OR
109-OR-6
304-WH-10
101-RD-6
109-OR-6
DDD
FFF
FH
FHHF
ALT BREAKER
9S0174
109-OR-6
109-OR-10
101-RD-6
101-RD
101-RD-14
101-RD-14
101-RD-14
105-BR
105-BR
KEY BREAKER
6N8589
START
RELAY
9F3099
306-GN
306-GN
304-WH
200-BK
304-WH
304-WH-10109-OR-10
FRONT
WIPERSW
3T6655
REAR
WIPERSW
3T6655
RUNNING
LAMP SW
8C9636
HORN SW
3T2357
CAB
LAMPSW
6T3990
10
10
10
10
10
10112-PU
10
TRANSMISSION
SPEED PICKUP
9G6724
LOCKUP
CLUTCH
SOLENOID
8E0756
OPERATOR STATION
B
WP
L
H
B
B
WP
L
H
B
200-BK
614-PU
540-WH
L27
HORN
HIGH TONE
7T0970
OPERATOR MONITOR
HORN
LOW TONE
7T0969
L30
A789-PK
604-OR
572-PU
490-GN
321-BR
201-BK
614-PU
L24
L28
200-BK
103-YL
200-BK
FRONT WIPER
MOTOR
6T6216
504-YL
110-GN
503-BR
505-BU
624-YL
200-BK-14
200-BK
200-BK-14 200-BK-14
501-GN
118-GY
500-BR
502-OR
624-YL
200-BK-14
103-YL
501-GN
118-GY
500-BR
502-OR
602-WH
103-YL
200-BK
DOME
LAMP
8C9678
CAB LAMP
5U5915
REAR WIPER
MOTOR
6T6216
DOOR
LAMPSW
9D4068
504-YL
110-GN
503-BR
505-BU
602-WH103-YL
614-PU
572-PU
604-OR
614-PU
321-BR
490-GN
A789-PK
201-BK
122-BU
125-OR
2
4
3
1
6
4
7
5
2
1
3
200-BK-14
624-YL
GN
GY
BR
OR
4
2
3
1
H
L
MOTOR
T
3
2
1
BK
RD
WH
RD-00
122-BU
125-OR
709-OR
821-YL
815-GN
710-GN
705-PK
202-BK
GY
PU
BR
RED
WHITE
ORANGE
YELLOW
PINK
ABBREV COLOR
BLACK
GRAY
PURPLE
BROWN
DESCRIPTIONSYMBOL
CONNECTOR
ELECTRICAL CONNECTION
TO VEHICLESTRUCTURE
INTERNAL ELECTRICAL
CONNECTION TO SURFACE
OF COMPONENT
BLADE, SPADE, RING,
OR SCREW TERMINAL
BK
PK
YL
OR
WH
RD
GN
BU
GREEN
BLUE
CIRCUIT CONNECTED
CIRCUIT NOT CONNECTED
ATCH WIRE, CABLE,
COMPONENT
L #
CIRCUIT GROUPING
DESIGNATION
112-PU-14
102-BU-14
103-YL-14
610-OR-14
200-BK
308-YL
107-WH-14
105-BR
306-GN
109-OR
109-OR-6
109-OR-6
112-PU
112-PU-10
308-YL
MAIN POWER
RELAY
3T0376
103-YL-14
103-YL
112-PU-14
112-PU-14
112-PU
112-PU
112-PU
113-OR
140-BU
125-OR
122-BU
118-GY
110-GN
122-BU
130-GN
140-BU
FROHT WIPER
REAR WIPER
AIRDRYER
INDICATOR LAMP
RETARDER SOLENOID
HF
124-GN-14
101-RD
101-RD
101-RD-14
101-RD
101-RD-14
101-RD-14
112-PU-14
112-PU-14
112-PU-10
103-YL-14
102-BU-14
107-WH-14
AIR CONDITIONER
BREAKER
6N8589
TURN/PARK
BREAKER
9G9487
HEADLAMP
BREAKER
6N8589
ENGINE
SHUTDOWN BREAKER
9G9487
306-GN
304-WH
306-GN
105-BR
105-BR
102-BU-14
107-WH-14
103-YL-14
103-YL
124-GN-14
165-YL
123-WH
113-OR
173-YL
125-OR
122-BU
140-BU
130-GN
110-GN
118-GY
BRAKE AIR PRESSURE
GAGE LAMP
2U4806
BRAKE AIR PRESSURE
GAGE LAMP
2U4806
614-PU
200-BK
614-PU
200-BK
123-WH
123-WH
123-WH
123-WH
123-WH
200-BK
130-GN
201-BK
443-YL
606-GY
605-YL
446-PU
477-YL
449-BU
451-BR
450-YL
449-BU
477-YL
F
614-PU200-BK
123-WH
451-BR
450-YL
614-PU200-BK
123-WH
200-BK
200-BK
614-PU
123-WH
SPEEDOMETER
8C9806
TACHOMETER
8C9839
SERVICE
METER
6T7337
200-BK200-BK
200-BK
498-WH
130-GN
RIGHT TURN
INDICATOR
DIFFERENTIAL
LOCK INDICATOR
RETARDER
INDICATOR
HI BEAM
INDICATOR
SERVICE BRAKE
INDICATOR
TORQUE
CONVERTER LOCK
INDICATOR
9
2
1
3
10
4
5
8
6
7
8
7
2
6
1
10
5
301-BU
3
GY
PU
BR
RED
WHITE
ORANGE
YELLOW
PINK
4
ABBREV COLOR
BLACK
GRAY
PURPLE
BROWN
DESCRIPTION
9
OPERATOR STATION
SYMBOL
CONNECTOR
ELECTRICAL CONNECTION
TO VEHICLESTRUCTURE
INTERNAL ELECTRICAL
CONNECTION TO SURFACE
OF COMPONENT
LEFT TURN
INDICATOR
10A
10A
10A
10A
10A
15A
BLADE, SPADE, RING,
OR SCREW TERMINAL
15A
10A
10A
W
G
-
+24
W
G
-
+24
+-
OPERATOR STATION
OPERATOR STATION
A794-GN
A793-YL
A790-WH
130-GN
454-GN
130-GN
539-BU
540-WH
611-PU-14472-OR130-GN
130-GN
490-GN
472-OR
454-GN
498-WH
200-BK
540-WH
W
BK-6
D
L7
RD-00
403-GN
140-BU
113-OR
446-PU
443-YL
D
LOCK UP
PRESSURE SW
6T1546
200-BK-14
BK
200-BK
572-PU
490-GN
FAULT
ALARM
9G9813
FRONTBRAKE
OVERSTROKE SW
5U1452
PK
408-WH
410-WH
409-OR
409-OR201-BK
YL
201-BK
201-BK
201-BK
201-BK
201-BK
201-BK
200-BK-14
OR
RD-00
WH
RD
GN
302-OR
PANEL LAMP
8D1429
RESISTOR
9G1950
BLOWERSW
6P3236
L28
515-GY-14
BU
BLOWER
9G8697
BLOWER
9G8693
WH/RD-14
WH/RD-14
BK-14
BK-14
GREEN
200-BK-14
515-GY-14
200-BK-14
515-GY-14
614-PU
200-BK-14
RD
BK
410-WH
201-BK
124-GN-14
614-PU
521-YL-14
522-WH-14
200-BK-14
BLUE
CIRCUIT CONNECTED
CIRCUIT NOT CONNECTED
ATCH WIRE, CABLE,
COMPONENT
124-GN-14
521-YL-14
515-GY-14
516-GN-14
517-BU-14
522-WH-14
200-BK-14
THERMOSTAT
9P3498
522-WH-14
124-GN-14
521-YL-14
200-BK-14
614-PU
200-BK-14
101-RD-14
L
OPERATO
RS
TATION
#
3
2
1
2
1
CIRCUIT GROUPING
DESIGNATION
T
OR
GRN
BLU
BLK
RED
1
2
2
1
MOTOR
MOTOR
BK-18
RD-18
BU-18
L2
L2
NOTE C
200-BK-14
200-BK-14
109-OR-6
304-WH-10
101-RD-6
101-RD-6
304-WH-10
C
L9
469-GN
201-BK
311-WH
200-BK
2
1
2
1
709-OR
821-YL
815-GN
710-GN
705-PK
202-BK
125-OR
122-BU
A
BK-18
BK-18
FUEL
LEVEL SW
9W2403
COOLANT
TEMPSW
7X5988
COOLANT
TEMP SW
7N9785
T T
A
614-PU
R
A
614-PU
123-WH
165-YL
MASTER
FAULT LAMP
7N1996
OPERATOR
MONITORTEST SW
6T6066
CONVERTER
TEMP GAGE
4W2066
START
AIDSW
6T6066
310-PU
201-BK
201-BK
415-GN
200-BK
2
411-PK
200-BK
200-BK
200-BK-14
200-BK-14
200-BK
3
2
5
4
1
1
F
KEY
START SW
9G7641
TURN
SIGNAL SW
9G5589
308-YL
326-PU
306-GN
105-BR
OPERATOR
MONITOR
3T9100
7
D
6
4
537-GN103-YL
103-YL
3
605-YL
606-GY
540-WH
540-WH
539-BU
539-BU
200-BK-14
200-BK
201-BK
200-BK
200-BK
105-BR
308-YL
306-GN
107-WH-14
L36
BU-18
BK-18
WH-18
GN-18
PK-18
OR-18
YL-18
DASH
PANEL
GROUND
5
F
YL-18
WH-18
BK-18
BU-18
RD-18
OR-187
4
7
3
2
7
5
8
1202-BK
202-BK
573-GN
15A
8
7
6
140-BU
202-BK
815-GN
710-GN
705-PK
709-OR
821-YL
5
1
3
2
6
5306-GN
326-PU
200-BK
327-PK-14
107-WH-14 + BATTERY
GROUND
ENG SOL
RESET
OFF(KEY)
OFF
4
3
60A
F
2
BRAKEOIL
TEMP GAGE
4W2067 (NOTEA)
1
14
5
6
2
3
472-OR
REAR BRAKE
OVERSTROKESW
5U1452
REVERSE
LAMP
5Y5915
L10
C
ST
ON
C
614-PU
L13
200-BK
OFF
200-BK
B
S
C
200-BK
R
125-OR
A790-WH
A793-YL
A794-GN
MOTOR
407-PK
419-YL
140-BU
200-BK
REVERSE
ALARM
3T1815
443-YL
200-BK
507-WH
200-BK
506-PU
321-BR
321-BR
200-BK
CONVERTER
TEMP SENDER
6N5926
614-PU
604-OR
614-PU
REAR
WASHER MOTOR
2U4570
604-OR
FRONT
WASHER MOTOR
2U4570
605-YL
LH STOP/TAIL/TURN
LAMP
6U4358
RH STOP/TAIL/TURN
LAMP
6U4358
MOTOR
310-PU
311-WH
START AID
SOLENOID
9G4365
572-PU
490-GN
321-BR
310-PU
311-WH
BACK UP
ALARMSW
3T3132
321-BR
121-YL
A789-PK
408-WH
201-BK
E
EF
ED
611-PU-14
611-PU
610-OR-14 619-GN-14
611-PU-14
611-PU
610-OR-14
173-YL
200-BK
619-GN-14
611-PU-14
604-OR
A789-PK
408-WH
201-BK
604-OR
173-YL
BU-18
RD-18
BK-18
DIMMER SW
2H1855
1
2
3
A
B
C
D
B
A
D
C
201-BK
407-PK
BU-18
RD-18
BK-18
STOP LAMP SW
2U9346
PARK BRAKE
INHIBITSW
6T1546
BRAKE AIR
PRESSURE SW
9G8009
488-WH408-WH
BRAKE AIR
PRESSURE SW
9G8009
488-WH201-BK
J
521-YL-14
513-OR-14
REFRIGERANT
SWITCH
5V5698
TRANSMISSION
PRESSURE SENSOR
8C9792
A/C CLUTCH
SOLENOID
7U5517
522-WH-14
513-OR-14
6
4
3
2
HI BEAM
HEAD LAMP
6U0339
LOW BEAM
HEAD LAMP
5U5915
PARK-TURN
LAMP
2U4432
1
5
2
4
1
3
2
1
125-OR
A790-W
H
A793-YL
A794-GN
OPERATOR STATION
F
611-PU-14
PARK-TURN
LAMP
2U4432
LOW BEAM
HEAD LAMP
5U5915
HI BEAM
HEAD LAMP
6U0339
CD
CD
BC
AC
C
YL-18
BK-18
BR-18
+V
GROUND
SIGNAL
2
1
A789-PK
200-BK
BU-18
RD-18
BK-18
A
A
A
A
B
B
B
2
1
BK-18
NOTE A: D40DONLY
NOTE B: D400D ONLY
NOTE C: TERMINALSFOR NEUTRAL START SWITCH
CONNECTED INSIDE HARNESS D.
BK-18
450-YL
451-BR
200-BK-14
200-BK-14
200-BK
201-BK
L27
TACHOMETER
ENGINE SPEED
PICK UP
7T6945
ENGINE OIL
PRESSURESW
6T1546
109-OR-6
ENGINE
SHUTDOWN
SOLENOID
6T4122
FUEL SW
9W3187
ALTERNATOR
5N5692
DC
403-GN
CD
522-WH-14
521-YL-14
200-BK-14
327-PK-14
322-GY
450-YL
451-BR
311-WH
207-BK
203-BK
302-OR
403-GN
201-BK
413-BR
406-PU
469-GN
405-GY
413-BR
201-BK
403-GN
619-GN-14
611-PU-14
614-PU
540-WH
539-BU
ENGINE SHUTDOWN
CONTROL
9G9287
FLASHER
8D6946
FRAME
GROUND
203-BK
207-BK
BK-6
200-BK
322-GY
322-GY
200-BK
200-BK-14
200-BK-14
611-PU-14
619-GN-14
200-BK
540-MH
614-PU
619-GN-14
200-BK-14
611-PU-14
539-BU
614-PU
611-PU-14
L11
R
L11
L26
L12
L35
L26
L11
L25
R
C
200-BK-14
405-GY
201-BK
ALT
+
R
GN
GY
BR
OR
4
2
3
1
H
L
MOTOR
619-GN-14
2OO-BK
539-BU
614-PU
200-BK-14
BK-00
TO ENG
BLOCK
TO
FRAME
IGN
SEND
GRD
19
7
13
14
5
6
10
9
8
1
11
15
3
2
4
16
17
18
12
20
1
2
3
3
9
2
6
7
5
4
8
1
4
6
5
7
2
3
8
1
L18
C
L3
9
10
5
T
2
1
3
4
6
4
3
1
M7U541700A-6
N 7U362800A-5
P7U5418 00 A-4
Q 7U362700A-5
S7U362901A-5
UNLESS OTHERWISE SPECIFIED: ALLWIREIS16 GAGE
COMPONENTS ARE SHOWN INSTALLED ONAFULLY
OPERABLE MACHINE WITH THE KEY AND ENGINEOFF,
AND THE XMSN SHIFTER IN NEUTRAL.
THIS SCHEMATICISFOR THE D40D AND D400D
ARTICULATED DUMP TRUCKS (9X1125 CHG 00).
2
327-PK-14
200-BK-14
L20
L20
W9F433707A-2/A-6
A7U623800B-2
B7U623900B-2
C 7U623701B-2
D 7U514803B-3
E7U646400C-3
F7U4739 02 D-1
G 7U507602B-7
H 7U473801D-5
J7U639100F-11
K7U517400B-12
L 7U534300B-12 A
R7T8650 01 C-5
T 7U639500F-12
U 7U519603B-10 B
V7U6396 00 F-12 A
9 8 7 6 5 4 3 2 1
F
E
D
C
B
A
12
11
10
9 8 7 6 5 4 3 2 1
12
11
10
D29885
