PR-1000C COLD PLANER ELECTRICAL SYSTEM

KENR1648
June 1990
PR-1000C Cold Planer
Electrical System
5XC138-UP
Connectors
Machine
Location
Harness And/Or
Components
Schematic
Location
1
WW-7R9109
Diagnostic Connector
(3208)
B-5
1
XX-7R9110
Diagnostic Connector
(3412)
C-5
9 Contacts 2
AT - 7R9114
YY-7R9111
D-4
2
AT-7R9114
AV — 7R91 08
A-3
2
AT-7R9114
AW—7R9113
C-4
2
AB-7R9112
AT—7R9114
E-4
*
AT—7R9114
Rt. Console E-Stop
F-1
*
AT—7R9114
Lt. Console E-Stop
F-4
*
AW-7R9113
Rt. Front E-Stop
A-5
*
AW—7R9113
Lt. Front E-Stop
F-5
*
AW-7R9113
Cutter Door E-Stop
D-4
*
AW-7R9113
Rt. Rear E-Stop
A-9
*
AW-7R9113
Lt. Rear E-Stop
F-9
*
Cutter door
Inductor Sw
A-7
*
AW-7R9113
Kickback Inductor Sw
A-8
Machine locations are repeated for connectors located close together.
* = Connector is located at the component.
Harness Connector Location Chart
20 Contacts
7 Contacts
6 Contacts
4 Contacts
Component Location
Component
Schematic
Location
Machine
Location
Component
Schematic
Location
Machine
Location
Alarm - Backup C-9 1 Relay -(3) Starter C-6 B
Alarm - Overheat A-3 A Relay - E Stop* B-2 21
Alternator (3208) C-8 2 Relay - E Stop* B-5 B
Batteries A-6 3 Relay - Kickback B-2 22
Box - Cutter Door E-Stop* AS D-4 4 Relay - Main B-6 B
Box - Left Console E-Stop* AS F-4 5 Relay - Reverse B-3 23
Box - Left Front E-Stop* AS F-5 6 Resistors (2.7 Ohms) C-2 24
Box - Left Rear E-Stop* AS F-9 7 Sender - Coolant Temp (3208) B-8 25
Box - Right Console E-Stop* AS F-i 8 Sender - Coolant Temp (3412) E-6 26
Box - Right Front E-Stop* AS A-5 9 Sender - Hydraulic Oil Temp F-8 27
Box - Right Rear E-Stop* AS A-9 10 Sender - Oil Pressure (3208) B-7 28
Breaker - Alternator (3208) D-8 11 Sender - Oil Pressure (3412) E-5 29
Breaker - E-Stop* B-6 B Solenoid - Cutter Drum Clutch C-4 A
Breaker - Main B-6 B Solenoid - Fuel (3208) E-8 30
Breaker - Start C-6 B Solenoid - Fuel (3412) E-5 31
Clutch - Water Spray Mag E-8 12 Solenoid - Water Valve B-7 32
Flasher A-2 13 Switch - Coolant (High Temp) E-5 33
Gauge - Coolant Temp (3208) E-2 A Switch - Cutter Clutch C-4 A
Gauge - Coolant Temp (3412) E-2 A Switch - Cutter Door Inductor A-7 34
Gauge - Hydraulic Oil Temp F-3 A Switch - Engine Rack Ught E-6 A
Gauge - Oil Pressure (3208) F-2 A Switch - Flasher and Beacon A-4 A
Gauge - Oil Pressure (3412) F-3 A
Switch - Flood Lamp
(Conveyer, Cutter Floods)
A-4 A
Gauge - Pyrometer (3412) E-3 A
Switch - Flood Lamp
(Dash Lamps, Front Floods)
A-4 A
Horn - Warning A-2 14 Switch - Key Start D-2 A
Horn - Warning 0-5 15 Switch - Kickback Ski Inductor A-8 35
Lamp - Kickback Reset C-4 A Switch - Main Disconnect A-6 36
Meter - Service E-7 A Switch - Neutral Limit D-2 A
Meter - Volt E-2 A Switch - Oil Pressure D-7 37
Motor -(2) Starter Aft (3412) D-6 16 Switch - Reverse Pressure B-3 A
Motor -(3) Starter Forward (3412) D-5 17 Switch - Spray Bar B-4 A
Motor - Starter (1) (3208) C-8 18 Switch - Start D-3 A
Pickup - Magnetic (3412 Tach) E-4 19 Tachometer - (3208) E-2 A
Pickup - Magnetic (3208 Tach) 0-7 20 Tachometer - (3412) E-3 A
Relay -(2) Starter C-6 B Thermocouple E-5 38
Machine locations are repeated for components located close together.
A = Components on operator console.
B = Components on relay panel.
* = E-Stop represents machine stop
Off Machine Switch Specification
Part No.
Function
Actuate
Deactuate
Contact Position
6T7663 Engine Oil Pressure (S. Meter)
93 ± 21 kPa
(13.5 ± 3.0 psi)
69 ± 21 kPa
(10.0 ± 3.0 psi)
Normally Open
9D7032 Reverse Pressure
517 ± 35kPa
(75.0 ± 5.0 psi)
414 ± 35kPa
(60.0 ± 5.0 psi)
Normally Open
A
3
4
5
6
8
9
10
11
12
14
15
13
16
B
1
2
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
7
37
35
33
34
36
38
1
1
1
2
2
2
2
2
A
1
2
3
4
5
6
8
9
10
11
12
14
15
13
16
B
1
2
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
7
Machine Harness Connector And Component Locations
37
35
33
34
36
38
©
1990 Caterpillar
All Rights Reserved
Printed in U.S.A.
AD
GS11
RESISTOR
(2 PLACES)
6T2217
1
2
10
10
10
10
10
10
CUTTER
DRUM
200-BK 200-BK
B800-WH B800-WH
B801-BR
B801-BR
<
>
>
<
<
>
>
<
2
PLUG
4
31
BR
BU
BK
WH
CUTTER DOOR
INDUCTOR SW
6R0283
7N8205
7N82047N8204
7N8205
KICKBACK SKI
INDUCTOR SW
6R0283
BR
BU
BK
WH
13
4
PLUG
2
<
>
>
<
<
>
>
<
2V7396
5T1553
3Y7302
7P6681
7R9871
5R7461
7R9874
7R9872
6S1061
3V6201
7P6682
4M7146
7R9912
7R9875
7R9878
7R9880
7R9886
7R9885
AA
BB
CC
DD
EE
FF
GG
HH
JJ
KK
LL
MM
NN
PP
TT
VV
AK
AL
CABLE AS
RR
SS
UU
AE
AF
AG
AH
AJ
AM
AN
AP
AR
WIRE AS
HH
BUSS BAR 7R9830
112-PU-4
118-GY
103-YL
115-PK
110-GN
110-GN
103-YL
103-YL
108-BU
108-BU
116-BR
106-WH
127-OR
115-PK
B805-WH
200-BK
2
1
>
<
STARTER
3208
3T2652
-
1
NN
LL
MM
UU
RR
PP
VV
ALTERNATOR
60 AMP
4N3986
3412 ENGINE
XX
XX
101-RD-10
AF
AG
AR
AM
AL
AK
WW
3208 ENGINE
WW
AN
GS10
MAIN
FRAME
GROUND
GS12
MAIN
DISCONNECT
7N0718
AH
AA
BB
CC
DD
WATER
SOLVALVE
7R9866
ZZ
AT
YY
AT
YY
450-WH
451-BK
AC
AT
AT
AB
AB
KK
GS6
STARTER
FORWARD
3412
3T2650
STARTER
AFT
3412
6N1889
3
2
JJ
GG
FF
EE
THERMOCOUPLE
3N5991
3N8278
A484-RD
A483-YL
200-BK
DASH LAMPS (6)
GS7
1
2
COOLANT
TEMP
(3208)
4W0483
COOLANT
TEMP
(3412)
4W0483
E STOP
RELAY
6T4007
4W2217
54
3
2
1
REVERSE
RELAY
6T4007
4W2217
5
4
3
2
1
1
2
108BU
5
4
3
2
1
KICKBACK
RELAY
6T4007
4W2217
3
2
1
BR
BL
YL
200-BK
2
1
OVERHEAT
200-BK
2
1
LEFT FRONT
CUTTER FLOOD
9X4381
LEFT REAR
CUTTER FLOOD
9X4381
GS2
MAIN
FRAME
GROUND
MAIN
FRAME
GROUND
WARNING
HORN
7T0969
322-GY
200-BK
321-BR
RIGHTTAIL
& FLASHER
LAMP
8C6207
RIGHT
BACKUP
LAMP
9X4381
BACKUP
ALARM
3T1815
200-BK
642-WH
608-GN
200-BK
GS5
1
3
2
>
<
<
>
<
<
200-BK
321-BR
200-BK
321-BR
200-BK
321-BR
CONVEYER
HOPPER
FLOOD LAMP
9X4381
608-GN
608-GN
200-BK
608-GN
608-GN
200-BK
UPPER
CONVEYER
FLOOD LAMP
9X4381
321-BR
608-GN
LEFT
BACKUP
LAMP
9X4381
LEFT TAIL &
FLASHER LAMP
8C6207
200-BK
321-BR
642-WH
609-YL
200-BK
200-BK
603-PK
609-YL
603-PK
321-BR
608-GN
609-YL
609-YL
200-BK
609-YL
MF
GND
607-PK
1
2
<
>
<
>
600-BR
350-PK
350-PK
349-OR
607-PK
200-BK
115-PK
322-GY
+
4
3
2
1
HORN
E-STOP
RD
BK
GY
YL
YL
GY
RD
BK
BN
PK
A
B
C
D
E
F
>
>
>
>
>
>
>
>
>
>
>
>
349-OR
607-PK
115-PK
322-GY
348-PU
607-PK
115-PK
322-GY
349-OR
348-PU
607-PK
200-BK
115-PK
322-GY
200-BK
+
4
3
2
1
HORN
E-STOP
101-RD
109-OR
109-OR-4
109-OR-4
101-RD
109-OR
302-OR
207-BK
304-WH
306-GN
302-OR
207-BK
OIL PR
SENDER
9X1124
COOLANT
SENDER
6N5926
B803-PK
200-BK
A476-PU441-OR
RESISTOR
6T2217
441-OR
A476-PU
B803-PK
>
<
1
2
ALT BREAKER
9S4693
SS
101-RD-4
101-RD-4
304-WH-10
304-WH-10
BK-4
GND ON
ENGINE
BK-00
101-RD-00
302-OR
306-GN
304-WH
306-GN
GS3
200-BK
101-RD-10
WATER SPRAY
MAG CLUTCH
CMI 2-5318
HYD OIL
TEMP SENDER
8N3844
442-GY
MAG PICKUP
TACH
2W8918
450-WH
451-BK
FUEL SOL
4N9314
327-PK-10
327-PK-10
200-BK-10
105-BR
OIL PR SW
6T7663
200-BK
SERVICE
METER
6T7337
105-BR
341-BU
341-BU
341-BU
B805-WH
442-GY
105-BR
341-BU
306-GN
441-OR
A476-PU
B803-PK
451-BK
450-WH
308-YL
PYROMETER
(3412)
3N7012
GS9
OIL PR
SENDER
9X1124
COOLANT
HIGH TEMP
6T2665
COOLANT
SENDER
6N5926
A477-PK
T
T
327-PK-10
200-BK-10
FUEL
SOLENOID
7W6551
200-BK-10
MAGNETIC
PICKUP-TACH
7R9768
A481-WH
A482-BK
AJ
#3 STARTER
RELAY
9F3099
101-RD-00
314-PU-10
BK-00
200-BK
313-GN
207-BK
302-OR
207-BK
302-OR
313-GN
340-WH-10
RD-00
101-RD-00
BUS
BAR
9W0742
101-RD-00 101-RD-00
BK-00
BK-00
609-YL
200-BK
600-BR
200-BK
12V BATTERY
9G4231
12V BATTERY
9G4231
101-RD-00
RIGHT REAR
CUTTER FLOOD
9X4381
RIGHT FRONT
CUTTER FLOOD
9X4381
DIAGNOSTIC CONNECT
OR
DIAGNOSTIC CONNECT
OR
101-RD-10
200-BK
BK-00
200-BK
203-BK
203-BK
340-WH-10
342-GN
AE
#2 STARTER
RELAY
9F3099
BK
101-RD
101-RD
342-GN
314-PU
340-WH314-PU-10
342-GN
BK
BK
101-RD
E-STOP
BREAKER
3T8728
START
BREAKER
9G9487
105-BR
105-BR
105-BR
101-RD
101-RD-4
MAIN
BREAKER
9S4693
MAIN RELAY
3T0376
E STOP
RELAY
3T0376
112-PU-4
147-PU-4
308-YL
BK
308-YL
308-YL
112-PU
112-PU-4
112-PU
200-BK
302-OR
207-BK
313-GN
101-RD
112-PU
308-YL
105-BR
203-BK
101-RD
340-WH
342-GN
314-PU
112-PU
308-YL
105-BR
203-BK
306-GN
304-WH
207-BK
302-OR
109-OR
101-RD
1
13
7
2
10
11
3
5
8
12
15
16
17
18
19
20
14
6
4
9
1
9
2
7
4
6
10
11
13
14
15
16
17
18
19
20
3
5
8
12
350-PK
200-BK
351-YL-10 327-PK-10
607-PK
115-PK
322-GY
348-PU
348-PU
347-WH
607-PK
200-BK
115-PK
322-GY
-
+
+
4
3
2
1
HORN
E-STOP
RD
BK
GY
YL
YL
GY
RD
BK
BN
PK
A
B
C
D
E
F
>
>
>
>
>
>
>
>
>
>
>
>
WARNING
HORN
7T0969
F
B
A
D
C
E
200-BK
322-GY
347-WH
346-BR
607-PK
200-BK
115-PK
322-GY
GS4
RIGHT REAR
E-STOP BOX AS
7R9103
+
4
3
2
1
HORN
E-STOP
RD
BK
GY
YL
YL
GY
RD
BK
BN
PK
A
B
C
D
E
F
>
>
>
>
>
>
>
>
>
>
>
>
322-GY
115-PK
607-PK
FRAME
GROUND
346-BR
345-GN
607-PK
200-BK
115-PK
322-GY
RIGHT REAR
E-STOP BOX AS
7R9103
RIGHT FRONT
E-STOP BOX AS
7R9103
+
4
3
2
1
HORN
E-STOP
RD
BK
GY
YL
YL
GY
RD
BK
BN
PK
A
B
C
D
E
F
>
>
>
>
>
>
>
>
>
>
>
>
103-YL
442-GY
A476-PU
441-OR
306-GN
308-YL
105-BR
B805-WH
341-BU
B803-PK
442-GY
A476-PU
441-OR
306-GN
308-YL
105-BR
642-WH
607-PK
607-PK
642-WH
607-PK
642-WH
600-BR
200-BK
608-GN
609-YL
603-PK
321-BR
642-WH
607-PK
600-BR
322-GY
B801-BR
345-GN
350-PK
B801-BR
B800-WH
607-PK
115-PK
322-GY
1
3
2
RD
BK
GY
YL
RESISTORS
2.7
50 WATT
817042
344-GY
607-PK
115-PK
322-GY
345-GN
344-GY
607-PK
200-BK
115-PK
322-GY
CUTTER DOOR
E-STOP BOX AS
7R9103
LEFT HAND CONSOLE
E-STOP BOX AS
7R9103
+
4
3
2
1
HORN
E-STOP
RD
BK
GY
YL
YL
GY
RD
BK
BN
PK
A
B
C
D
E
F
>
>
>
>
>
>
>
>
>
>
>
>
YL
GY
RD
BK
BN
PK
A
B
C
D
E
F
>
>
>
>
>
>
BK
103-YL
>
>
>
>
>
>
RESET
LAMP
3T0304
SPRAY
BAR SW
8D2676
CLUTCH
SOLENOID
5T4434
350-PK
B801-BR
B802-OR
B803-PK
B800-WH
BK
B800-WH
B803-PK
B803-PK 110-GN
B802-OR
BK
B801-BR
341-BU343-PK
600-BR
GS1
103-YL
115-PK
607-PK
115-PK
607-PK
103-YL
344-GY
607-PK
115-PK
322-GY
KEY START
SW (3208)
9G7641
NEUTRAL
LIMIT SW
6T5925
306-GN307-OR
105-BR
307-OR
308-YL
342-GN343-PK
A479-BR
200-BK
VOLT
METER
4W5870
GROUND
POST
200-BK
200-BK
200-BK
BKBK
TACH (3208)
3T4060
TACH (3412)
3T2159
SHIELD
200-BK
451-BK
450-WH
SHIELD
200-BK
200-BK
103-YL
BK
441-OR
200-BK
200-BK
103-YL
A477-PK
A484-RD
A483-YL
RD
BK
406-PU
406-PU
200-BK
200-BK
103-YL
103-YL
A482-BK
A481-WH
SEND SEND
FRAME
GROUND
600-BR
600-BR600-BR600-BR600-BR
200-BK200-BK200-BK200-BK200-BK
OIL PRES
GAGE (3408)
7W2937
OIL PRES
GAGE (3412)
7W2937
HYDRAULIC
TEMP GAGE
4W0484
422-GY
BK
103-YL
A478-WH
BK
103-YL
A476-PU
103-YL
200-BK
LEFT FRONT
FLOOD LAMP
9X4381
LEFT FRONT
FLASHER
7X6066
642-WH
200-BK
344-GY
103-YL
607-PK
200-BK
115-PK
322-GY
200-BK
607-PK
FLOOD
LAMP SW
3T4405
FLOOD
LAMP SW
3T4405
FLASHER &
BEACON SW
3T4405
REVERSE
PRESSURE
SWITCH
9D7032
116-BR
118-GY
609-YL
608-GN
106-WH
110-GN
607-PK
607-PK
607-PK
600-BR
600-BR
ROTATING
BEACON
6T8941
200-BK
607-PK
608-GN
609-YL
600-BR
607-PK
603-PK
642-WH
321-BR
537-GN
603-PK
127-OR
B803-PK
350-PK
B801-BR
B800-WH
B802-OR
B804-OR
B805-WH
B803-PK
108-BU 331-OR
FLASHER
7D8087
HORN
7T0969
ALARM
9G9813
537-GN
642-WH
WARNING
MAIN FRAME
GROUND TO
(STRAP)
CONSOLE
GROUND TO
GS8
(STRAP)
200-BK-10
322-GY
200-BK
RD
BK
406-PU
200-BK
A479-BR
103-YL
321-BR
BK
350-PK
331-OR
BK
B800-WH
B800-WH
B802-OR
B801-BR
FRAME
GROUND
200-BK
642-WH
600-BR
200-BK
RIGHT FRONT
FLASHER
7X6066
RIGHT FRONT
FLOOD LAMP
9X4381
7R9114
7R9108
7R9113
7R9109
7R9110
7R9111
7R9767
7R9112
7R9772
7R9769
80
T
T
S
TT
ALT
+
R
GS
MTRBAT
MOTOR
T
NEGPOSNEGPOS
20
80
10
GS
MTRBAT
MOTOR
GS
MTRBAT
MOTOR
103-YL
103-YL
A478-WH
406-PU
103-YL
A477-PK
B800-WH
ENGAGE
OFF (RESET)
CUTTER
CLUTCH SW
SE-9300
MACHINE
KICKBACK
CUTTER DRUM
ATAW
ATAW
A
B
C
D
E
F
G
G
E
D
C
E
A
F
H
J
AT
AV
AW
WW
XX
YY
ZZ
AB
AC
AD
EMERGENCY STOP
ENGAGED
START SWITCH
(3412) 9D3721
AT
AV
A
B
C
D
E
F
G
AV
AT
342-GN
103-YL
A478-WH
406-PU
A477-PK
IGN
SEND
GRD
IGN
SEND
GRD
IGN
SEND
GRD
SEND
SEND
SEND
IGN
SEND
GRD
IGN
SEND
GRD
SEND
+
-
ST
ON
OFF
B
S
C
R
LEFT FRONT
E-STOP BOX AS
7R9103 RIGHT HAND CONSOLE
E-STOP BOX AS
7R9103
+
4
3
2
1
HORN
E-STOP
RD
BK
GY
YL
YL
GY
RD
BK
BN
PK
A
B
C
D
E
F
>
>
>
>
>
>
>
>
>
>
>
>
GY
PU
BR
RED
WHITE
ORANGE
YELLOW
PINK
ABBREV COLOR
BLACK
GRAY
PURPLE
BROWN
DESCRIPTIONSYMBOL
CONNECTOR
ELECTRICAL CONNECTION
TO VEHICLE STRUCTURE
INTERNAL ELECTRICAL
CONNECTIONTO 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
10
10
IDENT PA RT NO.LOC
HARNESS AS.
200-BK
200-BK
B-5
B-5
B-5
B-6
D-5
D-5
D-5
C-4
D-5
D-5
C-6
C-6
C-6
D-7
D-6
C-7
C-5
C-5
A-3
C-4
C-5
C-5
D-4
D-3
E-4
E- 4
E-4
AP
C-7
C-7
C-7
C-6
C-6
B-5
A-5
C-6
B-6
B-6
C-6
B-6, B-3
7R9876
7R9877
7R9879
7R9888
7R9889
7R9890
7R9891
7R9887
7R9882
7R9883
7R9884
7R9908
F
E
D
C
B
A
9 8 7
9 8 7
6 5 4
6 5 4
3 2
1
F
E
D
3 2
1
C
B
A