RENR9516-01

February 2007

A2 F2
A1
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.

Wheeled Excavator
GENERATOR CONNECTING POINTS Magnetic Controller
Electrical System
M318C: M322C: M322C MH:
BEB2001-UP BDK2001-UP H2F128-UP
BOX_GP_GENERATOR BDY2001-UP H2G163-UP
2330968 CONTROL_LAMP
2421974 H2E247-UP
GROUND GND 200-A03 BK-16 439-A06 YL-18 439-A06 YL-18
GROUND 8 H417-A07 OR-18 H417-A07 OR-18
CURRENT MONITORING 14 146-A15 GY-16
INDUCTOR VOLTAGE 7 147-A13 PU-16
CURRENT MONITORING 13 143-A11 BR-16 200-A03 BK-16
JOYSTICK_LH
+ 24 VDC OUTPUT 6
2412488
VOLTAGE MONITORING 12 145-A10 BU-16 143-A11 BR-16 M-C03
1552273
CONTROL-LAMP - 5 H417-A07 OR-18 GND_FRAME SWING
VOLTAGE MONITORING 11 143-A11 BR-16 1 BR BRAKE
(REAR-RH)
INDUCTOR VOLTAGE 4 143-A12 BR-16 2 BK
NOT CONNECTED 144-A14 GN-16 A-C01 M-C06 3 BU
3E3364 1552269 HORN
CONTROL LAMP + 3 439-A06 YL-18 4 GN FWD
FAULT ALARM 10 191-A04 WH-18 1 191-M13 WH-18 5 YL (REAR-LH)
BUTTON ON/OFF 2 191-A04 WH-18 190-A05 PK-18 2 283-M14 BK-18 6 GY MAGNET
9
ON/OFF For Machines with the 12.5kW Generator
FAULT ALARM
(FRONT)
BUTTON ON/OFF 1 190-A05 PK-18 © 2007 Caterpillar Printed in U.S.A.
X1
197-A01 GN-16 All Rights Reserved
BREAKER F1 (10A) 197-A01 GN-16 143-A12 BR-16
145-A10 BU-16
146-A15 GY-16
147-A13 PU-16
144-A14 GN-16
GENERATOR
2354352
Electrical Schematic Symbols And Definitions
BR F1 144-A14 GN-16 144-A14 GN-16 Symbols
BR F2 147-A13 PU-16 147-A13 PU-16
BR A2 146-A15 GY-16 146-A15 GY-16 1 3 3 1
145-A10 BU-16 145-A10 BU-16 2 4 4 2
T

Pressure Temperature Level Flow Circuit Breaker

G BR A1 BU-C03 CBL_05 143-A12 BR-16

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

5 5 Symbol Symbol Symbol Symbol Symbol
BR-C04 CBL_05 197-A01 GN-16
240V BR B2 143-A12 BR-16 Symbols And Definitions
BK1-C01 CBL_05 CBL_MAGNET Fuse - A component in an electrical circuit that will open the circuit if too much current flows
BK2-C02 CBL_05 BK1-C01 CBL_05 BK1-C01 CBL_05 1 through it.

BK2-C02 CBL_05 BK2-C02 CBL_05 2 Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
MAGNET circle indicates that the component has screw terminals and a wire can be disconnected from it.
BU-C03 CBL_05 BU-C03 CBL_05 3

RENR9516-01
197-A01 GN-16 BR-C04 CBL_05 BR-C04 CBL_05 4 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
240VDC_CONNECTOR grounded wire is fastened to the machine.
2339606
Ground (Case): This indicates that the component does not have a wire connected to ground.
A-C02 K-C37 MACHINE_CONTROL_MODUL_(MCM) It is grounded by being fastened to the machine.
GENERATOR_SOL 3E3370 1552267 1890077
1957747 A-C03
1552269 Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the
E984-A08 BU-18 A E984-K56 BU-18 25 GENERATOR_SOL contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.
J2 SCHEMATIC FOR 12,5 KW
1 E984-A08 BU-18 H804-A09 GN-18 B H804-K120 GN-18 13 SOLENOID_GROUND
GENERATOR SET Sender: A component that is used with a temperature or pressure gauge. The sender
2 H804-A09 GN-18 197-A01 GN-16 C 197-K199 GN-16 measures the temperature or pressure. Its resistance changes to give an indication to
PART NO. 243-5591 T
the gauge of the temperature or pressure.
A235-K13 BK-18 9 SWITCH_GROUND
J992-K26 YL-18 29 GENERATOR_SWITCH
J1 CHG-LEVEL 0A
Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.
DATE 27.07.04 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.
J992-F07 YL-18
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
F-C04 K-C08 K-C12 J-C05 can open or close a valve or move a piece of metal that can do work.
GENERATOR_SW 1552252 3E5179 1552252 3E5179
1939066 TO FUSE "4-07" (15A) 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)
1 1 176-J55 YL-16 that make electromagnet when current flows through them. It also has an internal switch that places
7
2 2 the latch coil circuit open at the time the coil latches.
4
A235-F38 BK-18 3 3 IDENT PART NO. LOC DESCRIPTION NOTE
5 Harness And Wire Symbols
4 4 A 243-5593 D-5 HARNESS AS (GENERATOR) B
6
5 5 C 233-9608 C-4 CABLE (BULK) B Wire, Cable, or Harness Component
1 Assembly Identification Part Number
6 6 F 241-8720 A-5 HARNESS AS (CAB) A Pin Socket Wire Color Fuse
2 A AA
J992-F07 YL-18 7 J992-K26 YL-18 7 J 241-8740 B-2 HARNESS AS (BOX-JUNCTION) A
105-9344
3 325-PK-14 1
197-F125 GN-16 8 8 K XXX-XXXX B-3 HARNESS AS (CHASSIS-ELECTRONIC) A/C Receptacle
176-F122 YL-16 9 176-K200 YL-16 9 M 241-8718 F-2 HARNESS AS (CONSOLE LH) A Single Wire Circuit Number Wire Gauge
F-C22 197-F125 GN-16 10 197-K199 GN-16 10
Connector Identification

1117898 Plug
11 11 NOTE A: STANDARD NOTE C: M313C FCR-M322C FCR = 241-8746 2 200-BK-14
176-F122 YL-16 A235-F38 BK-18 12 A235-K13 BK-18 176-K200 YL-16 12 M318C HCR/M322C HCR = 241-8738
M313C-M318C = 241-8730 Ground Connection Pin or Socket Number
NOTE B: ATTACHMENT M322C = 241-8734
1 Typical representation of a Deutsch 1 Typical representation of a Sure-Seal
connector. The plug contains all connector. The plug and receptacle
2 sockets and the receptacle contains 2 contain both pins and sockets.
all pins.
 R1

R2L R2M R3

10 9 8 7 6 5 4 3 2 1

CONTROL BOX
2330968

H H K7 K4
R1
2425576 K2 K1
ADJUSTED TO 250-260VDC
1 3 AT THE POWER CONNECTOR
2 WITHOUT LOAD
SCALE SCALE
A1
2425904 1-6 1-3

K6
014 RD-16

013 RD-16
K3

017 RD-16
SCALE
G G 1-6
240VAC
K7 K6 K3 K2
K4 K1 019 RD-16
2425586 2425586 2476937 2425581
1 5 2 6 3 7 4 8 1 5 2 6 3 7 4 8 2421309 1 5 2 6 3 7 4 8 1 5 4 8 1 5 4 8 2425581 1 5 4 8 1 1 1
R2L R2M R3
2425575 2425575 2425577
2 2.2 OHM 2 2.2 OHM 2 10.0 OHM
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
020 RD-16

015 RD-16 S1
018 RD-16

016 RD-16 1 2 3 4 5 6 7 8
A
013 RD-16
R4 B
014 RD-16
F1 9 10 11 12 13 14
C
015 RD-16
C1

GND
F D F
016 RD-16 K01 K8 K9 K10 K11
V4
E
017 RD-16
F
018 RD-16
9 10 11 12 13 14
V2

1 2 3 4 5 6 7 8
V1

V3

E E
12 11 10 9 8 7 6 5 4 3 2 1
012 BK-16

011 BK-16

008 GY-16

001 BU-16
007 BK-16
010 BU-16

002 GY-16
006 BU-16
009 GY-16

005 GY-16

004 BK-16

003 BU-16
025 PU-16 008 GY-16

D 026 BU-16 007 BK-16

D
R1
027 PU-16 006 BU-16

021 GY-16 005 GY-16 DOOR

003 BU-16 004 BK-16 025 PU-16

(A1) MAIN BOARD

004 BK-16 003 BU-16 027 PU-16

005 GY-16 021 GY-16 030 GY-16

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

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

025 PU-16
R2L R2M R3
029 GY-16 030 GY-16

030 GY-16 026 BU-16

008 GY-16 029 GY-16

C C A B C
025 PU-16

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

010 BU-16

021 GY-16

003 BU-16

011 BK-16

004 BK-16

012 BK-16

005 GY-16

022 BR-16

028 PU-16
006 BU-16

023 BR-16

007 BK-16

029 GY-16
030 GY-16

008 GY-16
RENR9516-01

1 4 1
009
026
027
028

8 5

039 GY-16
V3
031 GY-16

032 GY-16
029 GY-16

024 GY-16
034 GY-16

036 GY-16
035 GY-16

034 GY-16

035 GY-16

036 GY-16
044 GY-16

002 GY-16

037 BU-16
038 BU-16

039 GY-16
040 GY-16

031 GY-16

038 BU-16
026 BU-16

001 BU-16

043 BU-16
041 BU-16

041 BU-16
037 BU-16
1 2 3 4 5 6 7 8
K4 K2 D F
2
12 9 K1
B 9 10 11 12 13 14 GND S1
2361460
VOLTAGE MONITORING

VOLTAGE MONITORING

CURRENT MONITORING

CURRENT MONITORING

K8
K01
K9 K10 K11
14 13
INDUCTOR VOLTAGE

INDUCTOR VOLTAGE

2476931 2476931 2476931 2476931

2425583 A1 1 3 3 2 4 7 5 6 3 2 4 7 5 6 3 2 4 7 5 6 3 2 4 7 5 6
K7
CONTROL LAMP +

CONTROL LAMP -
BUTTON ON/OFF

BUTTON ON/OFF

+24VDC OUTPUT

027 PU-16
E
2543541

2543541

2543541

2543541

2543541

2543541

2543541

2543542
FAULT ALARM

FAULT ALARM
X1 TERMINAL A

X1 TERMINAL B

X1 TERMINAL C

X1 TERMINAL D

X1 TERMINAL E

X1 TERMINAL F

X1 TERMINAL G

X1 TERMINAL H
10A

1 4 V2 V1
GROUND

GROUND

C1
F1
2425585

A2 2 4
FREE

8 1 8 1 8 1 8 1
A 9 10 11 12 13 14 GND 5 8 10 9 8 V4
032 GY-16
033 GY-16

044 GY-16

023 BR-16

022 BR-16

043 BU-16

024 GY-16

021 GY-16

033 GY-16
042 GY-16

040 GY-16

042 GY-16
1 2 3 4 5 6 7 8 K6
B B 9 12 7 6 5 4 3 2 1
12 11
13 14

030 GY-16
021 GY-16
K3
043 BU-16
R4
022 BR-16

023 BR-16
GND CONTROL BOX

NAME FUNCTION PART NO. STANDARD SETTING

A1 Main Printed Circuit Board 242-5904 -
C1 Field Absorption Capacitor - -
F1 Main Breaker 242-5585 -
K01 Magnet On/Off Switching Relay 242-5583 -
WIRE GROUP COLOR DESCRIPTIONS K1 Field Magnetizing Relay 242-5581 -
A A
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.
SCHEMATIC FOR 12.5kW GENERATOR K2
K3
Drop Relay
Voltage Monitoring Relay (Not Used)
242-5581
247-6937
-
-
GROUND CIRCUIT. CONTROL BOX K4 Drop Timer Relay 242-1309 1,5 S (X1/S) / SCALE 0-3
GENERATOR 240V.
PART NO. 233-0968 K6 Time Delay Warning Relay (Not Used) 242-5586 6 S (X1/S) / SCALE 0-6
K7 Boost Timer Relay 242-5586 2 S (X1/S) / SCALE 0-6
CHG-LEVEL 02A K8 Current Monitoring Relay 247-6931 -
K9 Current Overload Protection Relay 247-6931 -
K10 System Activation Safety Relay 247-6931 -
10 9 8 7 6 5 4 3 2 1 K11 Reset Control Safety Relay 247-6931 -
R1 Excitation Voltage Variable Resistor 242-5576 Adjusted After Machine Installation
R2L Drop Resistor-1 242-5575 -
R2M Drop Resistor-2 242-5575 -
R3 Field Discharge Resistor 242-5577 -
S1 Main Switch 236-1460 -
V1 Diode - -
V2 Diode - -
V3 Diode - -
V4 Diode - -