KENR1648

June 1990

Harness Connector Location Chart

Machine
Location

Connectors

Harness And/Or
Components

WW-7R9109
Diagnostic Connector
(3208)
XX-7R9110
Diagnostic Connector
(3412)

20 Contacts
1
9 Contacts

Schematic
Location
B-5
C-5

AT - 7R9114
YY-7R9111

D-4

AT-7R9114
AV 7R91 08

A-3

2
2

AT-7R9114
AW7R9113

C-4

AB-7R9112
AT7R9114

E-4

AT7R9114
Rt. Console E-Stop

F-1

AT7R9114
Lt. Console E-Stop

F-4

AW-7R9113
Rt. Front E-Stop

A-5

AW7R9113
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

AW7R9113
Cutter door
Inductor Sw

A-7

AW-7R9113
Kickback Inductor Sw

7 Contacts

6 Contacts

4 Contacts

A-8

Machine locations are repeated for connectors located close together.

* = Connector is located at the component.

PR-1000C Cold Planer

Electrical System
5XC138-UP

Part No.

Function

6T7663

Engine Oil Pressure (S. Meter)

9D7032

Reverse Pressure

Off Machine Switch Specification

Actuate

93 21 kPa
(13.5 3.0 psi)
517 35kPa
(75.0 5.0 psi)

Deactuate

69 21 kPa
(10.0 3.0 psi)
414 35kPa
(60.0 5.0 psi)

Contact Position
Normally Open
Normally Open

1990 Caterpillar
All Rights Reserved

22

13

21
2

24

35

34

23

19
15

36
2

33

37

12

18
20

28

31 29

11

25 30

16

17

Alarm - Backup

38

Component

10

32

26
27

5
8
2

38
24

19

15

9
6

17

31

26

21 13
23 22

14

33

30

1
29
16

B
3

36

25 28
12

4
34

35

37

32

11

27
20
1

18
14

7
10

Machine Harness Connector And Component Locations

Schematic
Location
C-9

Component Location
Machine
Location
1

Component
Relay -(3) Starter

Schematic
Location
C-6

Machine
Location
B
21

Alarm - Overheat

A-3

Relay - E Stop*

B-2

Alternator (3208)

C-8

Relay - E Stop*

B-5

Batteries

A-6

Relay - Kickback

B-2

22

Box - Cutter Door E-Stop* AS

D-4

Relay - Main

B-6

Box - Left Console E-Stop* AS

F-4

Relay - Reverse

B-3

23

Box - Left Front E-Stop* AS

F-5

Resistors (2.7 Ohms)

C-2

24

Box - Left Rear E-Stop* AS

F-9

Sender - Coolant Temp (3208)

B-8

25

Box - Right Console E-Stop* AS

F-i

Sender - Coolant Temp (3412)

E-6

26

Box - Right Front E-Stop* AS

A-5

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

Solenoid - Cutter Drum Clutch

C-4

Breaker - Main

B-6

Solenoid - Fuel (3208)

E-8

30

Breaker - Start

C-6

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

Switch - Cutter Clutch

C-4

Gauge - Coolant Temp (3412)

E-2

Switch - Cutter Door Inductor

A-7

34

Gauge - Hydraulic Oil Temp

F-3

Switch - Engine Rack Ught

E-6

Gauge - Oil Pressure (3208)

F-2

A-4

Gauge - Oil Pressure (3412)

F-3

A-4

Gauge - Pyrometer (3412)

E-3

A-4

Horn - Warning

A-2

14

Switch - Flasher and Beacon

Switch - Flood Lamp
(Conveyer, Cutter Floods)
Switch - Flood Lamp
(Dash Lamps, Front Floods)
Switch - Key Start

D-2

Horn - Warning

0-5

15

Switch - Kickback Ski Inductor

A-8

35
36

Lamp - Kickback Reset

C-4

Switch - Main Disconnect

A-6

Meter - Service

E-7

Switch - Neutral Limit

D-2

Meter - Volt

E-2

Switch - Oil Pressure

D-7

37

Motor -(2) Starter Aft (3412)

D-6

16

Switch - Reverse Pressure

B-3

Motor -(3) Starter Forward (3412)

D-5

17

Switch - Spray Bar

B-4

Motor - Starter (1) (3208)

C-8

18

Switch - Start

D-3

Pickup - Magnetic (3412 Tach)

E-4

19

Tachometer - (3208)

E-2

Pickup - Magnetic (3208 Tach)

0-7

20

Tachometer - (3412)

E-3

Relay -(2) Starter

C-6

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

Printed in U.S.A.

A
B
C
D
E
F

>
>
>
>
>
>

349-OR
348-PU
607-PK
200-BK
115-PK
322-GY

200-BK
609-YL
609-YL
ROTATING
BEACON
6T8941

+
RD
BK
GY
1

E-STOP

200-BK
607-PK

YL

HORN

+
RD
BK
GY
1

609-YL

344-GY
607-PK
115-PK
322-GY

E-STOP

YL

>
>
>
>
>
>

YL
GY
RD
BK
BN
PK

HORN

A
B
C
D
E
F

>
>
>
>
>
>

348-PU
347-WH
607-PK
200-BK
115-PK
322-GY

YL
GY
RD
BK
BN
PK

>
>
>
>
>
>

A
B
C
D
E
F

>
>
>
>
>
>

345-GN
344-GY
607-PK
200-BK
115-PK
322-GY

200-BK
600-BR

RIGHT REAR
E-STOP BOX AS
7R9103

607-PK
115-PK
322-GY

349-OR

T
200-BK

HYD OIL
TEMP SENDER
8N3844

200-BK
600-BR

E-STOP

344-GY
103-YL
607-PK
200-BK
115-PK
322-GY

600-BR
200-BK

200-BK
600-BR

>
>
>
>
>
>

A>
B>
C>
D>
E>
F>

YL
GY
RD
BK
BN
PK

+
RD
BK
GY
1

YL

RIGHT HAND CONSOLE

E-STOP BOX AS
7R9103

HORN

F
GS9

LEFT HAND CONSOLE

E-STOP BOX AS
7R9103

103-YL

103-YL

103-YL

IGN

609-YL
603-PK
321-BR
608-GN

603-PK

344-GY
607-PK
115-PK
322-GY

DASH LAMPS (6)

200-BK
600-BR

422-GY
442-GY

SEND

IGN
OIL PRES
GAGE (3412)
7W2937

SEND

GRD
HYDRAULIC
TEMP GAGE
4W0484

GS4

103-YL

IGN

GRD

BK

OIL PRES
GAGE (3408)
7W2937

SEND

BK

GRD

BK

LEFT FRONT
FLASHER
7X6066

200-BK

HORN

>
>
>
>
>
>

115-PK
607-PK
103-YL

YL
GY
RD
BK
BN
PK

607-PK
115-PK
322-GY
348-PU

LEFT FRONT
E-STOP BOX AS
7R9103

LEFT FRONT
CUTTER FLOOD
9X4381

200-BK
200-BK
200-BK

YL

200-BK

+
RD
BK
GY
1

LEFT REAR
CUTTER FLOOD
9X4381

348-PU
607-PK
115-PK
322-GY

E-STOP

A476-PU

A478-WH

642-WH
200-BK

BK

1
2

COOLANT
HIGH TEMP
6T2665
A477-PK

A481-WH
A482-BK

200-BK
200-BK
321-BR

321-BR
608-GN

A483-YL

200-BK-10
327-PK-10

B805-WH
200-BK

FUEL
SOLENOID
7W6551

EE

MAG PICKUP
TACH
2W8918

347-WH
346-BR
607-PK
200-BK
115-PK
322-GY

FF

1
2

314-PU-10
101-RD-00

105-BR
105-BR

MTR BAT
313-GN

OIL PR SW
6T7663

MOTOR
2

TT

340-WH-10

MTR BAT

RD-00
STARTER
AFT
3412
6N1889
200-BK-10
200-BK

GG

207-BK

608-GN
608-GN
200-BK

GS6

101-RD-00

RESISTOR
(2 PLACES)
6T2217

>
>
>
>
>
>

A>
B>
C>
D>
E>
F>

YL
GY
RD
BK
BN
PK

+
RD
BK
GY
1

YL
2
4

ALT BREAKER
9S4693

SEND

SEND

GRD

441-OR

SEND
GRD

200-BK

A484-RD

COOLANT
TEMP
(3208)
4W0483

IGN

COOLANT
TEMP
(3412)
4W0483
200-BK

BK

EMERGENCY STOP
ENGAGED

307-OR

306-GN

450-WH
451-BK
442-GY
A476-PU
441-OR
306-GN
308-YL
105-BR
B805-WH
341-BU
B803-PK

KK

YY AT

YY

441-OR
306-GN
308-YL
105-BR

AT
343-PK

308-YL

307-OR
105-BR

C
S
B

342-GN

OFF
ON
ST
KEY START
SW (3208)
9G7641

START SWITCH
(3412) 9D3721
SS

MAIN RELAY
3T0376

B801-BR

108-BU
115-PK

10

10

10

351-YL-10

327-PK-10
E STOP
RELAY
3T0376

AN

306-GN
304-WH
207-BK
302-OR
109-OR
101-RD

127-OR

106-WH

10

103-YL
103-YL

4
110-GN

10

108BU

RIGHT REAR
E-STOP BOX AS
7R9103

2 4 3 1

7N8204

200-BK
B801-BR

B800-WH

RIGHT REAR
CUTTER FLOOD
9X4381

116-BR

10

7N8204

200-BK
B801-BR

BK-00

200-BK

BK-00
BB

POS NEG

POS NEG

12V BATTERY
9G4231

12V BATTERY
9G4231

MAIN
DISCONNECT
7N0718

112-PU-4

127-OR

YL

HORN

MAIN
FRAME
GROUND
GS12

YL
GY
RD
BK
BN
PK

>
>
>
>
>
>

A
B
C
D
E
F

>
>
>
>
>
>

346-BR
345-GN
607-PK
200-BK
115-PK
322-GY

106-WH
110-GN

116-BR
118-GY

537-GN
642-WH
200-BK

537-GN
603-PK

C-5

XX

7R9110

C-5

YY

7R9111

D-4

ZZ

7R9767

D-3

AB

7R9112

E-4

AC

7R9772

E- 4

AD

7R9769

E-4

RR

7R9876

C-7

SS

7R9877

C-7

UU

7R9879

C-7

AE

7R9888

C-6

AF

7R9889

C-6

AG

7R9890

B-5

AH

7R9891

A-5

AJ

7R9887

C-6

AM

7R9882

B-6

AN

7R9883

B-6

AP

7R9884

C-6

AR

7R9908

B-6, B-3

AA

2V7396

B-5

BB

5T1553

B-5

CC

3Y7302

B-5

DD

7P6681

B-6

EE

7R9871

D-5

FF

5R7461

D-5

GG

7R9874

D-5

HH

7R9872

C-4

JJ

6S1061

D-5

KK

3V6201

D-5

LL

7P6682

C-6

MM

4M7146

C-6

NN

7R9912

C-6

PP

7R9875

D-7

TT

7R9878

D-6

VV

7R9880

C-7

AK

7R9886

C-5

AL

7R9885

C-5

RIGHT FRONT
E-STOP BOX AS
7R9103

FRAME
GROUND

200-BK

5
3

321-BR

RIGHT FRONT
FLOOD LAMP
9X4381

B800-WH
B802-OR

KICKBACK
RELAY
6T4007
4W2217

1
2
3

YL
BL

FRAME
GROUND
GS8

200-BK
642-WH

1
2

RIGHT FRONT
FLASHER
7X6066

BR

ABBREV
RD
WH
OR
YL
PK
BK
GY
PU
BR
GN
BU
SYMBOL

DESCRIPTION

BLADE, SPADE, RING,

OR SCREW TERMINAL
CIRCUIT CONNECTED

ELECTRICAL CONNECTION
TO VEHICLE STRUCTURE

607-PK
607-PK
607-PK
600-BR
600-BR

AT

GS10

AV

COLOR
RED
WHITE
ORANGE
YELLOW
PINK
BLACK
GRAY
PURPLE
BROWN
GREEN
BLUE

CIRCUIT NOT CONNECTED

FLOOD
LAMP SW
3T4405

600-BR
200-BK

600-BR
600-BR
200-BK

FLASHER
7D8087

322-GY
WARNING
HORN
7T0969
OVERHEAT
ALARM
9G9813

AT

INTERNAL ELECTRICAL
CONNECTION TO SURFACE
OF COMPONENT
CONNECTOR
ATCH WIRE, CABLE,
COMPONENT
L#

(STRAP)
GROUND TO
CONSOLE

(STRAP)
GROUND TO
MAIN FRAME

642-WH
607-PK
600-BR

CIRCUIT GROUPING
DESIGNATION

AV

608-GN
609-YL
603-PK
321-BR

B801-BR

609-YL
608-GN

RIGHT FRONT
CUTTER FLOOD
9X4381

REVERSE
RELAY
6T4007
4W2217

10

FLOOD
LAMP SW
3T4405

+
RD
BK
GY
1

B800-WH

609-YL
200-BK

7N8205

2
1

CUTTER DOOR
INDUCTOR SW
6R0283

<
>
>
<

7N8205

322-GY
115-PK
607-PK

2 4 3 1

<
>
>
<

KICKBACK SKI
INDUCTOR SW
6R0283

203-BK
BK-00

7R9109

A
B
C
D
E
F
G

203-BK
CC

350-PK
349-OR
607-PK
200-BK
115-PK
322-GY

110-GN

FLASHER &
BEACON SW
3T4405

AA

PLUG

>
>
>
>
>
>

PLUG

HORN

A
B
C
D
E
F

<
>
>
<

>
>
>
>
>
>

<
>
>
<

YL
GY
RD
BK
BN
PK

331-OR

607-PK
642-WH

200-BK

WW
12
8
5
3
20
19
18
17
16
15
14
13
11
10
6
4
7
2
9
1
WW

E-STOP

YL

C-4

WW

607-PK
642-WH
600-BR
200-BK

350-PK

20
E-STOP
BREAKER
3T8728

DD

2
E STOP
RELAY
6T4007
4W2217

108-BU

AH
BR
BU
BK
WH

A-3

7R9113

200-BK-10

101-RD-00

101-RD

10

A479-BR

200-BK

BUS
BAR
9W0742

7R9108

AW

AM

CUTTER
DRUM

E-STOP

B803-PK
350-PK
B801-BR
B800-WH
B802-OR

108-BU

327-PK-10

+
RD
BK
GY
1

600-BR

ENGAGE

103-YL
115-PK

112-PU
308-YL
105-BR
203-BK

< 1 <
> 2 >
WATER
SOL VALVE
7R9866

BR
BU
BK
WH

REVERSE
PRESSURE
SWITCH
9D7032

331-OR
BK

AK

112-PU-4

101-RD
109-OR
302-OR
207-BK
304-WH
306-GN

112-PU
112-PU-4
112-PU

101-RD-00
101-RD-10
101-RD

101-RD-00

GS5

HH

103-YL

406-PU
200-BK

MAIN
BREAKER
9S4693

AL

OIL PR
SENDER
9X1124

B803-PK
200-BK

SPRAY
BAR SW
8D2676

AG
200-BK

110-GN

RD
BK

A476-PU

COOLANT
SENDER
6N5926

B803-PK

147-PU-4

80

> 1 > 642-WH

< 3 < 608-GN
< 2 < 200-BK

RESISTORS
2.7
50 WATT
817042

308-YL
101-RD-4

S
T

CUTTER DRUM
CLUTCH
SOLENOID
5T4434

B800-WH
200-BK

302-OR

441-OR
A476-PU
B803-PK
441-OR

B803-PK

B805-WH

AR

RIGHT TAIL
& FLASHER
LAMP
8C6207

B802-OR
BK

322-GY
200-BK

10
START
BREAKER
9G9487

1
2

AW AT

608-GN
609-YL
600-BR
607-PK
603-PK
642-WH
321-BR

321-BR
200-BK
200-BK

105-BR
105-BR
105-BR

308-YL
308-YL
BK

RIGHT
BACKUP
LAMP
9X4381

B800-WH

350-PK
BK

AF

RESISTOR
6T2217

BK

B804-OR

GS3

302-OR
207-BK
313-GN
101-RD

CUTTER
CLUTCH SW
SE-9300

345-GN
350-PK
B801-BR
B800-WH
607-PK
115-PK
322-GY

103-YL
115-PK
607-PK

101-RD-10

MM

AW AT
A
B
C
D
E
F
G

B801-BR
341-BU

B800-WH
BK

AP

OFF (RESET)

BK

112-PU
308-YL
105-BR
203-BK

103-YL
343-PK

MACHINE
KICKBACK
RESET
LAMP
3T0304

B803-PK

207-BK

MAIN
FRAME
GROUND

BK-00

GS2

AJ

NN

7R9114

AV

103-YL

STARTER
3208
3T2652
LL

AT

CABLE AS

118-GY

#3 STARTER
RELAY
9F3099

BUSS BAR 7R9830

302-OR

GND ON
ENGINE

321-BR
321-BR
200-BK
200-BK

BACKUP
ALARM
3T1815

BK-4

101-RD-00

MOTOR

340-WH

#2 STARTER
RELAY
9F3099

XX
9
4
6
14
20
19
18
17
16
15
12
8
5
3
11
10
2
7
13
1
XX

DIAGNOSTIC CONNECTOR
3412 ENGINE

101-RD-10

VV

306-GN
304-WH
304-WH-10

101-RD
340-WH
342-GN
314-PU

DIAGNOSTIC CONNECTOR
3208 ENGINE

MTR BAT

200-BK
306-GN
RR

342-GN
342-GN
314-PU
314-PU-10

350-PK
200-BK

ALT
+

BK

101-RD
101-RD

UU

BK

304-WH-10
101-RD-4

109-OR-4

ALTERNATOR
60 AMP
4N3986

350-PK
B801-BR
B802-OR
B803-PK
B800-WH

340-WH-10

AE

LOC

WIRE AS

ZZ

G
E
D
C
E
A
F
H
J

342-GN

PP

PART NO.
HARNESS AS.

NEUTRAL
LIMIT SW
6T5925

101-RD-4

80

A477-PK

JJ

313-GN
207-BK
302-OR

109-OR-4

IGN
RD
BK

AC

103-YL

HORN

GS11
322-GY
200-BK

SEND

CUTTER DOOR
E-STOP BOX AS
7R9103

WARNING
HORN
7T0969

STARTER
FORWARD
3412
3T2650

MOTOR

BK-00

450-WH
451-BK

103-YL

PYROMETER
(3412)
3N7012

E-STOP

302-OR

341-BU
341-BU

WARNING
HORN
7T0969

103-YL
A483-YL

200-BK

SERVICE
METER
6T7337

101-RD
109-OR

342-GN

IDENT

F
B
A
D
C
E
AB AT

341-BU

608-GN
608-GN
200-BK

103-YL
A478-WH
406-PU
A477-PK

THERMOCOUPLE
3N5991
3N8278

AT

200-BK

WATER SPRAY
MAG CLUTCH
CMI 2-5318

451-BK
AB

200-BK
322-GY

> 2 >
< 1 <

MF
GND

SHIELD

GS1

CONVEYER
HOPPER
FLOOD LAMP
9X4381

200-BK
SEND

LEFT FRONT
FLOOD LAMP
9X4381

VOLT
METER
4W5870

A482-BK

A484-RD

UPPER
CONVEYER
FLOOD LAMP
9X4381

200-BK
SEND

327-PK-10
200-BK-10

321-BR

103-YL

SEND

200-BK
A479-BR

LEFT
BACKUP
LAMP
9X4381

AD

TACH (3208)
3T4060

450-WH

SEND

A478-WH
406-PU
103-YL
A477-PK

FUEL SOL
4N9314

TACH (3412)
3T2159

A481-WH

MAGNETIC
PICKUP-TACH
7R9768

200-BK
607-PK
607-PK

200-BK
200-BK

642-WH
609-YL
200-BK

442-GY
A476-PU

1
3
2

FRAME
GROUND
GS7

406-PU

SHIELD

LEFT TAIL &

FLASHER LAMP
8C6207

406-PU

OIL PR
SENDER
9X1124

642-WH
607-PK

COOLANT
SENDER
6N5926

103-YL

B805-WH
442-GY
105-BR
341-BU
306-GN
441-OR
A476-PU
B803-PK
451-BK
450-WH
308-YL

GROUND
POST