9.
1 ELECTRIC SYSTEM
9.1 Introduction
9.1.1 Foreword
Electrical systems in earth-moving machinery have
spread far beyond the original fields of application
such as starting and lighting equipment. New ap-
plications are essentially monitoring and control
functions. This development has necessarily in-
creased the number of electrical circuits to such an
extent that the whole field of electrical applications
has become evermore complicated and confusing
to the non-electrician.
The schematic diagrams used in the past have
reinforced this impression.
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For these reasons, Caterpillar, like the automobile
industry, decided some years ago to adopt another
form of electrical diagram: the detailed circuit dia-
gram.
The present chapter describes how to use these
new, CAD-based circuit diagrams and their ac-
companying documents.
This Service Manual applies to automotive elec-
trical systems in earth-moving machinery. In any
case, the relevant accident prevention regulations
and the respective requirements for different oper-
ating voltages must be observed. The regulations
are not part of this manual.
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9.1 ELECTRIC, ELECTRONIC
9.1.2 Safety instructions
Prior to working on electrical
systems
The personnel carrying out repairs
must have know-how and experi-
ence in the repair of the electrical
systems installed in this machine
or of electrical systems of similar
machines.
If such know-how is lacking, me-
ticulous instruction must be given
by experienced personnel, e.g.
from Caterpillar.
Before carrying out any mainte-
nance and repair work, the ma-
chine must be secured as follows:
 Park the machine on level and
stable ground.
 Stand the working equipment on
the ground.
 Shut off the engine.
 Withdraw the key from the key-
operated switch of the electrical
system.
 Secure the machine against inad-
vertent movements by placing
chocks under the tracks or
wheels.
 Before carrying out work on the
electrical system or before weld-
ing set the battery main switch to
'OFF'.
After completion of the work:
Set the battery main switch to 'ON.
Page 9.1 - 2
Handling of batteries
Batteries give off explosive gases.
Do not use fire and unshielded
light sources in the vicinity of bat-
teries and do not smoke.
Battery acid is toxic and caustic.
Avoid any contact with the mouth,
skin, eyes and clothing. Do not
spill battery acid and do not inhale
the vapours.
Wear gloves, firm working clothing
and goggles when handling batte-
ries.
If the skin is splashed with acid,
rinse with plenty of water and con-
sult a doctor.
If the eyes are splashed with acid,
rinse thoroughly with running wa-
ter and consult a doctor immedi-
ately.
Do not set down tools on the bat-
tery. They may induce a short-
circuit, causing irreparable damage
to the battery and injuring persons.
Do not wear metal necklaces,
bracelets or watch-straps when
working on the battery. The metal
parts may induce a short-circuit,
resulting in burns.
Dispose of used batteries sepa-
rately from other waste in the in-
terests of environmental protec-
tion.
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9.1 ELECTRIC, ELECTRONIC
Alternator,
General notes
Do not disconnect electric cables
from the alternator and the regula-
tor when the engine is running.
This would damage the alternator
and the regulator.
Carry out voltage and continuity
checks with measuring instru-
ments only.
Do not use test lamps since the
currents in the circuit under test
may be very strong.
Do not "tap against ground". This
causes a short-circuit with conse-
quent damage to the alternator and
regulator.
Batteries
When connecting the batteries do
not interchange the cables (pay
attention to polarity).
Fuses
Risk of short-circuits and sparking
Remove fuses only after the corre-
sponding circuit has been de-
energized:
Shut off the engine, set the key-
operated switch of the electrical
system to "0" and withdraw the
key.
Set the battery main switch to
'OFF'.
Replace defective fuses only by
fuses of the same current rating.
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Personnel qualifications
Working on the electrical system of
the machine requires basic electri-
cal and mechanical knowledge, as
well as knowledge of the appropri-
ate technical terms. Working on
the electrical system includes all
tasks described in this chapter
including troubleshooting and re-
placing hardware components.
To ensure safe use, the specified
activities may only be carried out
by qualified technical personnel or
an instructed person under the
direction and supervision of quali-
fied personnel. In other words,
only appropriately trained and
qualified personnel are permitted
to work with or near the excavator.
Qualified personnel fulfils all of the
following requirements:
• Is able to recognize possi-
ble hazards and institute the ap-
propriate safety measures due to
their professional training, knowl-
edge, and experience as well as
their understanding of the relevant
conditions pertaining to the work
to be done.
• Observes the rules relevant
to the subject area.
• Is familiar with all warnings
and precautions according to this
documentation and the documen-
tation of the respective component
and understand their content.
• Has appropriate safety
equipment and has been trained in
first aid.
Persons who work on the electrical
system must not consume any
alcohol, drugs, or pharmaceuticals
that may affect their ability to re-
spond.
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9.1 ELECTRIC, ELECTRONIC

9.1.3 General

It must be ensured that all persons performing

work on the machine have read the relevant chap-
ters of the operating instructions before starting
any work.

The user of the machine is responsible for ensur-

ing that all relevant national and international laws
and regulations will be complied with.

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