SECTION 10 - ELECTRICAL - MyGradall.com

1 SECTION 10 - ELECTRICALELECTRICALS eries IV Highway Speed Excavators8080400110-2 ELECTRICAL Components, UpperstructurePA C 5 3 5 1 ELECTRICAL80804001 Series IV Highway Speed Excavators10-3 ELECTRICAL Components, UpperstructurePA C 5 3 6 2 ELECTRICALS eries IV Highway Speed Excavators8080400110-4 ELECTRICAL Components, UpperstructureItemPart SENSOR243411891 SWITCH SUPPORT3807630941 REMOTE UPPER HARNESS4A/RDI-ELECTRIC GREASE5246017102 SUPPORT CLAMP6771331402 COVER PLATE7771331682 CLAMP SET8771331772 HEX HD CAPSCREW, 5/16-18X1-3/89771430041 WHIZ-LOK SCREW, 5/16-18X1-1/410771430062 WHIZ-LOK NUT, 5/16-1811802230342 WHIZ-LOCK SCREW, 1/2-13X3/412802630421 GROUND STRAP CABLE13803631661 PROXIMITY SENSOR14809730962 WHIZ-LOK SCREW, 3/8-16X1-1/215832512892 CLAMP SET16832512912 COVER PLATE17807831161 WASHER FLUID BOTTLE18859410162 SUPPORT CLAMP, 1/219882010034 HEX HD CAPSCREW, 1/4-20X3/4, GR520882010068 HEX HD CAPSCREW, 1/4-20X1/4, GR521882010424 HEX HD CAPSCREW, 3/8-16X2-3/4, GR522885010041 HEX NUT, 1/4-2023885212066 HEX LOCKNUT, 3/8-1624885610025 FLAT WASHER, 1/425885610031 FLAT WASHER, 5/1626885610046 FLAT WASHER, 3/827902057931 CUSHION CLAMP, 1-1/228910431472 SUPPORT CLAMP, 3/429910630394 COVER PLATE CLAMP30910630404 CLAMP SET.

2 3/831833032391 HORN32913630182 SCREW, 5/16-18X133 Ref24V-12V POWER CONVERTER, (see page 7-6 for details)34807630781 UPPER CONTROLLER, (RC 6-9)35807630791 UPPER EXPANSION CONTROLLER, (RC 12-4) ELECTRICAL80804001 Series IV Highway Speed Excavators10-5 ELECTRICAL Components, UpperstructureItemPart IV Highway Speed Excavators8080400110-6 Battery Box InstallationPAC5381 MOUNTING OF + BATTERYCABLE TO STARTER234234234121283128233423413152230 251315192433352433352433111812 - BATTERY CABLETO ENGINE BLOCKRAILGEARONLYRAILGEARONLYELECTRICAL8 0804001 Series IV Highway Speed Excavators10-7 Battery Box InstallationPAC5391 ELECTRICALS eries IV Highway Speed Excavators8080400110-8 Battery Box InstallationItemPart GREASE2771331396 CLAMP SET3771331406 COVER PLATE4771331776 HEX HD CAPSCREW.

3 5/16-18X1-3/85771430157 WHIZ-LOK NUT, 3/8-166773835674 STAINLESS STEEL NUT7802630124 WHIZ-LOK SCREW, 1/4-20X1/28803811142 HOLD DOWN STUD9804831021 HEX HD CAPSCREW, 16-2X25, BUSHING11807812031 BATTERY BOX SUPPORT12807812041 INNER SUPPORT PLATE13807832011 POSITIVE BATTERY CABLE14807832021 NEGATIVE BATTERY CABLE15807832031 NEGATIVE BATTERY CABLE16807832041 BATTERY JUMPER CABLE17807832051 CHASSIS VEC HARNESS18 RefBATTERY BOX ASSY, (see page 10-10 for details)19 RefSERVICE PANEL ASSY, (see page 10-12 for details)20809730258 WHIZ-LOK SCREW, 3/8-16X121882010361 HEX HD CAPSCREW, 3/8-16X1-1/4, GR522831910073 HEX HD CAPSCREW, , , M1024832010929 HEX HD CAPSCREW, 5/8-11X2, GR8,(qty.)

4 3 for machines equipped with railgear)25859410162 SUPPORT CLAMP, 1/226868410691 HOLD DOWN ANGLE27885212052 HEX LOCKNUT, 5/16-1828910431472 SUPPORT CLAMP, 3/429885213062 HEX LOCKNUT, 3/8-1630885610033 FLAT WASHER, 5/1631885610043 FLAT WASHER, 3/832885611091 FLAT WASHER, 3/833900274729 HARDENED WASHER34910331341 HEX NUT, , (torque to 15-22 lb-ft)35886814556 HEX HD CAPSCREW, 5/8-11X1-1/2, GR8, (railgear equipped machines only)ELECTRICAL80804001 Series IV Highway Speed Excavators10-9 Battery Box InstallationItemPart IV Highway Speed Excavators8080400110-10 Battery Box AssemblyPAC5420UP PWR4 UPUPMR BAT2 BATT4CB620CB7 BATT320CB102020CB320CB4SP PWR2F115F2SP PWR115 PWR2 PWR1 BATT5MR BAT1CB1120 BATT2CB8CB9 BATT1CB5202020CB120UP PWR3CB2201415 FUSE DETAIL OF ITEM 41425367678910111213 ELECTRICAL80804001 Series IV Highway Speed Excavators10-11 Battery Box AssemblyItemPart BOX, (includes items 9 thru 13)B2771430174 WHIZ-LOK NUT, #10-243804812101 VEC BRACKET4804830661 BUSSMAN VEC, (includes items 14 & 15)

5 5804830934 SELF-TAPPING SCREW, #10-24X3/4688201005A/RHEX HD CAPSCREW, 1/4-20X1, GR5788521304A/RHEX LOCKNUT, 1/4-20888561107A/RFLAT WASHER, 1/49803047611 DRAW LATCH, (uses key 91144470)10882610106 SOCKET BUTTON HD CAPSCREW, #10-24x3/411885216056 HEX LOCKNUT, #10-2412885611056 FLAT WASHER, #1013804840464 HINGE148046400611 CIRCUIT BREAKER, 20 AMP, (rated 14-volt)15804640042 FUSE, 15 AMP80634083A/RVEC REPAIR KITELECTRICALS eries IV Highway Speed Excavators8080400110-12 Service Panel AssemblyPAC5442 ELECTRICAL80804001 Series IV Highway Speed Excavators10-13 Service Panel AssemblyItemPart DISCONNECT SWITCH2804830611 JUNCTION BLOCK3807630131 CAP4807730331 BRASS BUSHING5807811701 SERVICE BRACKET6807831661 SERVICE PANEL DECAL7851310754 GROMMET, 1 8866831221 TIE WRAP9886816052 ROUND HD MACHINE SCREW, , (zinc plated)10886816064 ROUND HD MACHINE SCREW, , (zinc plated)11910331336 HEX NUT, , (zinc plated)

6 12886816044 HEX LOCKNUT, SHUT-OFF TIMER DECALELECTRICALS eries IV Highway Speed Excavators8080400110-14 Tail & Marker LightsPAC5450910111214201319567123818481 23848151617 ELECTRICAL80804001 Series IV Highway Speed Excavators10-15 Tail & Marker LightsItemPart LIGHT, RED2807831842 LIGHT GROMMET3807831832 STOP, TAIL & TURN LIGHT4807831812 BACK-UP LIGHT5771430152 WHIZ-LOCK NUT, 3/8-166858410942 SUPPORT CLAMP7809730252 WHIZ-LOK SCREW, 3/8-16X18807831854 LIGHT GROMMET9 RefREAR FENDER, (see page 1-20 for details)10885016102 HEX NUT, #8-3211885510062 LOCKWASHER, #612885611042 FLAT WASHER, #8 13883010752 ROUND HD MACHINE SCREW, #8-32X1, GR814807851051 REAR ID LIGHT ASSEMBLY, (includes items 15 thru 17 & 20)-15773632282 SOLID PIN TERMINAL16VA213900441 CONNECTOR17VA213900451 WEDGE CONNECTOR18803833742 RUBBER GROMMET19807831932 TAIL LIGHT HARNESS20807831771 REAR ID LIGHT ELECTRICALS eries IV Highway Speed Excavators8080400110-16 Head & Marker LightsPA C 5 4 6 074444473338192562519 ELECTRICAL80804001 Series IV Highway Speed Excavators10-17 Head & Marker LightsItemPart LIGHT, (amber)

7 2807831852 GROMMET3771430063 WHIZ-LOK NUT, 5/16-184859410165 SUPPORT CLAMP, 1/25807831822 TURN LIGHT, (amber)6 RefFRONT BUMPER & HEAD LIGHTS, (see page 1-8 for details)7900273192 SELF TAPPING SCREW, 1/4-208807831921 FRONT BUMPER HARNESS9807831842 LIGHT GROMMET NOTE: Some machines may use tie-wraps in place of support clamps/hardware. Tie-wraps are an approved replacement for the support clamps, if desired: 86683122A/RTIE-WRAP ELECTRICALS eries IV Highway Speed Excavators8080400110-18 Cab Console Circuit Board, UpperstructureNOTE: THE SCHEMATIC SHOWNON THIS PAGE IS FOR SPAREPARTS IDENTIFICATION. ANENLARGED, DETAILED VIEWOF THE SCHEMATIC CAN BEFOUND IN THE ASSOCIATEDMODEL S SERVICE C 6 4 9 0 ELECTRICAL80804001 Series IV Highway Speed Excavators10-19 Cab Console Circuit Board, UpperstructureItemPart CAB CONSOLE CIRCUIT BOARD, (includes all items)B1915040461 CONNECTOR2915041001 CONNECTOR3803642011 HOUSING4803642021 STRAIN RELIEF5803642031 HOUSING CAP6803642041 PIN7805440221 CONNECTOR8805440211 CONNECTOR9805440201 CONNECTOR10807641028 RELAY, (24v)11807641011 RELAY, (24v)12805440241 CONNECTORNOTE: The circuit board is stamped with a part number for a 12-volt system and a part number for a 24-volt system.

8 This machine uses a 24-volt system. If ordering a new circuit board, use part number 80763082 only. ELECTRICALS eries IV Highway Speed Excavators8080400110-20 Cab Console Circuit Board, UndercarriagePA C 6 4 8 1 ELECTRICAL80804001 Series IV Highway Speed Excavators10-21 Cab Console Circuit Board, UndercarriageItemPart CAB CONSOLE CIRCUIT BOARD, (includes all items)B1869845501 CONNECTOR2773632294 PIN CONTACT3773633495 PLUG4805440171 CONNECTOR5805440181 CONNECTOR6809630571 WEATHERPACK TOWER, (2-wire)7809630682 FEMALE TERMINAL PIN8809630662 CABLE SEAL, 16GA., (gray)9809630581 WEATHERPACK SHROUD, (2-wire)10809630692 MALE TERMINAL PIN11805440161 CONNECTOR12773835542 CONNECTOR\13773633471 CONTACT14806040051 CONTACT15805440191 CONNECTOR16773632281 PIN CONTACT17773633451 CONTACT18773633461 CONTACT19834812861 NUT20834812851 LOCKWASHER21869845561 TERMINAL22869845551 CONNECTOR23869845531 CONNECTOR24869845541 TERMINAL25807040011 FLASHER, 24V ELECTRICALS eries IV Highway Speed Excavators8080400110-22 Work Lights InstallationPAC4830 WORK LTSWORK LT GNDCABLIGHTSBOOMLIGHTSBOOM LTSWORKLIGHT(RIGHT SIDE)

9 BOOM LTS GNDWORK LTSWORK LT GND9144101511351326121471015161471015168 9141015 ELECTRICAL80804001 Series IV Highway Speed Excavators10-23 Work Lights InstallationItemPart LIGHTS INSTALLATION, (includes all items)A114404173A/RSILICONE CAULK2249213151 GROMMET, 1-1/23771430151 WHIZ-LOK NUT, 3/8-164771631054 FEMALE BULLET TERMINAL, .1575803030941 WHIZ-LOK SCREW, 3/8-16X3/46803610291 LIGHT BRACKET7803630382 WORK LIGHT SPACER8803630401 WIRING DUCT9803630941 CAB WORK LIGHT HARNESS10807630934 FLOOD LIGHT, (includes bulb)807641554 FLOOD LIGHT BULB11807631082 SPOT LIGHT12809730252 WHIZ-LOK SCREW, 3/8-16X113866212301 SUPPORT CLAMP, 11/3214866831226 TIE WRAP15869831934 MALE BULLET TERMINAL.

10 15716807610442 LIGHT BRACKET ELECTRICALS eries IV Highway Speed Excavators8080400110-24 Work Lights (LED) InstallationPA C 1 5 4 1 0251113181092581113182581113181313131316 10101104103102 CABLIGHTSDETAIL VIEWOF ITEM 11 BOOMLIGHTSWORKLIGHTS(RIGHT SIDE)WORK LTSBOOM LTSBOOM LTS GNDWORK LTSREAR WORKLT GNDWORK LT GNDWORK LTSWORK LT GNDWORK LTSWORK LT GND7144615316 ELECTRICAL80804001 Series IV Highway Speed Excavators10-25 Work Lights (LED) InstallationItemPart LIGHTS (LED) INSTALLATION, (includes all items)A114403364A/RLOCTITE, #242 (blue)214404173A/RSILICONE CAULK3249213151 GROMMET, 1-1/24771430151 WHIZ-LOK NUT, 3/8-165771631054 FEMALE BULLET TERMINAL.