RENR3037-03

September 2001

Systems Operation
554 Forwarder and
574 Forwarder
Electrical System
1AM1-Up (Machine)
1FM1-Up (Machine)
 i01097883

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Electrical System
Systems Operation Section

Systems Operation Section

i01546801

Electrical System Schematic

SMCS Code: 7566

Table of Contents
Power Distribution .................................................. 5

Engine Starting and Stopping - 554 Forwarder ..... 7

Engine Starting and Stopping - 574 Forwarder ..... 9

Roading and Parking Lights ................................ 11

Brake Lights, Turn Signals, and Hazard Lights ... 13

Cab Roof Lights ................................................... 15

Backup Lights, Boom Lights, Hitch Lights, and

Backup Alarm ....................................................... 17

Front and Rear Windshield Wipers ...................... 19

Left and Right Windshield Wipers ....................... 21

Windshield Washers ............................................. 23

Vacuum Pump and Fill Pump ............................... 25

Heating, Ventilation, and Cooling System ............ 27

Dome Light, Horn, Seat Controls, and Beacon ... 29

Cigarette Lighter, Radio, and Voltage Converter .. 31

Speed Control ...................................................... 33

Power Train System - 554 Forwarder ................... 35

Power Train System - 574 Forwarder ................... 37

Steering System ................................................... 39

Bogie Lift System ................................................. 41

Boom Control System ........................................... 43

Boom Tilt Controls and Gate Controls ................. 45

IQAN Modules ...................................................... 47

IQAN Monitoring System ...................................... 49

Fuse Table ............................................................ 50

Machine Harness Connector and Relay

Locations .............................................................. 52
4
Electrical System
Systems Operation Section

Power Distribution
 5
Electrical System
Systems Operation Section

g00813885
Illustration 1
6
Electrical System
Systems Operation Section

Engine Starting and Stopping - 554

Forwarder
 7
Electrical System
Systems Operation Section

g00813892
Illustration 2
8
Electrical System
Systems Operation Section

Engine Starting and Stopping - 574

Forwarder
 9
Electrical System
Systems Operation Section

g00814009
Illustration 3
10
Electrical System
Systems Operation Section

Roading and Parking Lights

 11
Electrical System
Systems Operation Section

g00660770
Illustration 4
12
Electrical System
Systems Operation Section

Brake Lights, Turn Signals, and

Hazard Lights
 13
Electrical System
Systems Operation Section

g00823026
Illustration 5
14
Electrical System
Systems Operation Section

Cab Roof Lights

 15
Electrical System
Systems Operation Section

g00554324
Illustration 6
16
Electrical System
Systems Operation Section

Backup Lights, Boom Lights, Hitch

Lights, and Backup Alarm
 17
Electrical System
Systems Operation Section

g00816764
Illustration 7
18
Electrical System
Systems Operation Section

Front and Rear Windshield Wipers

 19
Electrical System
Systems Operation Section

g00818813
Illustration 8
20
Electrical System
Systems Operation Section

Left and Right Windshield Wipers

 21
Electrical System
Systems Operation Section

g00818815
Illustration 9
22
Electrical System
Systems Operation Section

Windshield Washers
 23
Electrical System
Systems Operation Section

g00660795
Illustration 10
24
Electrical System
Systems Operation Section

Vacuum Pump and Fill Pump

 25
Electrical System
Systems Operation Section

g00814246
Illustration 11
26
Electrical System
Systems Operation Section

Heating, Ventilation, and Cooling

System
 27
Electrical System
Systems Operation Section

g00814267
Illustration 12
28
Electrical System
Systems Operation Section

Dome Light, Horn, Seat Controls,

and Beacon
 29
Electrical System
Systems Operation Section

g00660804
Illustration 13
30
Electrical System
Systems Operation Section

Lighter, Radio, and Voltage

Converter
 31
Electrical System
Systems Operation Section

g00814278
Illustration 14
32
Electrical System
Systems Operation Section

Speed Control
 33
Electrical System
Systems Operation Section

g00814290
Illustration 15
34
Electrical System
Systems Operation Section

Power Train System - 554 Forwarder

 35
Electrical System
Systems Operation Section

g00814334
Illustration 16
36
Electrical System
Systems Operation Section

Power Train System - 574 Forwarder

 37
Electrical System
Systems Operation Section

g00815163
Illustration 17
38
Electrical System
Systems Operation Section

Steering System
 39
Electrical System
Systems Operation Section

g00815181
Illustration 18
40
Electrical System
Systems Operation Section

Bogie Lift System

 41
Electrical System
Systems Operation Section

g00554390
Illustration 19
42
Electrical System
Systems Operation Section

Boom Control System

 43
Electrical System
Systems Operation Section

g00663250
Illustration 20
44
Electrical System
Systems Operation Section

Boom Tilt Controls and Gate

Controls
 45
Electrical System
Systems Operation Section

g00828666
Illustration 21
46
Electrical System
Systems Operation Section

IQAN Modules
 47
Electrical System
Systems Operation Section

g00554392
Illustration 22
48
Electrical System
Systems Operation Section

IQAN Monitoring System

 49
Electrical System
Systems Operation Section

g00815280
Illustration 23
50
Electrical System
Systems Operation Section

Fuse Table

g00818374
Illustration 24
Fuses Located Under the Rear Console and the Left Side of the Machine

Table 1
Power Distribution Fuse Layout
Fuse Size Function Circuit ID Page(s)
F1 7.5 A Engine Stop, Alternate Light 115-PK 5, 15
F2 7.5 A Dash, Brake, and Dome Lights 152-RD 5, 11, 13, 29
F3 15 A HVAC 127-OR 5, 27
F4 10 A Parking Brake 134-YL 5, 35, 37
F5 15 A Condenser Fan 124-GN 5, 27
F6 7.5 A High Beam Lights 611-PU 11
F7 7.5A Low Beam Lights 619-GN 11
F8 10 A IQAN-MG Inputs 117-YL 5, 7, 19, 21, 33, 39, 45,
47, 49
F9 10 A IQAN-MG 129-BU 5, 35, 37, 47
F10 10 A IQAN-XP 130-GN 5, 47
F11 10 A IQAN-XP 131-BR 5, 47
F12 7.5 A Hazard Lamps 162-RD 5, 13
F13 7.5 A Engine Start Switch 104-RD 5
F14 10 A Head Lights 119-RD 5, 11
F15 7.5 A Back-Up Alarm 121-RD 5, 17
F16 10 A Windshield Wiper/Washer 118-GY 5, 19, 21, 23
F17 7.5 A Turn Signal, Seat Heater 157-YL 5, 13, 29
F18 - - -

F19 10 A Seat Air Compressor 190-PK 5, 29

(continued)
 51
Electrical System
Systems Operation Section

(Table 1, contd)
Power Distribution Fuse Layout
Fuse Size Function Circuit ID Page(s)
F20 5A Beacon 120-RD 5, 29
F21 - - -

F22 10 A Voltage Converter, Radio 150-RD 5, 31

F23 10 A Lighter 123-RD 5, 31
F24 5A Preheater Timer, IQAN-MG 142-RD 5, 27, 47
F25 3A Left Rear Tail Lights 617-BR 11
F26 3A Right Rear Tail Lights 618-YL 11
F27 - - -

F28 7.5 A Horn 114-RD 5, 29

F29 10 A Working Lights (Right Front Side 652-YL 15
of Cab)
F30 7.5 A Working Lights (Right Front Side 680-GN 15
of Cab)
F31 7.5 A Working Lights (Left Front Side of 615-PK 15
Cab)
F32 10 A Working Lights (Left Front Side of 653-GN 15
Cab)
F33 7.5 A Working Lights (Left Rear Side of 630-GY 15
Cab)
F34 7.5 A Working Lights (Left Rear Side of 609-YL 15
Cab)
F35 7.5 A Working Lights (Right Rear Side of 683-YL 15
Cab)
F36 7.5 A Working Lights (Right Rear Side of 684-OR 15
Cab)
F37 10 A Working Lights (Rear of Cab) 651-PK 15
F38 10 A Working Lights (Rear of Cab) 681-OR 15
F39 15 A Working Lights (Boom and Hitch) 616-BU 17
F40 7.5 A Backup Lights 608-GN 17
F51 10 A Main Fuse for F12 and F24 106-RD 5
F52 15 A Vacuum Pump 108-RD 5, 25
F53 15 A Hydraulic Fill Pump 110-RD 5, 25
F54 10 A Diesel Preheater 154-RD 5, 27
F55 20 A Diesel Preheater 155-RD 5, 27
F56 10 A Spare - 5
F57 10 A Spare - 5
F58 20 A 24V Outlet 107-RD 5
52
Electrical System
Systems Operation Section

Machine Harness Connector and

Relay Locations

g00817821
Illustration 27
Front Console

g00817530
Illustration 25
Top View of Cab

g00818224
Illustration 28
Top View of Engine

g00817692
Illustration 29
Rear Console

g00817794
Illustration 30
g00817671 Rear Console
Illustration 26
 53
Electrical System
Systems Operation Section

g00817690
Illustration 31
Rear Console

g00817696
Illustration 32
Side Console
54
Electrical System
Systems Operation Section

g00817578
Illustration 33

g00815666
Illustration 34
 55
Electrical System
Systems Operation Section

Table 2
Wire Harness Connectors
Wire
Function Page(s) Illus.
Connector
5, 11, 13, 27, 29, 35, 37,
X1 Cab Bulkhead 29
41, 45, 47, 49
X2 Cab Bulkhead 11, 13, 17 29
X3 Cab Bulkhead 5, 7, 9, 27, 33, 35, 37, 49 29
X5 Hydraulic Tank Harness Connector 17, 49 34
X6 Cab Bulkhead 17, 33, 35, 37, 49 29
X7 Roof Harness to Rear Console Bulkhead 15, 19, 27, 29, 31 31
X8 Side Console to Rear Console Bulkhead 19, 21, 29, 33, 39, 47 31
5, 7, 9, 11, 13, 17, 19, 23,
X9 Side Console to Rear Console Bulkhead 31
27, 29, 33, 35, 37, 39
5, 7, 9, 11, 15, 17, 19,
X10 Side Console to Rear Console Bulkhead 21, 23, 27, 29, 33, 35, 31, 32
37, 39, 45, 47, 49
X11 Side Console Interconnection 5, 7, 9, 27, 33, 35, 37, 39 32
X12 Side Console Interconnection 5, 7, 9, 27, 29, 35, 37, 39 32
X13 Side Console Interconnection 7, 9, 27 32
X14 IQAN Talk Connector 47 31
X15 Cab Bulkhead 17, 35, 37, 39, 43, 45, 49 29
X16 Cab Bulkhead - -
X19 Steering Column Connector 11, 13, 29 27
X21.1 Working Lights (Right Front Roof) 15, 19, 29 25
X21.2 Working Lights (Left Front Roof) 15 25
X22.1 Working Lights (Left & Right Rear Side Roof) 15, 19 25
X22.2 Working Lights (Rear Roof) 15 25
X23 Backup Lights Harness 17 33
X24 Throttle Pedal Sensor (Front) - -
X25 Throttle Pedal Sensor (Rear) - -
X27 4.7 K
Resistors 35, 37, 49 -
X29 Rear Lighting Harness Connector 11, 13 33
33, 35, 37, 39, 41, 45,
X30 IQAN-MG 30
47, 49
7, 19, 21, 33, 35, 37, -
X31 IQAN-MG
39, 45, 49
17, 19, 21, 35, 37, 39,
X32 IQAN-XP 30
41, 43, 47, 49
19, 21, 35, 37, 39, 41,
X33 IQAN-XS 26
43, 45
X34 IQAN-MG 47 30
X35 IQAN-MG 47 30
X36 IQAN-XP 47 30
X37 IQAN-XP 47 30
(continued)
56
Electrical System
Systems Operation Section

(Table 2, contd)
Wire Harness Connectors
Wire
Function Page(s) Illus.
Connector
X38 IQAN-XS 47 26
X39 IQAN-XS 47 26
X40 IQAN-DG 47 32
X41 IQAN-DG 47 32
X42 IQAN-DG 49 32
X44 Engine Governor Position Motor 33 34
X45 Front Windshield Wiper Motor 19 25
X46 Rear Windshield Wiper Motor 19 25
X48 Left & Right Rear Tail Lights 11, 13 33
X49 Left & Right Bogie Solenoids 41 34
X50 Seat Direction Switch 19, 21, 33, 39 26
X51 IQAN-XS 39 26
X54 Terrain Toggle Switch Steering Control 39 32
Speed & Direction Selector Switch, Toggle Switch Steering
X55.1 35, 37, 39, 43 26
Control, Left Implement Hydraulics Joystick
X55.2 Front & Rear Diff-Lock Switch 35, 37 26
Oscillation Lock Switch, Left & Right Bogie Joystick
X56.1 Control, Left Bogie Float Switch, Right Implement 35, 37, 41, 43, 45 26
Hydraulics Joystick, Boom Switch
X56.2 Boom Active Indicator Lamp, Boom Tilt In & Out Switch 43, 45 26
X59 Diesel Preheater Harness 27 34
X60 Air Conditioning Thermostat 27 27
X61 Engine Preheater Control Monitor - 32
X64 High & Low Beam Lights, Horn 11, 29 33
X66 Seat Heater 29 26
X67 Seat Suspension Air Compressor 29 26
X69 Radio 31 24
X70 Windshield Washer Pump Motors 26 27
X72 Rear Lighting 11, 13 33
X73 Motor Back Voltage Blocking Diode 27 27
X74 Left Wiper Harness Connector 21 32
X75 Right Wiper Harness Connector 21 32
X76 Splice Connector 19, 23 27
X77 Beacon 29 25
X89 Gearshift Solenoids, Charge Pump Pressure Sensor 37, 49 34
X90 Condenser Fan Motor 27 25
X91 Condenser Fan Motor 27 25
(continued)
 57
Electrical System
Systems Operation Section

(Table 2, contd)
Wire Harness Connectors
Wire
Function Page(s) Illus.
Connector
X92 Door Switch 7, 9 27
X93 Engine Start Switch 5, 7, 9 32
X94 Splice Connector 15 32
X95 Splice Connector 39, 45 32
X96 Splice Connector 19, 21, 23 32
X97 Backup Alarm 17 33
X98 Splice Connector 39 32
X99 Splice Connector 11 27
5, 7, 9, 13, 15, 17, 19,
X100 Relays 21, 23, 27, 31, 33, 35, -
37, 39, 45, 47, 49
X101 Splice Connector 39, 43, 45 -
X102 Splice Connector 43 -
X104 Left Windshield Wiper Motor 21 9
X105 Right Windshield Wiper Motor 21 9
X107 Warning Lamp 49 32
X121 Front Windshield Washer Pump Motor 23 -
X122 Rear Windshield Washer Pump Motor 23 -
X123 Right Windshield Washer Pump Motor 23 -
X124 Left Windshield Washer Pump Motor 23 -
X125 Preheater Fuel Pump 27 34
X126 Left Rear Roading Lights - 33
X127 Right Rear Roading Lights - 33
58
Electrical System
Systems Operation Section

Table 3
Relay Locations
Relay Function Page(s) Illus.
K1 Main Power Relay 1 5, 7, 9 31
K2 Main Power Relay 2 5 31
K3 Main Power Relay 3 5 31
K4 Right Front Lights Relay 15 31
K5 Left Front Lights Relay 15 31
K6 Left Rear Lights Relay 15 31
K7 Right Rear Lights Relay 15 31
K8 Rear Roof Lights Relay 15 31
K9 Boom Lights Relay 17 31
K10 Backup Lights Relay 17 31
K11 Front Windshield Wiper Relay 19 31
K12 Rear Windshield Wiper Relay 19 31
K13 Flasher - -
K14 Condensor Fan Relay 27 31
K15 Backup Alarm Relay 17 31
K16 Left Wiper Relay 21 30
K17 Right Wiper Relay 21 32
Air Compressor Interlock
K18 5, 29 31
Relay
K31 Start Relay 7, 9 28
K32 Engine Air Inlet Heater Relay 9 28
K33 Diesel Preheater Relay 27 34
 59
Electrical System
Index Section

Index
E

Electrical System Schematic ................................. 3

Backup Lights, Boom Lights, Hitch Lights, and
Backup Alarm................................................... 16
Bogie Lift System ............................................... 40
Boom Control System ........................................ 42
Boom Tilt Controls and Gate Controls ............... 44
Brake Lights, Turn Signals, and Hazard Lights .. 12
Cab Roof Lights ................................................. 14
Dome Light, Horn, Seat Controls, and Beacon.. 28
Engine Starting and Stopping - 554 Forwarder.. 6
Engine Starting and Stopping - 574 Forwarder.. 8
Front and Rear Windshield Wipers .................... 18
Fuse Table ......................................................... 50
Heating, Ventilation, and Cooling System .......... 26
IQAN Modules.................................................... 46
IQAN Monitoring System ................................... 48
Left and Right Windshield Wipers...................... 20
Lighter, Radio, and Voltage Converter ............... 30
Machine Harness Connector and Relay
Locations.......................................................... 52
Power Distribution .............................................. 4
Power Train System - 554 Forwarder ................. 34
Power Train System - 574 Forwarder ................. 36
Roading and Parking Lights............................... 10
Speed Control .................................................... 32
Steering System ................................................ 38
Table of Contents ............................................... 3
Vacuum Pump and Fill Pump............................. 24
Windshield Washers .......................................... 22

Important Safety Information ................................. 2

Systems Operation Section ................................... 3

©2001 Caterpillar
All Rights Reserved Printed in U.S.A.