M0110005-01

April 2021

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
ATC OPTION (3 PHASE)

M0110005-01 VOL 1 of 3
L L L POWER SCHEMATIC (50Hz SINGLE PHASE) FUW C1.1 , C1-S , C2-2 L
L
105-E260 WH-18
78-E262 WH-18
77-E266 WH-18
14
12
MBCR
11
TERM 4 5-E217 WH-18
L

45XX CONTROLLER GBCR

A1 A2

LC FRAME ALT ONLY 1 PHASE 2 WIRE

111-E317 WH-18
7 OUTPUT D (GCBC) 22-E220 WH-18 5-E218 WH-18

SEE NOTE B 115-E267 WH-18

(SHEET 1)
MBCR

(Dimensions: 56 inches x 35 inches)

N3-K52 BK-8 A1 A2
GEN BREAKER CONNECTION N2-K48 BK-8
L6-K50 BK-8 L9-K55 BK-8 8 OUTPUT E (MCBC) 50-E221 WH-18 5-E219 WH-18
SINGLE PHASE REF SHEET 8-[6,I] L5-K49 BK-8
K GBCR L8-K54 BK-8 K
12 L4-K51 BK-8
K K K K L7-K53 BK-8
14 11 184-E261 WH-18
108-E264 WH-18
MCB 7
L1-UA1 BR-8
CUSTOMER LOAD
L4-K2 BK-8 45XX CONTROLLER
CONNECTION
77-E266 WH-18
OPTIONAL TRANSFER SWITCH 187-E255 WH-18 184-E252 WH-18 25 MAINS SENSING L1
A1 A2 A1 A2
CONNECTION 78-E262 WH-18
186-E256 WH-18 183-E253 WH-18 26 MAINS SENSING L2
185-E257 WH-18 182-E254 WH-18 27 MAINS SENSING L3
AC ALTERNATOR REF [9,E] 181-E258 WH-18 181-E259 WH-18 28 MAINS SENSING N

L3-WA1 BR-8 L6-K4 BK-8 TERM 20

J MC/AUX J
SC/AUX
J J J J
EXCITER
E2 SC MC
105-E260 WH-18
T1 T2 T3 T4 6 5 4 1 2 3 TERM 21
A-C5
101-A48 WH-18 101-A10 WH-18
45XX CONTROLLER L10-K77 BK-8 CUSTOMER MAINS
E1 L11-K79 BK-8 CONNECTION
MCB 4 (2A) L12-K82 BK-8
24 GEN VOLTS SENSING N
N4-K83 BK-8
E N/C 102-A9 WH-18 110-A11 WH-18 23 GEN VOLTS SENSING L3
N4-K81 BK-8 N4-K56 BK-8
I I

C1.1, C1.5, C2.2, and C3.3

I MCB 3 (2A) I L12-K80 BK-8 L12-K58 BK-8
I I 171-E263 WH-18 SEE NOTE C
L11-K78 BK-8 L11-K59 BK-8
SIGNAL NAMES SYMBOL LEGEND TABLE 103-A47 WH-18 109-A12 WH-18 22 GEN VOLTS SENSING L2
L10-K76 BK-8 L10-K75 BK-8
(SHEET 1)
MCB 2 (2A)
CIRCUIT ID COLOR DESCRIPTION CUSTOMER EARTH ETH-A90 GN-YL-16

Generator Set
+ WH UNFUSED BATTERY POSITIVE SUPPLY MINIATURE CIRCUIT BREAKER 104-A46 WH-18 108-A13 WH-18 21 GEN VOLTS SENSING L1
10 WH GLOW PLUG RELAY OUTPUT
101 WH GEN SENSING NEUTRAL ATC OPTION (1 PHASE 3 WIRE)
102 WH GEN SENSING PHASE L3 BEFORE FUSE EMERGENCY STOP PUSHBUTTON R220/R221 AVR PANEL BODY
103 WH GEN SENSING PHASE L2 BEFORE FUSE
HARNESS TABLE

Electrical System
104 WH GEN SENSING PHASE L1 BEFORE FUSE CONNECT TO ALTERNATOR T1 RD 0V
105-E260 WH-18
105 WH MOTORISED CHANGEOVER SUPPLY CONNECT TO ALTERNATOR T2 RD 110V H 14 11
TERM 4 5-E217 WH-18 H
C90-A17 WH-18 PANEL DOOR 78-E262 WH-18
H 108 WH GEN SENSING L1 PHASE FUSED AUTOMOTIVE RELAY IDENT PART NO. CHG DESCRIPTION NOTE H H E+ H 12
RD E+ VOLTS ADJ. POT. 77-E266 WH-18 MBCR
109 WH GEN SENSING L2 PHASE C90-A18 WH-18 45XX CONTROLLER GBCR
HARNESS AS - - - - E- BK E- VOLTS ADJ. POT.1
110 WH GEN SENSING L3 PHASE A 464-3889 0 CONTROL PANEL 111-E317 WH-18 A1 A2
C90-A19 WH-18 C90-A23 WH-18 32 GEN CURRENT SENSING COM 7 OUTPUT D (GCBC) 22-E220 WH-18 5-E218 WH-18
111 WH MOTORISED CHANGEOVER SUPPLY C 508-8990 0 ENGINE (403-15/404-22)
115 WH AC CONTROL (-) FROM GEN SENSING CONNECT TO M4
RELAY E 500-4423 1 TRANSFER SWITCH CONTROL C50-A14 WH-18 31 GEN CURRENT SENSING L3 115-E267 WH-18
131 WH AUX SUPPLY (-) (WIRE 110)
132 WH AUX SUPPLY (+)
F
H
345-1117
512-0494
4
0
CANOPY EMERGENCY STOP
ENGINE (403-11)
C30-A15 WH-18 30 GEN CURRENT SENSING L2 MBCR Y4B1-UP
C10-A16 WH-18 29 GEN CURRENT SENSING L1 N3-K52 BK-8 A1 A2
139 WH BATTERY CHARGER AC SUPPLY
17 WH EMERGENCY STOP EARTH/GROUND
K
PL
501-7636
-
0
-
TRANSFER SWITCH LINK
POWER CABLES
GEN BREAKER CONNECTION
REF SHEET 10-[6,I]
L6-K50 BK-8 L9-K55 BK-8 8 OUTPUT E (MCBC) 50-E221 WH-18 5-E219 WH-18 Y5B1-UP
171 WH AC CONTROL (-) FROM MAINS SENSING GBCR N2-K48 BK-8 L8-K54 BK-8
181 WH MAIN SENSING NEUTRAL
WIRE/CABLE AS
GND
-
-
-
- EARTH/GROUND G 12 L4-K51 BK-8
L7-K53 BK-8 G Y6B1-UP
182 WH MAINS SENSING L3 14 11 184-E261 WH-18
G N - - BATTERY NEGATIVE G G G 108-E264 WH-18
183 WH MAINS SENSING L2 CURRENT TRANSFORMER P - - BATTERY POSITIVE
L6-K4 BK-8
CUSTOMER MAINS CUSTOMER LOAD MCB 7 Y7B1-UP
184 WH MAINS SENSING L1 CONNECTION CONNECTION 45XX CONTROLLER
185 WH MAINS SENSING L3 BEFORE FUSE
GEN BREAKER 77-E266 WH-18 GB81-UP
186 WH MAINS SENSING L2 BEFORE FUSE PANEL TERMINAL BLOCK 187-E255 WH-18 184-E252 WH-18 25 MAINS SENSING L1
187 WH MAINS SENSING L1 BEFORE FUSE CONNECTION 220/240V A1 A2 A1 A2 N/C 186-E256 WH-18 183-E253 WH-18 26 MAINS SENSING L2 YMG1-UP
19 WH CHARGING ALTERNATOR EXCITAION 78-E262 WH-18
TERMINAL REF [6,I] L4-K2 BK-8 185-E257 WH-18 182-E254 WH-18 27 MAINS SENSING L3
22 WH GBRRELAY OUTPUT 220/230/240 V
110/120V 110/120V
GB91-UP

42 Page,
24 WH REMOTE START COLOR ABBREVIATIONS REF [12,E] 184-E12 WH-18 181-E258 WH-18 181-E259 WH-18 28 MAINS SENSING N

3 WH FUEL CONTROL RELAY OUTPUT CONNECTOR TRANSFER SWITCH OPTION MC/AUX

TERM 20
GBY1-UP
30 WH PANEL ANALOGUE GROUND ABBREVIATION DESCRIPTION SC/AUX
MCB 7 F F
RD RED
F
4
5
WH
BK
STARTER MOTOR RELAY OUTPUT
BATTERY NEGATIVE WH WHITE F F F
110/120V 110/120V
TYB1-UP
OR ORANGE + TERM 13 ETH-E89 GN-YL-16 SC MC
50
51
WH
WH
MBR RELAY OUTPUT
STARTER MOTOR RELAY CONTROL YL YELLOW BATTERY
MSR 187-E4 WH-18
105-E260 WH-18
220/240V YMH1-UP
PK PINK CONNECT TO TERM 20 (WIRE 181)
53 WH FUEL CONTROL RELAY CONTROL 186-E5 WH-18
58 WH GLOW PLUG SUPPLY BK BLACK
WIRE
CONNECT TO TERM 21 (WIRE 101)
N/C
N/C 185-E6 WH-18 CUSTOMER MAINS TYC1-UP
GY GREY 171-E13 WH-18
12 L10-K77 BK-8
58A WH GLOW PLUG SUPPLY (FUSED)
7 WH PANEL DC POSITIVE (FUSED) PU PURPLE CONNECT TO MCB 2 (WIRE 108) MSR 14 11 L11-K79 BK-8 CONNECTION TY21-UP
OP
OP SENSOR (RESISTIVE) 115-E22 WH-18 115-E10 WH-18 111-E14 WH-18 181-E77 WH-18 L12-K82 BK-8
76 WH TRANSFER SWITCH CONTROL COM BR BROWN TERM 20 N4-K83 BK-8
A1 A2 22
77 WH TRANSFER SWITCH CONTROL GN GREEN 108-E21 WH-18 108-E7 WH-18 115-E16 WH-18 REF [3,F] 184-E12 WH-18 (NOTE C)
N4-K81 BK-8 N4-K56 BK-8
BU BLUE TEMP SENSOR (RESISTIVE) 24 21
78 WH TRANSFER SWITCH CONTROL 108-E11 WH-18 105-E15 WH-18 E
E L12-K80 BK-8 L12-K58 BK-8 E
8 WH MODBUS MODULE SUPPLY CU COPPER 171-E263 WH-18 CONNECT TO MCB 7 (WIRE 185)
E N E L11-K78 BK-8 L11-K59 BK-8
E GN-YL GREEN-YELLOW E
88 WH CAR RELAY OUTPUT
L L10-K75 BK-8
C10 WH CT PHASE L1 L10-K76 BK-8
FUEL SENSOR (RESISTIVE)
C30 WH CT PHASE L2
C50 WH CT PHASE L3
76-E18 WH-18 COM
C90 WH CT COMMON ABBREVIATIONS
ET WH ENGINE TEMPERATURE SENSOR SIGNAL FUEL SOLENOID POS II ATC OPTION (1 PHASE 2 WIRE)
ETH GN-YL EARTH/GROUND ABBREVIATION DESCRIPTION POS I
OP WH OIL PRESSURE SENSOR SIGNAL AVR AUTOMATIC VOLTAGE REGULATOR POS O
SA3 WH PANEL ANALOGUE INPUT AC ALTERNATING CURRENT TERM 4 5-E23 WH-18 GBCR 105-E260 WH-18
AMF AUTOMATC MAINS FAIL 14 11 5-E217 WH-18
TERM 4
GBCR D 78-E262 WH-18 D
CAR COMMON ALARM RELAY 45XX CONTROLLER 12 12
D D D D 77-E266 WH-18 MBCR 45XX CONTROLLER GBCR
DC DIRECT CURRENT A1 A2 14
11
ECR ENGINE CRANK RELAY 22-E26 WH-18 5-E24 WH-18 77-E19 WH-18 111-E317 WH-18 A1 A2
7 CLOSE GEN O/P F (POS) 7 OUTPUT D (GCBC) 22-E220 WH-18 5-E218 WH-18
ET ENGINE TEMPERATURE
ETH EARTH CONNECT TO TERM 21
MBCR (WIRE 101) 115-E267 WH-18
FCR FUEL CONTROL RELAY MBCR
45XX CONTROLLER
GRR GENERATOR RUNNING RELAY A1 A2
50-E27 WH-18 5-E25 WH-18 MBCR N3-K52 BK-8 A1 A2
MCB MINIATURE CIRCUIT BREAKER 8 CLOSE MAINS O/P G (POS) 184-E1 WH-18 25 MAINS SENSING L1 GEN BREAKER CONNECTION L9-K55 BK-8 8 OUTPUT E (MCBC) 50-E221 WH-18 5-E219 WH-18
OP OIL PRESSURE NOTES 12 183-E2 WH-18 26 MAINS SENSING L2 REF SHEET 11-[6,I]
L6-K50 BK-8
TERM TERMINAL GBCR L8-K54 BK-8
182-E3 WH-18 12 L4-K51 BK-8
Volume 1 of 3: 4520 Control Wiring
11 14 27 MAINS SENSING L3
MSR MOTOR SUPPLY RELAY 76-E28 WH-18 78-E20 WH-18 L7-K53 BK-8
NOTES DESCRIPTION C 14 11 184-E261 WH-18 C
GBCR GENERATOR BREAKER CLOSE RELAY 181-E80 WH-18 28 MAINS SENSING N 108-E264 WH-18
A WIRING NOT FACTORY SUPPLIED. REFER TO CONTROL MODULE OPERATION MANUAL IF REQUIRED. MCB 7
C MBCR MAINS BREAKER CLOSE RELAY
B FOR 380-440V SYSTEM CONNECT TO TERM 21 (WIRE 101). FOR 200-240V SYSTEM CONNECT TO MCB 4 (WIRE 110)
C C C CUSTOMER LOAD
GEN GENERATOR
C FOR 380-440V SYSTEM CONNECT TO TERM 20 (WIRE 181). FOR 200-240V SYSTEM CONNECT TO MCB 7 (WIRE 185)
CUSTOMER LOAD CONNECTION 45XX CONTROLLER
POS POSITION CONNECTION 77-E266 WH-18
187-E255 WH-18 184-E252 WH-18 25 MAINS SENSING L1
220/240V
220/230/240 V
78-E262 WH-18
A1 A2 A1 A2 N/C 186-E256 WH-18 183-E253 WH-18 26 MAINS SENSING L2 PUBLICATIONS.CAT.COM
N/C 185-E257 WH-18 182-E254 WH-18 27 MAINS SENSING L3

181-E258 WH-18 181-E259 WH-18 28 MAINS SENSING N

TERM 20
MC/AUX
SC/AUX
B B
B B B B
SC MC
105-E260 WH-18
220/240V

L10-K77 BK-8 CUSTOMER MAINS

L10-K117 BK-8 L11-K79 BK-8 CONNECTION
L12-K82 BK-8

N4-K113 BK-8
L11-K118 BK-8
L12-K119 BK-8
N4-K120 BK-8
N4-K121 BK-8
N4-K81 BK-8
L12-K80 BK-8
N4-K83 BK-8
N4-K56 BK-8
L12-K58 BK-8
Harness And Wire Electrical Schematic Symbols
A 171-E263 WH-18 CONNECT TO MCB 7 (WIRE 181) A
A A A
L12-K114 BK-8
L11-K115 BK-8
L12-K122 BK-8
L11-K123 BK-8
A
L11-K78 BK-8
L10-K76 BK-8
L11-K59 BK-8
L10-K75 BK-8 Symbols
L10-K116 BK-8 L10-K124 BK-8

SHEET 3
SHEET 1 SHEET 2 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
T

Pressure Temperature Level Flow Circuit Breaker

Symbol Symbol Symbol Symbol Symbol

Symbols and Definitions

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Fuse: A component in an electrical circuit that will open the circuit if too much current flows
through it.

L
ADDITIONAL INFORMATION L L L L CONTROL SCHEMATIC 4520 (WITH C1.1 ENGINE) L Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
circle indicates that the component has screw terminals and a wire can be disconnected from it.
DIN RAIL 1 CONTROL SCHEMATIC 4520 (WITH C1.5 & C2.2 ENGINES) FUW LC & M14 FRAME ALTS ONLY Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.).
5-H5 WH-18 53-H19 WH-18 REF [16,I]
REF [14,F] No circle indicates that the wire cannot be disconnected from the component.
FUW LC & M14 FRAME ALTS ONLY K
FUEL STOP SOLENOID
H-C3
K
Ground (Wired): This indicates that the component is connected to a grounded wire. The
K COMPONENT CURRENT RATING DESCRIPTION NOTE K K K 2 H-C1 A-C1
MCB 1 MCB 2 MCB 3 MCB 4 MCB 5 MCB 6 MCB 1 6A PANEL SUPPLY DC
1 53-H15 WH-18 53-H1 WH-18 3 45XX CONTROLLER
grounded wire is fastened to the machine.
MCB 2 2A GEN L1 SENSING 45XX CONTROLLER
MCB 3 2A GEN L2 SENSING REF [6,F] 5-A25 WH-18 1 BATTERY NEGATIVE
MCB 4 2A GEN L3 SENSING REF [6,F] 5-A25 WH-18 1 BATTERY NEGATIVE 51-H9 WH-16 4
TERM 21 - GEN NEUTRAL SENSING B Ground (Case): This indicates that the component does not have a wire connected to ground.
MCB 5
MCB 6
TBD
TBD
BATTERY CHARGER SUPPLY
COOLANT HEATER SUPPLY REF [7,G] 7-A24 WH-18 2 BATTERY POSITIVE
It is grounded by being fastened to the machine.
REF [7,G] 7-A24 WH-18 2 BATTERY POSITIVE

DYNO

BL H-C5 H-C4 VOLTAGE REGULATOR Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the
J J J J
J J
A
1 BL1-H16 WH-16 1 BL AC IN contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.
2
5-C16 WH-18 FCR FCR
REF [14,F] BL BL2-H17 WH-16 3 BL AC IN
C-C2
REF [10,G] +-A26 WH-16 30 REF [10,G] +-A26 WH-16 30 Sender: A component that is used with a temperature or pressure gauge. The sender
REF [13,G] 5-H18 WH-16 2 BK BATT -
FUEL STOP SOLENOID
2 C-C4 A-C1
10A
53-A3 WH-16 87
10A measures the temperature or pressure. Its resistance changes to give an indication to
1 53-C8 WH-18 3 53-A3 WH-16 87 T
+-H8 RD-8 20A 4 RD BATT + (OUT) REF [12,B] 5A-A49 WH-18 86 the gauge of the temperature or pressure.
DIN RAIL 2 REF [12,B] 5A-A49 WH-18 86
85
85
ECR ECR
53-H19 WH-18 5 YL IGN +
I I
I I I
REF [10,F] +-A28 WH-16 30
I REF [10,F] +-A28 WH-16 30
3-A44 WH-18 3 OUTPUT A (POS)
Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.
3-A44 WH-18 3 OUTPUT A (POS) 6 GN WARNING LAMP
COMPONENT WIRE ID DESCRIPTION
20A (FUEL)
51-A43 WH-18 87
20A (FUEL)
It has a coil that makes an electromagnet when current flows through it. The
51-C19 WH-16 4 51-A43 WH-18 87
TERM 1 7 FUSED PANEL SUPPLY
REF [12,B] 5A-A51 WH-18 86
REF [15,K]
19
REF [12,B] 5A-A51 WH-18 86 electromagnet can open or close the switch part of the relay.
TERM 2 7 FUSED PANEL SUPPLY 85
ONLY REQUIRED WITH TRANSFER SWITCH OPTION TERM 3 17A ESTOP COMMON 85
TERM 4 5 BATTERY NEGATIVE
TERM 5 5 BATTERY NEGATIVE 58A-H4 WH-12 40A 22 4-A45 WH-18 4 OUTPUT B (POS)
Solenoid: A solenoid is an electrical component that is activated by electricity. It has a
TERM 6 5A RELAY COIL COMMON 4-A45 WH-18 4 OUTPUT B (POS)
TERM 7 17 E-STOP N/C CHARGING ALT
(CRANK)
(CRANK)
coil that makes an electromagnet when current flows through it. The electromagnet
19-C2 WH-18 19
H
TERM 8 24 REMOTE START INPUT
H H 19-A29 WH-18 5 CHARGE ALT O/P H H
GLOW PLUGS 19-A29 WH-18 5 CHARGE ALT O/P H can open or close a valve or move a piece of metal that can do work.
TERM 9 SA1 ANALOG INPUT 2
SAR STARTER MOTOR SAR
TERM 10 5V 5V SENDER SUPPLY 1 3 1
A 58-A33 WH-12
TERM 11 SPARE 58A-C17 WH-12 40A 22 58-A33 WH-12 87
C-C1 87 86
MCB 7
TERM 12 SPARE 2 86
10-A30 WH-18 6 OUTPUT C (POS) 10-A30 WH-18 6 OUTPUT C (POS) Magnetic Latch Solenoid: A magnetic latch solenoid is an electrical component that is
GENERATOR BREAKER TERM 13 EARTH GLOW PLUGS (PREHEAT)
(PREHEAT)
TERM 14 ETH EARTH 5-A31 WH-18
activated by electricity and held latched by a permanent magnet. It has two coils (latch and unlatch)
- 5-A31 WH-18 85
CAR GRR MSR MBCR GBCR TERM 15
TERM 16 -
AUX NEUTRAL(N) SUPPLY AC
AUX LIVE(L) SUPPLY AC
STARTER MOTOR +-A32 WH-12
30
85
7 OUTPUT D (POS) +-H13 WH-12 1 +-A41 WH-12 +-A32 WH-12
30 7 OUTPUT D (POS) that make electromagnet when current flows through them. It also has an internal switch that places
TERM 17 134 WH OPTION LIVE(L) FEED
PROGRAMMABLE OUTPUTS 8 OUTPUT E (POS)
the latch coil circuit open at the time the coil latches.
TERM 18 - AUX NEUTRAL(-) SUPPLY DC 1 +-A41 WH-12 PROGRAMMABLE OUTPUTS 8 OUTPUT E (POS)
(NOTE A) MCB 1 (6A) (NOTE A)
TERM 19 - AUX LIVE(+) SUPPLY DC MCB 1 (6A) G G
G G G G
TERM 20
TERM 21
CAR
181
101
-
MAINS NEUTRAL SENSING (OPTION)
GEN NEUTRAL SENSING (OPTION)
COMMON ALARM RELAY (OPTION)
+-C50 WH-12 +-C29 WH-12 +-A42 WH-16 7-A27 WH-18 9 OUTPUT F (POS) BATT (+)-N1 1 RD-2
+

5-H18 WH-16 REF [15,I]

+-A42 WH-16 7-A27 WH-18 9 OUTPUT F (POS)
Harness and Wire Symbols
GRR - GEN RUNNING RELAY (OPTION) +-C51 RD-8
MSR - MOTOR SUPPLY RELAY (OPTION)
+-A26 WH-16 REF [5,J]
Wire, Cable, or Harness Harness Identification Letter(s):
MBCR - MAINS BREAKER CLSOR RELAY (OPTION) +-A26 WH-16 REF [5,J]
GBCR - GEN BREAKER CLOSE RELAY (OPTION)
REF [11,D] 7-A22 WH-18 30-P1 1 BK-2
5-H5 WH-18 REF [16,K]
REF [11,D] 7-A22 WH-18 Assembly Identification: Includes (A, B, C, ..., AA, AB, AC, ...)
+
MCB 7 - MAINS SENSING MCB (2A) (OPTION)
BATT (+)-N1 RD-2 Harness Identification Letters and
GENERATOR LOAD CONNECTION GENERATOR N - GENERATOR NEUTRAL Harness Connector Serialization Code:
CUSTOMER TERMINALS VFC VFC +-A28 WH-16 REF [8,I] REF [5,J] 7-A24 WH-18 5-A4 WH-18 REF [12,C] 5
+-A28 WH-16 REF [8,I] REF [5,J] 7-A24 WH-18 5-A4 WH-18 REF [12,C] Harness Connector Serialization
GENERATOR MCB - GENERATOR PHASES 5-H11 BK-8 5-H7 WH-16 The "C" stands for "Connector" and the
Codes (see sample).
F F F 30-P1 BK-2 5-C16 WH-18 REF [15,J] F F
5-A25 WH-18
F number indicates which connector in the
5-A25 WH-18 REF [5,K] REF [5,K]
AG-C4 L-C12 harness (C1, C2, C3, ...).
L-C12
5-C88 BK-8 5-C37 WH-16 5 5-A21 WH-16 REF [15,D] 30-H3 WH-18
5-A21 WH-16 111-7898 3E-5179 3E-5179
REF [15,D] 30-C15 WH-18
Part Number: for Connector Plug 1
30-C33 WH-18 30-C40 WH-18 6 30-A20 WH-18 10 ANALOG SENSOR RETURN 30-H12 WH-18 30-H10 WH-18 6 30-A20 WH-18 10 ANALOG SENSOR RETURN Part Number: for Connector Receptacle
30 11 ANALOG I/P A (OP)
30 11 ANALOG I/P A (OP) 2
ATS OPTIONAL ATC OPTIONAL C-C14
12 ANALOG I/P B (ET) E 2
C-C14
12 ANALOG I/P B (ET) E
5A
E E E GND 2 E GND
(TRANSFER SWITCH CONNECTIONS) (TRANSFER CONTACTOR CONNECTIONS) SIGNAL 3 OP-H2 WH-18 7 OP-A8 WH-18 SA1-A2 WH-18 13 ANALOG I/P C Plug Receptacle Component
SIGNAL 3 OP-C10 WH-18 7 OP-A8 WH-18 SA1-A2 WH-18 13 ANALOG I/P C
Vs 1 Vs 1
Pin or Socket Number Fuse (5 Amps) 9X-1123 Part Number
MAINS IN GEN IN
C-C3 OP SENDER
H-C2
1 Deutsch connector: Typical representation
OP SENDER 325-AG135 PK-14
LOAD 1 ET-C9 WH-18 8 ET-A7 WH-18 1 ET-H14 WH-18 8 ET-A7 WH-18 of a Deutsch connector. The plug contains all
Harness identification code:
2 30-C15 WH-18 REF [16,F]
2 30-H3 WH-18 REF [16,F] 2 sockets and the receptacle contains all pins. Wire Gauge*
TERM 1 TERM 1 This example indicates wire group 325,
DC VOLTAGE REGULATOR
REF [7,G] 7-A22 WH-18 ET SENDER REF [7,G] 7-A22 WH-18 DC VOLTAGE REGULATOR wire 135 in harness "AG". Wire Color
D SC MC D D
ET SENDER
TERM 2 RD Vin (6.5-32V) TERM 9 D D TERM 2 RD Vin (6.5-32V)
TERM 9 D
Sure-Seal connector: Typical representation
5V 9 5V 9 1 *Wire gauge is shown in AWG (American Wire Gauge)
5V BR Vout (5V) 5V
TERM 10
BR Vout (5V) of a Sure-Seal connector. The plug and receptacle
TERM 10
GND GND 2 contain both pins and sockets. but could also be shown in metric denoted with mm

BK
TERM 3
BK
17A-A94 WH-18
TERM 3 © 2021 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate Yellow”, the
17A-A94 WH-18
TERM 4 TERM 4 “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not
MAINS REF [6,F] 5-A4 WH-18 LINK TO START
(AUTO)
24-A5 WH-18 14 INPUT A (REMOTE START) REF [6,F] 5-A4 WH-18 LINK TO START
(AUTO) TERM 8
24-A5 WH-18 14 INPUT A (REMOTE START)
be used without permission.
TERM 8
TERM 5
C LOAD OUT C C EMERGENCY STOP TERM 5 C C EMERGENCY STOP C

F-C1 A-C2 F-C1 A-C2

1 2
1 2 17A-F1 WH-18 1
17A-F1 WH-18 1

855 & 857 OPTION 890 & 892 OPTION TERM 7

17C-F2 WH-18 2 17-A95 WH-18
TERM 7
17-A93 WH-18 15 INPUT B (E-STOP)
17C-F2 WH-18 2 17-A95 WH-18 17-A93 WH-18 15 INPUT B (E-STOP)
16 INPUT C
16 INPUT C TERM 6 PROGRAMMABLE INPUTS
500mA 7 TERM 2 3A 7 TERM 2 TERM 6 PROGRAMMABLE INPUTS 17 INPUT D
(NOTE A) 17 INPUT D REF [5,I] 5A-A49 WH-18 (NOTE A)
REF [5,I] 5A-A49 WH-18 18 CAN HI
5 TERM 4 5 TERM 4 18 CAN HI
CAN (NOT USED) 19 CAN LO B CAN (NOT USED) 19 CAN LO B
B B B B REF [8,I] 5A-A51 WH-18 (NOTE A)
REF [8,I] 5A-A51 WH-18 (NOTE A) 20 CAN SCR
20 CAN SCR

857 MODULE 890/892 MODULE

1 BATTERY -VE 1 BATTERY -VE GSM GSM&GPS CONNECTIONS
GPS NOT AVAILABLE ON MODEL 892
8 2 BATTERY +VE 8 2 BATTERY +VE
3 RS485 A 3 I/O A USB CABLE
CUSTOMER
4 RS485 B CUSTOMER 4 I/O B TO CONTROLLER
CONNECTIONS RS485 A 7
USB CABLE CONNECTIONS CUSTOMER
NOTE:RS485 CONNECTIONS 5 RS485 SCR TO CONTROLLER 5 I/O C RS485 B 8
NOT AVAILABLE ON MODEL 855 (-VE INPUT/+VE OUTPUT) 6 I/O D CONNECTIONS
RS485 SCR 9
A A A A
A A

SHEET 5 SHEET 6
SHEET 4 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
M0110005-01 VOL 1 of 3

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

J J
L L L PARALLEL-STAR (V608)
POWER SCHEMATIC (3 PHASE) FUW LC FRAME ALT ONLY L L
PARALLEL-STAR (V608) POWER SCHEMATIC (3 PHASE) FUW R FRAME ALTS ONLY L
(Dimensions: 56 inches x 35 inches)

CONTROL SCHEMATIC 4520 (WITH C3.3 ENGINES) SERIES DELTA

T7 T2
T7 T2
EXCITER EXCITER T12 T1
EXCITER T1 T8
T1 T8 SERIES DELTA T5
T5

K
FUW LC, M17 & R FRAME ALT'S K K
T4
T10
T11
EXCITER T12
T1

K K
T4

T12
T10

T6
T11

T6
T9 T4

T7 K
T12 T6

45XX CONTROLLER 1 T3
T9 T4 T10
E T9 T3 T8 T5
E T9 T3 T6
REF [6,F] 5-A111 WH-18 1 BATTERY NEGATIVE T7
T11 T2
T3
T10 E
T8 T5
REF [7,G] 7-A110 WH-18 2 BATTERY POSITIVE
T11 T2
E
J J J J J J

5-C20 WH-18 REF [14,F] FCR SERIES STAR SERIES STAR

C-C13 REF [10,F] +-A118 WH-16 30 L1-UA2 BR-8 L5-K6 BK-8

L1-UA1 BR-8 L5-K3 BK-8
2 C-C11 A-C6
FUEL STOP SOLENOID 15A
1 53-C22 WH-18 3 53-A97 WH-16 87

I REF [12,B] 5A-A119 WH-18 86

85
L2-VA1 BR-8 L6-K4 BK-8 OPTIONAL TRANSFER SWITCH
AC ALTERNATOR
L2-VA2 BR-8 L6-K7 BK-8
OPTIONAL TRANSFER SWITCH I
ECR CONNECTION CONNECTION
I I I AC ALTERNATOR I I I
REF [9,F]
REF [10,F] +-A116 WH-16 30 REF [9,F] L3-WA2 BR-8 N2-K5 BK-8
3-A101 WH-18 3 OUTPUT A (POS) L3-WA1 BR-8 N2-K1 BK-8 T2
25A (FUEL) T2
T1 T5
51-C19 1 WH-16 4 51-A100 WH-18 87 T1 T5
EXCITER
EXCITER T8 N-NA2 BL-8 L4-K8 BK-8
REF [12,B] 5A-A120 WH-18 86 T8 N-NA1 BL-8 L4-K2 BK-8 T4
T4
85 T7 T11
T7 T11
6 5 4 1 2 3 TERM 21
6 5 4 1 2 3 TERM 21 T10 A-C8
T10 A-C5 (NOTE B)
(NOTE B) T12
T12
101-A48 WH-18 101-A10 WH-18 101-A138 WH-18 101-A129 WH-18
4-A102 WH-18 4 OUTPUT B (POS) 45XX CONTROLLER 2
CHARGING ALT (CRANK) 45XX CONTROLLER
T9
19 T9
MCB 4 (2A) MCB 4 (2A) 1 24 GEN SENSING N
H H H 24 GEN SENSING N H H T6 H
T6
2 19-C21 WH-18
NOT REQUIRED 19-A113 WH-18 5 CHARGE ALT O/P
102-A9 WH-18 110-A11 WH-18 23 GEN SENSING L3 E 102-A128 WH-18 110-A130 WH-18 23 GEN SENSING L3
E
SAR
1 A 3 1
MCB 3 (2A) T3 MCB 3 (2A) 1
22 58-A141 WH-12 T3
C-C12 87 86 103-A127 WH-18 109-A131 WH-18 22 GEN SENSING L2
2 10-A142 WH-18 6 OUTPUT C (POS) 103-A47 WH-18 109-A12 WH-18 22 GEN SENSING L2
42 Page,

(PREHEAT) MCB 2 (2A) 1

ETH-A90 GN-YL-16 MCB 2 (2A) ETH-A140 GN-YL-16
5-A143 WH-18 104-A126 WH-18 108-A132 WH-18 21 GEN SENSING L1
STARTER MOTOR +-A144 WH-12
30
85
7 OUTPUT D (POS) CUSTOMER EARTH 104-A46 WH-18 108-A13 WH-18 21 GEN SENSING L1 CUSTOMER EARTH
PROGRAMMABLE OUTPUTS PANEL BODY
1 +-A98 WH-12 (NOTE A) 8 OUTPUT E (POS) PANEL BODY
G MCB 1 (6A) 1 G G G G G
+-C23 WH-12 +-C29 1 WH-12
+-A99 WH-16 7-A96 WH-18 9 OUTPUT F (POS)
R220 AVR AUX WINDING OPTION
C90-A17 WH-18 C90-A125 WH-18 PANEL DOOR
CONNECT TO ALTERNATOR T11 RD 0V PANEL DOOR
+-C24 RD-8 RD 110V C90-A18 WH-18 C90-A135 WH-18
CONNECT TO ALTERNATOR T8
RD E+ VOLTS ADJ. POT. C90-A19 WH-18 C90-A23 WH-18 32 CURRENT SENSING COM C90-A124 WH-18 C90-A136 WH-18 32 CURRENT SENSING COM
+-A118 WH-16 REF [5,J]
REF [11,D] 7-A22 1 WH-18 BK E- VOLTS ADJ. POT.1 C50-A133 WH-18 31 CURRENT SENSING L3
+ C50-A14 WH-18 31 CURRENT SENSING L3
BATT (+)-N1 2 RD-2 60 HZ P Q C30-A137 WH-18 30 CURRENT SENSING L2
C30-A15 WH-18 30 CURRENT SENSING L2 - EXCITER -
REF [12,C] + MARELLI EXCITER + MARELLI 29 CURRENT SENSING L1
+-A116 WH-16 REF [8,I] REF [5,J] 7-A110 WH-18 5-A109 WH-18 C10-A16 WH-18 29 CURRENT SENSING L1

H F
30-P1 2 BK-2 5-C20 WH-18 REF [15,J]
F F TRANSFER SWITCH OPTION F F
ALT TERM T7
U
S
MARK V
REG
AUX WIRE 15
ALT TERM T7
MARK V
REG F
H
5-A111 WH-18 REF [5,K] ALT TERM T8 O AUX WIRE 3 N2-K5 BK-8
N2-K1 BK-8 TO ALT GND TERM TO ALT GRND TERM REF [12,D] 184-E44 WH-18
5-C88 1 BK-8 5-C37 1 WH-16 5 5-A104 WH-16 GEN BREAKER L6-K7 BK-8
CUSTOMER MAINS
GEN BREAKER L6-K4 BK-8 CUSTOMER MAINS CONNECTION CONNECTION
REF [16,D] 30-C14 WH-18 CONNECTION CONNECTION REF [6,I]
MCB 7
L5-K6 BK-8
REF [6,I] L5-K3 BK-8
30-C33 1 WH-18 30-C40 1 WH-18 6 30-A103 WH-18 10 ANALOG SENSOR RETURN
REF [12,D] 184-E12 WH-18 TRANSFER SWITCH OPTION L4-K8 BK-8 187-E29 WH-18
11 ANALOG I/P A (OP) L4-K2 BK-8 TERM 13 1 ETH-E52 GN-YL-16 186-E30 WH-18
E E E 104-A46 WH-18 E
12 ANALOG I/P B (ET) E MSR 185-E31 WH-18 E
MCB 7
REF [5,G]
OP SENDER OP OP-C13 WH-18 7 OP-A108 WH-18 SA1-A106 WH-18 13 ANALOG I/P C SEE NOTE C 171-E46 WH-18 12
108-A13 WH-18 TERM 13 ETH-E89 GN-YL-16 181-E43 WH-18
115-E35 WH-18 115-E41 WH-18 14 11 TERM 20
MSR 187-E4 WH-18 111-E47 WH-18
(NOTE C)
SEE NOTE C 186-E5 WH-18 22
C-C10 SEE NOTE B REF [3,E] 184-E44 WH-18
MCB 2 (2A) 12 185-E6 WH-18 24 21
171-E13 WH-18 108-E42 WH-18 105-E48 WH-18
1 ET-C12 WH-18 8 ET-A107 WH-18 14 11
MSR 115-E22 WH-18 115-E10 WH-18 111-E14 WH-18 181-E77 WH-18
30-C14 WH-18 104-A126 WH-18
2 REF [16,F] TERM 20 76-E49 WH-18
A1 A2 22
108-E21 WH-18 108-E7 WH-18 115-E16 WH-18 REF [3,E] 184-E12 WH-18 (NOTE C) REF [5,G]
115-E33 WH-18 E
24 21
D ET SENDER D D 108-E11 WH-18 105-E15 WH-18 E D D 108-A132 WH-18 GBCR D
TERM 9 1 N
N
L
12
108-E11 WH-18 76-E18 WH-18
L
SEE NOTE B 11 14
77-E50 WH-18
REF [7,G] 7-A22 1 WH-18 TERM 1 1 GBCR MCB 2 (2A) 1
COM
TERM 2 1 COM MSR
POS II
12 POS II A2 MBCR
A1 POS I
17A-A122 WH-18 17A-A122 WH-18 TERM 3 1 11 14 POS I
108-E34 WH-18 108-E32 WH-18
77-E19 WH-18 POS O
TERM 4 1 POS O
12
REF [6,F] 5-A109 WH-18 LINK TO START 24-A105 WH-18 14 INPUT A (REMOTE START) MBCR
11 14
(AUTO) TERM 8 1 TERM 4 5-E23 WH-18 76-E53 WH-18 78-E51 WH-18
C TERM 5 1 C C 12 C C C
G EMERGENCY STOP 45XX CONTROLLER
A1
GBCR
A2 76-E28 WH-18
11 14
78-E20 WH-18
G
7 OUTPUT D (GCBC) 22-E26 WH-18 5-E24 WH-18
F-C1 1 A-C7
CUSTOMER LOAD
1 2
17A-F3 WH-18 1 CUSTOMER LOAD CONNECTION
TERM 7 1 MBCR CONNECTION
45XX CONTROLLER
17C-F4 WH-18 2 17-A123 WH-18 17-A121 WH-18 15 INPUT B (E-STOP) A1 A2
8 OUTPUT E (MCBC) 50-E27 WH-18 5-E25 WH-18 TERM 4 2 5-E36 WH-18
PROGRAMMABLE INPUTS
16 INPUT C 184-E1 WH-18 25 MAINS SENSING L1
TERM 6 1
(NOTE A) 17 INPUT D 183-E2 WH-18 26 MAINS SENSING L2 45XX CONTROLLER 2 GBCR
REF [5,I] 5A-A119 WH-18
18 CAN HI 182-E3 WH-18 27 MAINS SENSING L3 A1 A2
B CAN (NOT USED) B B B B 7 OUTPUT D (GCBC) 22-E39 WH-18 5-E37 WH-18 B
19 CAN LO 181-E80 WH-18 28 MAINS SENSING N
REF [8,I] 5A-A120 WH-18 (NOTE A)
20 CAN SCR

MBCR
45XX CONTROLLER 2
A1 A2
8 OUTPUT E (MCBC) 50-E40 WH-18 5-E38 WH-18
184-E8 WH-18 25 MAINS SENSING L1
L10-K129 BK-8 183-E9 WH-18 26 MAINS SENSING L2
L10-K105 BK-8 L11-K130 BK-8
L11-K106 BK-8 L12-K131 BK-8 182-E17 WH-18 27 MAINS SENSING L3
L12-K107 BK-8 N4-K132 BK-8 181-E45 WH-18 28 MAINS SENSING N
N4-K108 BK-8 N4-K133 BK-8
N4-K125 BK-8
A A A N4-K101 BK-8 N4-K109 BK-8 A A L12-K126 BK-8 L12-K134 BK-8 A
L12-K102 BK-8 L12-K110 BK-8 L11-K135 BK-8
L11-K127 BK-8
L11-K103 BK-8 L11-K111 BK-8 L10-K136 BK-8
L10-K128 BK-8
L10-K104 BK-8 L10-K112 BK-8

SHEET 7 SHEET 8 SHEET 9

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

F F

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

L
POWER SCHEMATIC (3 PHASE) FUW M14 & M17 FRAME ALTS ONLY L L POWER SCHEMATIC(60Hz SINGLE PHASE)FUW C1.1,C2.2 LC & M14 FRAME ALT ONLY L L POWER SCHEMATIC (50Hz SINGLE PHASE) FUW C1.1 , C1-S , C2-2 L

STAR (6P) (V608)

1 PHASE 3 WIRE M14 FRAME ALT ONLY 1 PHASE 2 WIRE

T1 T2
NOTE: ALTERNATOR COMES WITH ALL THE 3 CABLES BUT,
EXCITER SINGLE PHASE SINGLE PHASE L2 SHOULD NOT BE USED WITH 1PHASE 2WIRE
K K K K K SYSTEM FOR CUSTOMER LOAD CONNECTION K
T5
T4 T6
L1-UA1 BR-8 L4-K2 BK-8
L1-UA1 BR-8 L4-K2 BK-8

OPTIONAL TRANSFER SWITCH OPTIONAL TRANSFER SWITCH

E
N-NA1 BL-8 CONNECTION
L2-VA1 BR-8 CONNECTION
N2-K1 BK-8 AC ALTERNATOR
AC ALTERNATOR REF [9,E]
T3 REF [9,E]
L3-WA1 BR-8 L6-K4 BK-8
L3-WA1 BR-8 L6-K4 BK-8
J J J J J J
STAR (6S)
E EXCITER
EXCITER
E
T1 T2 T3 T4 TERM 21
6 5 4 1 2 3
L1-UA3 BR-8 L5-K12 BK-8 T1 T2 T3 T4
6 5 4 1 2 3 TERM 21 A-C5 (NOTE B)
A-C5 (NOTE B) 101-A48 WH-18 101-A10 WH-18
OPTIONAL TRANSFER SWITCH 101-A48 WH-18 101-A10 WH-18 45XX CONTROLLER
45XX CONTROLLER
L2-VA3 BR-8 L6-K10 BK-8 CONNECTION MCB 4 (2A)
MCB 4 (2A) 24 GEN VOLTS SENSING N
24 GEN VOLTS SENSING N
REF [9,F] E N/C 102-A9 WH-18 110-A11 WH-18 23 GEN VOLTS SENSING L3
T2 102-A9 WH-18 110-A11 WH-18 23 GEN VOLTS SENSING L3
T1 E
I EXCITER I I I MCB 3 (2A)
I I
L3-WA3 BR-8 N2-K11 BK-8 MCB 3 (2A)
103-A47 WH-18 109-A12 WH-18 22 GEN VOLTS SENSING L2
T5 N/C 103-A47 WH-18 109-A12 WH-18 22 GEN VOLTS SENSING L2
T4 ETH-A90 GN-YL-16 MCB 2 (2A)
T6
N-NA3 BL-8 L4-K9 BK-8
CUSTOMER EARTH ETH-A90 GN-YL-16 MCB 2 (2A) CUSTOMER EARTH
104-A46 WH-18 108-A13 WH-18 21 GEN VOLTS SENSING L1
104-A46 WH-18 108-A13 WH-18 21 GEN VOLTS SENSING L1
6 5 4 1 2 3 TERM 21
A-C9 (NOTE B)
101-A158 WH-18 101-A150 WH-18 PANEL BODY
45XX CONTROLLER 3 R220/R221 AVR PANEL BODY
E
T3 MCB 4 (2A) 2 24 GEN SENSING N RD 0V
CONNECT TO ALTERNATOR T1 C90-A17 WH-18
H 102-A149 WH-18 H H H H PANEL DOOR H
110-A151 WH-18 23 GEN SENSING L3 RD 110V C90-A17 WH-18 PANEL DOOR
CONNECT TO ALTERNATOR T2
C90-A18 WH-18
MCB 3 (2A) 2 RD E+ VOLTS ADJ. POT. C90-A18 WH-18
CONNECT TO EXCITER BK E- VOLTS ADJ. POT.1 C90-A19 WH-18 C90-A19 WH-18 C90-A23 WH-18 32 GEN CURRENT SENSING COM
103-A148 WH-18 109-A152 WH-18 22 GEN SENSING L2 C90-A23 WH-18 32 GEN CURRENT SENSING COM

ETH-A159 GN-YL-16 MCB 2 (2A) 2 C50-A14 WH-18 31 GEN CURRENT SENSING L3

FUW LC ALTERNATOR (OPTION) C50-A14 WH-18 31 GEN CURRENT SENSING L3
C30-A15 WH-18 30 GEN CURRENT SENSING L2
CUSTOMER EARTH 104-A147 WH-18 108-A153 WH-18 21 GEN SENSING L1 C30-A15 WH-18 30 GEN CURRENT SENSING L2
C10-A16 WH-18 29 GEN CURRENT SENSING L1
C10-A16 WH-18 29 GEN CURRENT SENSING L1
F1 F+-AVR213 WH-16
PANEL BODY R121 AVR
F2 F--AVR214 WH-16
G G G G G N N-AVR215 WH-16 G
C90-A146 WH-18 U U-AVR216 WH-16
CUSTOMER MAINS
PANEL DOOR L6-K4 BK-8
R121 AVR R2
CONNECTION
D R120 AVR
C90-A155 WH-18
C90-A145 WH-18 C90-A156 WH-18 32 CURRENT SENSING COM F1 F+-AVR21 WH-16 R1
POT GEN BREAKER
CONNECTION
D
F2 F--AVR22 WH-16
F+-AVR6 WH-18 C50-A154 WH-18 31 CURRENT SENSING L3
AVR-T3

F1
N N-AVR23 WH-16 REF [6,I] L4-K2 BK-8
F2
AVR-T5

F--AVR7 WH-18 C30-A157 WH-18 30 CURRENT SENSING L2 220/230/240 V

U U-AVR24 WH-16 REF [12,E] 184-E12 WH-18
N
AVR-T6

N-AVR8 WH-18 29 CURRENT SENSING L1

R2
U
AVR-T7

U-AVR9 WH-18 R1
POT TRANSFER SWITCH OPTION
MCB 7
F N1
F F F F F
V
AVR-T8

V-AVR10 WH-18 N2-K11 BK-8

FUW M14 ALTERNATOR FRAMES (STANDARD) TERM 13 ETH-E89 GN-YL-16
REF [12,E] 184-E72 WH-18
CONNECT TO 'N1' FOR 6P (220/127V , 60Hz) GEN BREAKER L6-K10 BK-8
CUSTOMER MAINS MSR 187-E4 WH-18
CONNECT TO TERM 20 (WIRE 181)
CONNECT TO 'V' FOR 6S (380/415V , 50Hz) CONNECTION CONNECTION N/C 186-E5 WH-18
MCB 7 CONNECT TO TERM 21 (WIRE 101)
REF [6,I] 12 N/C 185-E6 WH-18
L5-K12 BK-8 171-E13 WH-18
CONNECT TO MCB 2 (WIRE 108)
TRANSFER SWITCH OPTION MSR 115-E22 WH-18 115-E10 WH-18
14 11
111-E14 WH-18 181-E77 WH-18
TRANSFER SWITCH OPTION L4-K9 BK-8 187-E57 WH-18 A1 A2 22
TERM 20
108-E21 WH-18 108-E7 WH-18 115-E16 WH-18 REF [3,F] 184-E12 WH-18 (NOTE C)
TERM 13 2 ETH-E82 GN-YL-16 186-E58 WH-18 24 21
MSR 108-E11 WH-18 105-E15 WH-18 E
185-E59 WH-18
E E E GEN BREAKER CUSTOMER MAINS E E N E
L6-K4 BK-8
SEE NOTE C 171-E74 WH-18 12 181-E71 WH-18 CONNECTION CONNECTION
L

115-E63 WH-18 115-E69 WH-18 14 11 TERM 20 REF [6,I] N2-K1 BK-8

111-E75 WH-18
(NOTE C)
22 76-E18 WH-18 COM
REF [3,E] 184-E72 WH-18
24 21 L4-K2 BK-8 POS II
108-E70 WH-18 105-E76 WH-18 220/240 V
TERM 13 ETH-E89 GN-YL-16 POS I
104-A147 WH-18 REF [12,C] 184-E12 WH-18
76-E78 WH-18 POS O
CONNECT TO TERM 20 (WIRE 181) MSR
REF [5,G] TERM 4 5-E23 WH-18 GBCR
115-E61 WH-18 E
CONNECT TO TERM 21 (WIRE 110) MCB 7
108-A153 WH-18 GBCR N 12
D D D 171-E13 WH-18 D D 45XX CONTROLLER GBCR 12 D
L CONNECT TO MCB 2 (WIRE 108) 14 11 A1 A2
12 MSR 115-E22 WH-18 115-E10 WH-18 111-E14 WH-18 11 14
22-E26 WH-18 5-E24 WH-18 77-E19 WH-18
SEE NOTE B 11 14 A1 A2 22
187-E4 WH-18 7 CLOSE GEN O/P F (POS)
77-E79 WH-18 115-E16 WH-18 REF [3,D] 184-E12 WH-18
MCB 2 (2A) 2 108-E21 WH-18 108-E7 WH-18 N/C 186-E5 WH-18
COM 24 21
108-E11 WH-18 105-E15 WH-18
C A1
MSR
A2
MBCR
POS II
POS I
76-E18 WH-18
185-E6 WH-18

181-E77 WH-18 50-E27 WH-18

MBCR
A1 A2
5-E25 WH-18 MBCR
45XX CONTROLLER C
108-E62 WH-18 108-E60 WH-18 GBCR 8 CLOSE MAINS O/P G (POS) 184-E1 WH-18 25 MAINS SENSING L1
POS O TERM 20
12
(NOTE C) 12 183-E2 WH-18 26 MAINS SENSING L2
11 14 12
76-E83 WH-18 78-E81 WH-18 E 11 14 182-E3 WH-18 27 MAINS SENSING L3
11 14 76-E28 WH-18 78-E20 WH-18
N 181-E80 WH-18 28 MAINS SENSING N
C C C C C C
CUSTOMER LOAD MBCR L
CONNECTION CUSTOMER LOAD
CUSTOMER LOAD 220/240 V 12
CONNECTION
CONNECTION 11 14
COM
76-E28 WH-18 77-E19 WH-18 POS II 220/230/240 V
78-E20 WH-18 POS I
TERM 4 3 5-E64 WH-18 POS O

45XX CONTROLLER 3 TERM 4 5-E23 WH-18

GBCR
A1 A2 GBCR
22-E67 WH-18 5-E65 WH-18 45XX CONTROLLER
7 OUTPUT D (GCBC)
B B B A1 A2 B B B
22-E26 WH-18 5-E24 WH-18
7 CLOSE GEN O/P F (POS)
MBCR
45XX CONTROLLER 3
A1 A2 MBCR
8 OUTPUT E (MCBC) 50-E68 WH-18 5-E66 WH-18 L10-K117 BK-8
184-E54 WH-18 25 MAINS SENSING L1 45XX CONTROLLER
A1 A2 L11-K118 BK-8
L10-K129 BK-8 183-E55 WH-18 26 MAINS SENSING L2 50-E27 WH-18 5-E25 WH-18 L12-K119 BK-8 L10-K117 BK-8
8 CLOSE MAINS O/P G (POS) N4-K120 BK-8 184-E1 WH-18 25 MAINS SENSING L1
L11-K130 BK-8 L11-K118 BK-8
L12-K131 BK-8 182-E56 WH-18 27 MAINS SENSING L3
183-E2 WH-18 26 MAINS SENSING L2 L12-K119 BK-8
N4-K113 BK-8 N4-K121 BK-8
N4-K132 BK-8 181-E73 WH-18 28 MAINS SENSING N
182-E3 WH-18 27 MAINS SENSING L3 N4-K120 BK-8
L12-K114 BK-8 L12-K122 BK-8
N4-K125 BK-8 N4-K133 BK-8 N4-K113 BK-8 N4-K121 BK-8
L11-K115 BK-8 L11-K123 BK-8 181-E80 WH-18 28 MAINS SENSING N
L12-K126 BK-8 L12-K134 BK-8 L12-K114 BK-8 L12-K122 BK-8
A A A L10-K116 BK-8 L10-K124 BK-8 A A A
L11-K127 BK-8 L11-K135 BK-8 L11-K115 BK-8 L11-K123 BK-8
L10-K128 BK-8 L10-K136 BK-8 L10-K116 BK-8 L10-K124 BK-8

SHEET 10 SHEET 11 SHEET 12

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B B
NOTES
NOTES DESCRIPTION
A WIRING NOT FACTORY SUPPLIED. REFER TO CONTROL MODULE OPERATION MANUAL IF REQUIRED.
B FOR 380-440V SYSTEM CONNECT TO TERM 21 (WIRE 101). FOR 200-240V SYSTEM CONNECT TO MCB 4 (WIRE 110)
C FOR 380-440V SYSTEM CONNECT TO TERM 20 (WIRE 181). FOR 200-240V SYSTEM CONNECT TO MCB 7 (WIRE 185)

SYMBOL DESCRIPTION ABBREV COLOR

CIRCUIT CONNECTED RD RED

WH WHITE
CIRCUIT NOT CONNECTED
OR ORANGE
ELECTRICAL CONNECTION TO
MACHINE STRUCTURE
YL YELLOW
INTERNAL ELECTRICAL CONNECTION
TO SURFACE OF COMPONENT PK PINK

CONNECTOR BK BLACK

H# GY GRAY
CIRCUIT GROUPING DESIGNATION
Do not operate or work on this product unless you have
PU PURPLE
ATCH WIRE, CABLE, COMPONENT read and understood the instruction and warnings in the
BR BROWN relevant Operation and Maintenance Manuals and
/ SPLICE
GN GREEN
relevant service literature. Failure to follow the instruc-
BLADE, SPADE, RING OR SCREW
tions or heed the warnings could result in injury or
TERMINAL BU BLUE death. Proper care is your responsibility.

A A
THIS SCHEMATIC IS FOR THE C1.1, C1.5, C2.2, AND C3.3 GENERATOR SET
ELECTRICAL SYSTEM
VOLUME 1 of 3: 4520 CONTROL WIRING
MEDIA NUMBER: M0110005-01
SCHEMATIC PART NUMBER: 515-0496, CHANGE: 11, VERSION: DK
Components are shown installed on a fully operable generator set in a non powered state.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
Refer to the Parts Manual using a specific serial number prefix in SIS before ordering parts from this schematic.

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
 M0110005-01
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
April 2021

L L L

CONTROL SCHEMATIC 7410/7420/7320 (WITH C1.5 & C2.2 ENGINES) L L

CONTROL SCHEMATIC 7410 / 7420 / 7320 (WITH C1.1 ENGINE)

L

FUW LC & M14 FRAME ALTS ONLY TCP2000 / TC3000 CONTROLLER

FUW LC & M14 FRAME ALTS ONLY

M0110005-01 VOL 2 of 3
TCP2000 / TCP3000 CONTROLLER
REF [6,F] 5-A25 WH-18 1 BATTERY NEGATIVE

K K K K K REF [6,F] 5-A25 WH-18 1 BATTERY NEGATIVE K

EMERGENCY STOP
EMERGENCY STOP REF [7,G] 7-A24 WH-18 2 BATTERY POSITIVE
REF [7,G] 7-A22 WH-18 TERM 1
REF [7,G] 7-A22 WH-18 TERM 1 F-C1 A-C2 TERM 2 REF [7,G] 7-A24 WH-18 2 BATTERY POSITIVE
F-C1 A-C2 TERM 2 1 2
17A-F1 WH-18 1 17A-A94 WH-18 TERM 3
1 2
17A-F1 WH-18 1 17A-A94 WH-18 TERM 3
TERM 7

(Dimensions: 56 inches x 35 inches)

TERM 7 17C-F2 WH-18 2 17-A95 WH-18
17C-F2 WH-18 2 17-A95 WH-18 17-A93 WH-18 3 EMERGENCY STOP I/P
& COMMON (OUTPUT A&B)
17-A93 WH-18 3 EMERGENCY STOP I/P
J J J J J J
& COMMON (OUTPUT A&B)

5-H5 WH-18 REF [14,E] 53-H19 WH-18 REF [16,G]

5-C16 WH-18 REF [14,F] FCR
C-C2
REF [10,G] +-A26 WH-16 30 FUEL STOP SOLENOID FCR
2 C-C4 A-C1 H-C3
FUEL STOP SOLENOID 10A REF [10,G]
1 +-A26 WH-16 30
53-C8 WH-18 3 53-A3 WH-16 87
2 H-C1 A-C1 10A
REF [11,D] 5A-A49 WH-18 86
1 53-H15 WH-18 53-H1 WH-18 3 53-A3 WH-16 87
85
ECR REF [9,B] 5A-A49 WH-18 86
I I I I I 51-H9 WH-16 4 85 I
REF [10,F] +-A28 WH-16 30 ECR
SIGNAL NAMES SYMBOL LEGEND TABLE 20A
3-A44 WH-18 4 FUEL O/P (POS)
REF [10,F] +-A28 WH-16 30
CIRCUIT ID COLOR DESCRIPTION 51-C19 WH-16 4 51-A43 WH-18 87 3-A44 WH-18 4 FUEL O/P (POS)
+ WH UNFUSED BATTERY POSITIVE SUPPLY MINIATURE CIRCUIT BREAKER REF [11,C] 5A-A51 WH-18 86 20A
10 WH GLOW PLUG RELAY OUTPUT DYNO 51-A43 WH-18 87
85
101 WH GEN SENSING NEUTRAL VOLTAGE REGULATOR REF [9,B] 5A-A51 WH-18 86
BL H-C5 H-C4
102 WH GEN SENSING PHASE L3 BEFORE FUSE EMERGENCY STOP PUSHBUTTON 85
1 BL1-H16 WH-16 1 BL AC IN
103 WH GEN SENSING PHASE L2 BEFORE FUSE
HARNESS TABLE 4-A45 WH-18 5 CRANK O/P (POS)

A
104 WH GEN SENSING PHASE L1 BEFORE FUSE 2
CHARGING ALT 19 3
105 WH MOTORISED CHANGEOVER SUPPLY BL BL2-H17 WH-16 BL AC IN 4-A45 WH-18 5 CRANK O/P (POS)
H 108 WH GEN SENSING L1 PHASE FUSED AUTOMOTIVE RELAY IDENT PART NO. CHG DESCRIPTION NOTE H H H
19-A29 WH-18 6 CHARGE ALT O/P H H
HARNESS AS - - - - 2

C1.1, C1.5, C2.2, and C3.3

109 WH GEN SENSING L2 PHASE 19-C2 WH-18
SAR REF [13,E] 5-H18 WH-16 2 BK BATT -
110 WH GEN SENSING L3 PHASE A 464-3889 0 CONTROL PANEL 1 A 3 1 19-A29 WH-18 6 CHARGE ALT O/P
C 508-8990 0 ENGINE (403-15/404-22) 58A-C17 WH-12 40A 22 58-A33 WH-12
111 WH MOTORISED CHANGEOVER SUPPLY C-C1 87 86 SAR
115 WH AC CONTROL (-) FROM GEN SENSING RELAY E 500-4423 1 TRANSFER SWITCH CONTROL 2 10-A30 WH-18 8 PREHEAT O/P G (POS) +-H8 RD-8 20A 4 RD BATT + (OUT)
F 345-1117 4 CANOPY EMERGENCY STOP GLOW PLUGS 58-A33 WH-12
131 WH AUX SUPPLY (-) 87 86
H 512-0494 0 ENGINE (403-11) 10-A30 WH-18 8 PREHEAT O/P G (POS)
132 WH AUX SUPPLY (+)

Generator Set
5-A31 WH-18 9 CONFIG O/P F (POS) 53-H19 WH-18 5 YL IGN +
K 501-7636 0 TRANSFER SWITCH LINK STARTER MOTOR 85
139 WH BATTERY CHARGER AC SUPPLY 30
PL - - POWER CABLES +-A32 WH-12
17 WH EMERGENCY STOP EARTH/GROUND 5-A31 WH-18 9 CONFIG O/P F (POS)
WIRE/CABLE AS - - 10 CONFIG O/P G (POS) 6 GN WARNING LAMP 85
171 WH AC CONTROL (-) FROM MAINS SENSING 30
1 +-A32 WH-12
181 WH MAIN SENSING NEUTRAL GND - - EARTH/GROUND +-A41 WH-12
N - - BATTERY NEGATIVE MCB 1 (6A) REF [15,I] 10 CONFIG O/P G (POS)
182 WH MAINS SENSING L3 G 11 CONFIG O/P H (POS) G

Electrical System
G G PROGRAMMABLE OUTPUTS G 19 G
183 WH MAINS SENSING L2 P - - BATTERY POSITIVE +-C50 WH-12 +-C29 WH-12 (NOTE A)
CURRENT TRANSFORMER +-A42 WH-16 7-A27 WH-18
184 WH MAINS SENSING L1 MCB 1 (6A) 11 CONFIG O/P H (POS)
12 CONFIG O/P I (POS) PROGRAMMABLE OUTPUTS
185 WH MAINS SENSING L3 BEFORE FUSE +-A42 WH-16 7-A27 WH-18
+-C51 RD-8 (NOTE A)
186 WH MAINS SENSING L2 BEFORE FUSE PANEL TERMINAL BLOCK 58A-H4 WH-12 40A 22 12 CONFIG O/P I (POS)
187 WH MAINS SENSING L1 BEFORE FUSE 13 CONFIG O/P J (POS)
+-A26 WH-16 REF [5,J]
19 WH CHARGING ALTERNATOR EXCITAION TERMINAL REF [10,K] 7-A22 WH-18
22 WH GBRRELAY OUTPUT + 13 CONFIG O/P J (POS)
BATT (+)-N1 RD-2 7 +-A26 WH-16 REF [5,I]
24 WH REMOTE START COLOR ABBREVIATIONS REF [8,K] 7-A22 WH-18
3 WH FUEL CONTROL RELAY OUTPUT
ABBREVIATION DESCRIPTION
CONNECTOR +-A28 WH-16 REF [8,I] REF [5,K] 7-A24 WH-18
STARTER MOTOR GLOW PLUGS 7 EARTH Y4B1-UP
30 WH PANEL ANALOGUE GROUND
RD RED
F 4
5
WH
BK
STARTER MOTOR RELAY OUTPUT
BATTERY NEGATIVE WH WHITE F F 30-P1 BK-2 5-C16 WH-18 REF [15,J]
REF [5,K] 5-A25 WH-18
F F
+-A28 WH-16 REF [7,I] REF [3,K] 7-A24 WH-18
F Y5B1-UP
OR ORANGE +
50
51
WH
WH
MBR RELAY OUTPUT
STARTER MOTOR RELAY CONTROL YL YELLOW BATTERY
5
REF [11,D] 5-A4 WH-18
1
REF [3,K] 5-A25 WH-18 Y6B1-UP
PK PINK 5-C88 BK-8 5-C37 WH-16 5-A21 WH-16 +-H13 WH-12 +-A41 WH-12
53 WH FUEL CONTROL RELAY CONTROL 14 ANALOG COMMON GND REF [9,B] 5-A4 WH-18
58 WH GLOW PLUG SUPPLY BK BLACK
WIRE REF [15,D] 30-C15 WH-18
Y7B1-UP
58A WH GLOW PLUG SUPPLY (FUSED) GY GREY 15 ANALOG I/P (A) 14 ANALOG COMMON GND
7 WH PANEL DC POSITIVE (FUSED) PU
BR
PURPLE
BROWN
OP
OP SENSOR (RESISTIVE) 30-C33 WH-18 30-C40 WH-18 6 30-A20 WH-18
(OIL PRESSURE)
16 ANALOG I/P (B) 15 ANALOG I/P (A)
GB81-UP
76 WH TRANSFER SWITCH CONTROL COM ENGINE TEMPERATURE + (OIL PRESSURE)
77
78
WH
WH
TRANSFER SWITCH CONTROL
TRANSFER SWITCH CONTROL
GN
BU
GREEN
BLUE TEMP SENSOR (RESISTIVE) 30 TERM 9 SA1-A2 WH-18 17 CONFIG ANALOG I/P (C)
BATT (+)-N1 1 RD-2
5-H18 WH-16
16 ANALOG I/P (B) YMG1-UP
C-C14 REF [15,H] ENGINE TEMPERATURE
CU COPPER
8 WH MODBUS MODULE SUPPLY 18 CONFIG ANALOG I/P (D) GB91-UP

42 Page,
E GN-YL GREEN-YELLOW E E 2 E E TERM 9 SA1-A2 WH-18 17 CONFIG ANALOG I/P (C)
E
88 WH CAR RELAY OUTPUT GND
C10 WH CT PHASE L1 SIGNAL 3 OP-C10 WH-18 7 OP-A8 WH-18 SPARE ANALOG INPUT 19 CONFIG ANALOG I/P (E) 30-P1 1 BK-2 18 CONFIG ANALOG I/P (D)
C30 WH CT PHASE L2
FUEL SENSOR (RESISTIVE)
Vs 1 (NOTE A) 5-H5 WH-18 REF [16,J] GBY1-UP
C50 WH CT PHASE L3 20 CONFIG ANALOG I/P (F) SPARE ANALOG INPUT 19 CONFIG ANALOG I/P (E)
C90 WH CT COMMON ABBREVIATIONS FUEL SOLENOID C-C3 5-H11 BK-8 5-H7 WH-16 5 5-A21 WH-16
(NOTE A)
20 CONFIG ANALOG I/P (F)
TYB1-UP
ET WH ENGINE TEMPERATURE SENSOR SIGNAL OP SENDER
ETH
OP
GN-YL
WH
EARTH/GROUND
OIL PRESSURE SENSOR SIGNAL
ABBREVIATION
AVR
DESCRIPTION
AUTOMATIC VOLTAGE REGULATOR
1 ET-C9 WH-18 8 ET-A7 WH-18 YMH1-UP
2 30-C15 WH-18 REF [16,F]
SA3 WH PANEL ANALOGUE INPUT AC
AMF
ALTERNATING CURRENT
AUTOMATC MAINS FAIL TERM 4
TYC1-UP
CAR COMMON ALARM RELAY ET SENDER 5-A4 WH-18 LINK TO START 24-A5 WH-18 51 REMOTE START I/P (A) 48 30-H3 WH-18
D DC DIRECT CURRENT D D REF [6,F] (AUTO) TERM 8 52 CONFIG I/P B (NEG) 49
D D
REF [15,C]
D TY21-UP
ECR ENGINE CRANK RELAY 5V 9 TERM 5 24-A5 WH-18 51 REMOTE START I/P (A) 48
53 CONFIG I/P C (NEG) 50
ET ENGINE TEMPERATURE 52 CONFIG I/P B (NEG) 49
TERM 6 54 CONFIG I/P D (NEG) 51 30-H12 WH-18 30-H10 WH-18 6 30-A20 WH-18
ETH EARTH BK FUW 7320 MKII 53 CONFIG I/P C (NEG) 50
FCR FUEL CONTROL RELAY REF [5,I] 5A-A49 WH-18 PROGRAMMABLE INPUTS 55 CONFIG I/P E (NEG) 52
(NOTE A) 30 54 CONFIG I/P D (NEG) 51
GRR GENERATOR RUNNING RELAY 56 CONFIG I/P F (NEG) 53
C-C14 PROGRAMMABLE INPUTS 55 CONFIG I/P E (NEG) 52
MCB MINIATURE CIRCUIT BREAKER 5A-A51 WH-18 57 CONFIG I/P G (NEG) 54 FUW 7320 MKII
OP OIL PRESSURE NOTES REF [8,I]
DC VOLTAGE REGULATOR 58 CONFIG I/P H (NEG) 55
GND 2 (NOTE A) 56 CONFIG I/P F (NEG) 53
TERM TERMINAL SIGNAL 3 OP-H2 WH-18 7 OP-A8 WH-18 57 CONFIG I/P G (NEG) 54
MSR MOTOR SUPPLY RELAY GND Vs 1 58 CONFIG I/P H (NEG) 55
NOTES DESCRIPTION TERM 10
GBCR GENERATOR BREAKER CLOSE RELAY
C A WIRING NOT FACTORY SUPPLIED. REFER TO CONTROL MODULE OPERATION MANUAL IF REQUIRED. C C Vout (5V) C
MBCR MAINS BREAKER CLOSE RELAY 5V BR C C
B FOR 380-440V SYSTEM CONNECT TO TERM 21 (WIRE 101). FOR 200-240V SYSTEM CONNECT TO MCB 4 (WIRE 110) H-C2
GEN GENERATOR RD Vin (6.5-32V) OP SENDER
C FOR 380-440V SYSTEM CONNECT TO TERM 20 (WIRE 181). FOR 200-240V SYSTEM CONNECT TO MCB 7 (WIRE 185)
POS POSITION TERM 2 21 MPU + 8
1 ET-H14 WH-18 ET-A7 WH-18
MAG PICKUP (NOT USED) 22 MPU - 2 30-H3 WH-18 REF [16,D]
(NOTE A) 21 MPU +
23 MPU SCR
MAG PICKUP (NOT USED) 22 MPU -
ET SENDER
(NOTE A) 23 MPU SCR
30 CAN HIGH
5V 9
CAN (NOT USED)
(NOTE A)
31 CAN LOW FUW 74XX MKII 30 CAN HIGH
32 CAN SCR CAN (NOT USED)
TERM 4 31 CAN LOW
B B B
27 NET LINK +
B B REF [6,F] 5-A4 WH-18 LINK TO START (NOTE A) 32 CAN SCR
FUW 74XX MKII B
(AUTO) TERM 8
NETLINK CONNECTIONS 28 NET LINK -
TERM 5 27 NET LINK +
(NOTE A) 29 NET LINK SCR
NETLINK CONNECTIONS 28 NET LINK -
TERM 6

RS485 CONNECTIONS
RS485 A
RS485 B
REF [5,I] 5A-A49 WH-18
BK
(NOTE A)
29 NET LINK SCR
Volume 2 of 3: 7410, 7420, and 7320 Control Wiring
(NOTE A) RS485 A
RS485 SCR REF [7,I] 5A-A51 WH-18 RS485 CONNECTIONS
DC VOLTAGE REGULATOR RS485 B
(NOTE A) RS485 SCR
RS232 RJ45
A A A RS232 & ETHERNET
CONNECTIONS A A TERM 10
GND
A PUBLICATIONS.CAT.COM
(NOTE A) 5V BR Vout (5V) RS232 RJ45
RS232 & ETHERNET
RD Vin (6.5-32V) CONNECTIONS
TERM 2 (NOTE A)

SHEET 1 SHEET 2 SHEET 3

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

Harness And Wire Electrical Schematic Symbols

Symbols

Pressure Temperature Level Flow Circuit Breaker

Symbol Symbol Symbol Symbol Symbol

Symbols and Definitions

Fuse: A component in an electrical circuit that will open the circuit if too much current flows
through it.

Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
circle indicates that the component has screw terminals and a wire can be disconnected from it.

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.

Ground (Wired): This indicates that the component is connected to a grounded wire. The
grounded wire is fastened to the machine.

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Ground (Case): This indicates that the component does not have a wire connected to ground.
It is grounded by being fastened to the machine.

POWER SCHEMATIC (3 PHASE) FUW LC FRAME ALTS ONLY

L
CONTROL SCHEMATIC 7410 / 7420 / 7320 (WITH C3.3 ENGINES) L L PARALLEL-STAR (V608) L L
PARALLEL-STAR (V608) POWER SCHEMATIC (3 PHASE) FUW R FRAME ALTS ONLY L
Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the
contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.

FUW LC, M17 & R FRAME ALT'S TCP2000 / TC3000 CONTROLLER

EXCITER
T7 T2
T7 T2
SERIES DELTA Sender: A component that is used with a temperature or pressure gauge. The sender
T1 T8
SERIES DELTA EXCITER T1 T8
measures the temperature or pressure. Its resistance changes to give an indication to
REF [6,F] 5-A111 WH-18 1 BATTERY NEGATIVE T5 T
T1
T4
T10
T11
T5
T10
EXCITER T12 the gauge of the temperature or pressure.
EXCITER T12 T1
T4 T11
K K K K K K
REF [7,G] 7-A110 WH-18 2 BATTERY POSITIVE T12 T6
EMERGENCY STOP T9
REF [7,G] 7-A22 1 WH-18 TERM 1 1
T12 T6 T4
Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.
T9 T4 T6 T7

1 2
F-C1 1 A-C7 TERM 2 1 E T9 T3
T6 T7
It has a coil that makes an electromagnet when current flows through it. The
1 E T9 T3 T3
17A-F3 WH-18 17A-A122 WH-18 TERM 3 1
T3 T8 T5
T10
electromagnet can open or close the switch part of the relay.
TERM 7 1 T10
17C-F4 WH-18 2 17-A123 WH-18 17-A121 WH-18 3 EMERGENCY STOP I/P T8 T5 T11 T2
& COMMON (OUTPUT A&B)
E
T11 T2
Solenoid: A solenoid is an electrical component that is activated by electricity. It has a
E
J J J J J J coil that makes an electromagnet when current flows through it. The electromagnet
5-C20 WH-18 FCR
C-C13
REF [14,F]
can open or close a valve or move a piece of metal that can do work.
REF [10,G] +-A118 WH-16 30 SERIES STAR
2 C-C11 A-C6
15A
SERIES STAR
FUEL STOP SOLENOID
L1-UA1 BR-8
1 53-C22 WH-18 3
REF [11,D]
53-A97 WH-16 87 L5-K3 BK-8
L1-UA2 BR-8 L5-K6 BK-8
Magnetic Latch Solenoid: A magnetic latch solenoid is an electrical component that is
5A-A119 WH-18 86
OPTIONAL TRANSFER SWITCH activated by electricity and held latched by a permanent magnet. It has two coils (latch and unlatch)
ECR
85 OPTIONAL TRANSFER SWITCH
L2-VA1 BR-8 L6-K4 BK-8 CONNECTION that make electromagnet when current flows through them. It also has an internal switch that places
REF [10,F] +-A116 WH-16 30 AC ALTERNATOR REF [9,F]
L2-VA2 BR-8 L6-K7 BK-8 CONNECTION
I
25A
3-A101 WH-18 4 FUEL O/P (POS) I I I I AC ALTERNATOR REF [9,E] I the latch coil circuit open at the time the coil latches.
51-C19 1 WH-16 4 51-A100 WH-18 87 L3-WA1 BR-8 N2-K1 BK-8
T2 L3-WA2 BR-8 N2-K5 BK-8
REF [11,D] 5A-A120 WH-18 86
85 EXCITER
T1

T4 T8
T5
N-NA1 BL-8 L4-K2 BK-8 EXCITER
T1

T4 T8
T5
T2

N-NA2 BL-8 L4-K8 BK-8

Harness and Wire Symbols
T7 T11
4-A102 WH-18 5 CRANK O/P (POS) 6 5 4 1 2 3 TERM 21 T7 T11
T10 A-C5 (NOTE B) 6 5 4 1 2 3 TERM 21 Wire, Cable, or Harness Harness Identification Letter(s):
CHARGING ALT T12 T10 A-C8 (NOTE B)
19 101-A48 WH-18 101-A10 WH-18
7410/20 MKII CONTROLLER T12 Assembly Identification: Includes (A, B, C, ..., AA, AB, AC, ...)
19-A113 WH-18 6 CHARGE ALT O/P 101-A138 WH-18 101-A129 WH-18
2 19-C21 WH-18 NOT REQUIRED H
T9
MCB 4 (2A) H
7410/20 MKII CONTROLLER Harness Identification Letters and
H
SAR
H
T6 40 GEN VOLTS SENSING N 37 H T9 H Harness Connector Serialization Code:
1 A 3 1
22 58-A141 WH-12 102-A9 WH-18 110-A11 WH-18 39 GEN VOLTS SENSING L3 36 T6
MCB 4 (2A) 1 40 GEN VOLTS SENSING N 37 Harness Connector Serialization
C-C12 87 86
E
102-A128 WH-18 36
The "C" stands for "Connector" and the
2 10-A142 WH-18 8 PREHEAT O/P G (POS) T3 MCB 3 (2A) E 110-A130 WH-18 39 GEN VOLTS SENSING L3 Codes (see sample).
T3 MCB 3 (2A) 1 number indicates which connector in the
103-A47 WH-18 109-A12 WH-18 38 GEN VOLTS SENSING L2 35
5-A144 WH-18 9 CONFIG O/P F (POS) 103-A127 WH-18 109-A131 WH-18 38 GEN VOLTS SENSING L2 35 AG-C4 L-C12 harness (C1, C2, C3, ...).
STARTER MOTOR
+-A143 WH-12 30
85
MCB 2 (2A) L-C12
MCB 2 (2A) 1 111-7898 3E-5179

FUW 7320 MKII

10 CONFIG O/P G (POS)
CUSTOMER EARTH 104-A46 WH-18 108-A13 WH-18 37 GEN VOLTS SENSING L1 34
104-A126 WH-18 108-A132 WH-18 37 GEN VOLTS SENSING L1 34
3E-5179
1 +-A98 WH-12 CUSTOMER EARTH

FUW 7320 MKII

ETH-A53 GN-YL-16
+-C29 1 WH-12
MCB 1 (6A) 1
PROGRAMMABLE OUTPUTS 11 CONFIG O/P H (POS)
PANEL BODY Part Number: for Connector Plug 1
G
+-C23 WH-12 +-A99 WH-16 7-A96 WH-18 (NOTE A) G G G G PANEL BODY
ETH-A139 GN-YL-16
G
Part Number: for Connector Receptacle
12 CONFIG O/P I (POS) R220 AVR
+-C24 RD-8
CONNECT TO ALTERNATOR T11 RD 0V C90-A17 WH-18 PANEL DOOR
2
13 CONFIG O/P J (POS) AUX WINDING OPTION C90-A125 WH-18 PANEL DOOR 5A
+-A118 WH-16 REF [5,J] CONNECT TO ALTERNATOR T8 RD 110V C90-A18 WH-18
REF [10,K] 7-A22 1 WH-18 C90-A135 WH-18
+ RD E+ VOLTS ADJ. POT. C90-A19 WH-18 C90-A23 WH-18 49 GEN CURRENT SENSING COM 46
BATT (+)-N1 2 RD-2 7 C90-A136 WH-18 49 GEN CURRENT SENSING COM 46
Plug Receptacle Component
+-A116 WH-16 REF [8,I] REF [5,K] 7-A110 WH-18
BK E- VOLTS ADJ. POT.1
C50-A14 WH-18 47 GEN CURRENT SENSING L3 44
C90-A124 WH-18
Pin or Socket Number Fuse (5 Amps) 9X-1123 Part Number
C30-A15 WH-18 46 GEN CURRENT SENSING L2 43 -
60 HZ P Q EXCITER - - 60 HZ P Q C50-A133 WH-18 47 GEN CURRENT SENSING L3 44
+ MARELLI EXCITER + + MARELLI C30-A137 WH-18 46 GEN CURRENT SENSING L2 43
C10-A16 WH-18 45 GEN CURRENT SENSING L1 42
MARK V MARK V
1 Deutsch connector: Typical representation
30-P1 2 BK-2 5-C20 WH-18 REF [15,J]
REF [5,K] 5-A111 WH-18
F
48 45
F ALT TERM T7
U
REG AUX WRE 15 U
REG
C10-A134 WH-18 45 GEN CURRENT SENSING L1 42 325-AG135 PK-14
F
REF [11,D] 5-A109 WH-18
F
50
F S ALT TERM T7 S 48 45 F of a Deutsch connector. The plug contains all
47
ALT TER T8 O O 2 Harness identification code:
5-C88 1 BK-8 5-C37 1 WH-16 5 5-A104 WH-16
14 ANALOG COMMON GND
AUX WIRE 3 50 47
sockets and the receptacle contains all pins. This example indicates wire group 325, Wire Gauge*
TO ALT GND TERM TO ALT GND TERM
REF [16,D] 30-C14 WH-18
15 ANALOG I/P (A)
TRANSFER SWITCH OPTION wire 135 in harness "AG". Wire Color
(OIL PRESSURE)
30-C33 1 WH-18 30-C40 1 WH-18 6 30-A103 WH-18 16 ANALOG I/P (B)
N2-K1 BK-8
1 Sure-Seal connector: Typical representation
ENGINE TEMPERATURE
GEN BREAKER CUSTOMER MAINS TRANSFER SWITCH OPTION of a Sure-Seal connector. The plug and receptacle *Wire gauge is shown in AWG (American Wire Gauge)
TERM 9 1 SA1-A106 WH-18 17 CONFIG ANALOG I/P (C)
CONNECTION L6-K4 BK-8
CONNECTION N2-K5 BK-8
2 contain both pins and sockets. but could also be shown in metric denoted with mm
18 CONFIG ANALOG I/P (D) REF [6,I] L5-K3 BK-8
E E E E GEN BREAKER L6-K7 BK-8
CUSTOMER MAINS
OP SENDER E E
OP OP-C13 WH-18 7 OP-A108 WH-18 SPARE ANALOG INPUT
(NOTE A)
19 CONFIG ANALOG I/P (E)
L4-K2 BK-8
REF [12,D] 184-E12 WH-18 CONNECTION CONNECTION © 2021 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate Yellow”, the
20 CONFIG ANALOG I/P (F)
104-A46 WH-18 REF [6,I] L5-K6 BK-8 “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not
MCB 7
C-C10 REF [5,G]
L4-K8 BK-8
REF [12,D] 184-E44 WH-18 be used without permission.
1 ET-C12 WH-18 ET-C12 WH-18 8 ET-A107 WH-18 ET-A107 WH-18 108-A13 WH-18 TERM 13 ETH-E89 GN-YL-16
104-A126 WH-18
2 30-C14 WH-18 REF [16,F] MSR 187-E4 WH-18 MCB 7
REF [5,G]
TERM 4 SEE NOTE C 186-E5 WH-18
LINK TO START SEE NOTE B (SHEET 1)
ET SENDER REF [6,F] 5-A109 WH-18 24-A105 WH-18 51 REMOTE START I/P (A) 12 185-E6 WH-18 108-A132 WH-18 TERM 13 1 ETH-E52 GN-YL-16
(AUTO) MCB 2 (2A) (SHEET 1) 171-E13 WH-18
TERM 8 1 52 CONFIG I/P B (NEG) 14 11 MSR 187-E29 WH-18
D TERM 5 2 D D MSR 115-E22 WH-18 115-E10 WH-18 111-E14 WH-18 181-E77 WH-18 D
53 CONFIG I/P C (NEG) D SEE NOTE C 186-E30 WH-18 D
A1 A2 22
TERM 20 SEE NOTE B
108-E21 WH-18 108-E7 WH-18 115-E16 WH-18 REF [3,D] 184-E12 WH-18 (SHEET 1) 12 185-E31 WH-18
TERM 6 1 54 CONFIG I/P D (NEG) (NOTE C) MCB 2 (2A) 1
24 21 (SHEET 1) 171-E46 WH-18
REF [5,I] 5A-A119 WH-18 55 CONFIG I/P E (NEG) 108-E11 WH-18 105-E15 WH-18 E
MSR 14 11
PROGRAMMABLE INPUTS 115-E35 WH-18 115-E41 WH-18 111-E47 WH-18 181-E43 WH-18
(NOTE A) 56 CONFIG I/P F (NEG) N
A1 A2 22 TERM 20
5A-A120 WH-18 57 CONFIG I/P G (NEG) L 108-E34 WH-18 108-E32 WH-18 115-E33 WH-18 REF [3,D] 184-E44 WH-18 (NOTE C)
REF [8,I] 76-E18 WH-18 24 21
58 CONFIG I/P H (NEG) 108-E42 WH-18 105-E48 WH-18 E
GBCR N
COM
L
POS II
12
POS I
C C C 11 14 C C C
77-E19 WH-18 POS O 76-E49 WH-18 COM
21 MPU + GBCR
TERM 4 5-E23 WH-18 POS II
MAG PICKUP (NOT USED) 22 MPU - MBCR
(NOTE A) 12 POS I
23 MPU SCR 7420 CONTROLLER GBCR
14 POS O
A1 A2 12 11 77-E50 WH-18
22-E26 WH-18 5-E24 WH-18 TERM 4 1 5-E36 WH-18
30 CAN HIGH 9 CLOSE GEN O/P F (POS) 11 14
76-E28 WH-18 78-E20 WH-18
CAN (NOT USED) 7420 CONTROLLER GBCR
31 CAN LOW MBCR
(NOTE A) MBCR
32 CAN SCR A1 A2
A1 A2
CUSTOMER LOAD 7420 MKII CONTROLLER
9 CLOSE GEN O/P F (POS)
22-E39 WH-18 5-E37 WH-18
12
27 NET LINK +
10 CLOSE MAINS O/P G (POS)
50-E27 WH-18 5-E25 WH-18 CONNECTION 184-E1 WH-18 41 MAINS SENSING L1 CUSTOMER LOAD
B B B B B 11 14 B
NETLINK CONNECTIONS 28 NET LINK -
183-E2 WH-18 42 MAINS SENSING L2 MBCR CONNECTION 76-E53 WH-18 78-E51 WH-18
(NOTE A) 29 NET LINK SCR 7420 MKII CONTROLLER
182-E3 WH-18 43 MAINS SENSING L3 A1 A2
50-E40 WH-18 5-E38 WH-18
181-E80 WH-18 44 MAINS SENSING N 10 CLOSE MAINS O/P G (POS) 184-E8 WH-18 41 MAINS SENSING L1
RS485 A L10-K128 BK-8
183-E9 WH-18 42 MAINS SENSING L2
RS485 CONNECTIONS RS485 B L11-K129 BK-8
(NOTE A) L10-K31 BK-8 182-E17 WH-18 43 MAINS SENSING L3
RS485 SCR L12-K131 BK-8 38 L11-K30 BK-8 38
181-E45 WH-18 44 MAINS SENSING N
N4-K132 BK-8 39 L12-K32 BK-8 39
RS232 RJ45 N4-K17 BK-8 N4-K12 BK-8 40 N4-K29 BK-8 40
RS232 & ETHERNET
CONNECTIONS 41 N4-K25 BK-8 N4-K24 BK-8 41
L12-K18 BK-8 L12-K11 BK-8
A (NOTE A) A A A A A
L11-K19 BK-8 L11-K10 BK-8 L12-K26 BK-8 L12-K23 BK-8

L10-K20 BK-8 L10-K9 BK-8 L11-K27 BK-8 L11-K22 BK-8

FUW 7320 MKII L10-K28 BK-8 L10-K21 BK-8 FUW 7320 MKII
SHEET 4 SHEET 5 SHEET 6
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

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

POWER SCHEMATIC (3 PHASE) FUW M14 & M17 FRAME ALTS ONLY L POWER SCHEMATIC (60Hz SINGLE PHASE) FUW C1-1, C1-5, C2-2 L L
POWER SCHEMATIC (50Hz SINGLE PHASE) FUW C1-1, C1-5, C2-2 L
M0110005-01 VOL 2 of 3

L L

J STAR (6P) (V608)

LC & M14 FRAME ALTS ONLY 1 PHASE 3 WIRE M14 FRAME ALTS ONLY 1 PHASE 2 WIRE J
NOTE: ALTERNATOR COMES WITH ALL THE 3 CABLES BUT,
T1 T2
SINGLE PHASE L2 SHOULD NOT BE USED WITH 1PHASE 2WIRE
(Dimensions: 56 inches x 35 inches)

EXCITER SYSTEM FOR CUSTOMER LOAD CONNECTION

K K K K
K T5 K
T4 L1-UA1 BR-8 L4-K2 BK-8
T6

SINGLE PHASE OPTIONAL TRANSFER SWITCH

L2-VA1 BR-8 CONNECTION
E
AC ALTERNATOR

L1-UA1 BR-8 L4-K2 BK-8 L3-WA1 BR-8 L6-K4 BK-8

T3

OPTIONAL TRANSFER SWITCH J EXCITER J

J J
J J N-NA1 BL-8 N2-K1 BK-8 CONNECTION
STAR (6S) AC ALTERNATOR T1 T2 T3 T4
6 5 4 1 2 3 TERM 21
A-C5 (NOTE B)
L3-WA1 BR-8 L6-K4 BK-8 101-A48 WH-18 101-A10 WH-18
TCP2000 / TCP3000 CONTROLLER
L1-UA3 BR-8 L5-K36 BK-8
MCB 4 (2A) 40 GEN VOLTS SENSING N
EXCITER
OPTIONAL TRANSFER SWITCH E N/C 102-A9 WH-18 110-A11 WH-18 39 GEN VOLTS SENSING L3 37
36
L2-VA3 BR-8 L6-K34 BK-8 CONNECTION T1 T2 T3 T4
6 5 4 1 2 3
TERM 21 MCB 3 (2A)
T2 A-C5 (NOTE B) I REF SHEET 2-[4,F] ETH-A91 GN-YL-16 I
T1 REF [9,F] I I N/C 103-A47 WH-18 109-A12 WH-18 38 GEN VOLTS SENSING L2
EXCITER
I I 101-A48 WH-18 101-A10 WH-18
TCP2000 / TCP3000 CONTROLLER CUSTOMER EARTH MCB 2 (2A)
35
L3-WA3 BR-8 N2-K35 BK-8 ETH-A90 GN-YL-16
T5 MCB 4 (2A) 40 GEN VOLTS SENSING N 104-A46 WH-18 108-A13 WH-18 37 GEN VOLTS SENSING L1
T4 37 34
E 102-A9 WH-18 110-A11 WH-18 39 GEN VOLTS SENSING L3
T6 N-NA3 BL-8 L4-K33 BK-8 36

I 6 5 4 1 2 3 TERM 21 1 REF SHEET 2-[4,F] ETH-A91 GN-YL-16

N/C 103-A47 WH-18
MCB 3 (2A)
109-A12 WH-18 38 GEN VOLTS SENSING L2
PANEL BODY ETH-A53 GN-YL-16 I
A-C9 (NOTE B) 35 FUW
MCB 2 (2A)
E 101-A159 WH-18 101-A150 WH-18 CUSTOMER EARTH ETH-A90 GN-YL-16 C90-A17 WH-18 PANEL DOOR
T3
7410/20 MKII CONTROLLER
104-A46 WH-18 108-A13 WH-18 37 GEN VOLTS SENSING L1 7320 MKII
34 H C90-A18 WH-18 H
MCB 4 (2A) 2 H H

FUW 7320 MKII

40 GEN VOLTS SENSING N 37
H H C90-A19 WH-18
102-A149 WH-18 110-A151 WH-18 39 GEN VOLTS SENSING L3 36 R221 AVR C90-A23 WH-18 49 GEN CURRENT SENSING COM 46
PANEL BODY ETH-A53 GN-YL-16
MCB 3 (2A) 2 C50-A14 WH-18 47 GEN CURRENT SENSING L3 44
CONNECT TO ALTERNATOR T1 RD 0V
103-A148 WH-18 109-A152 WH-18 38 GEN VOLTS SENSING L2 35 C30-A15 WH-18 46 GEN CURRENT SENSING L2 43
CONNECT TO ALTERNATOR T2 RD 110V
C90-A17 WH-18 PANEL DOOR R121 AVR C10-A16 WH-18 45 GEN CURRENT SENSING L1 42
MCB 2 (2A) 2 RD E+ VOLTS ADJ. POT.
CONNECT TO EXCITER C90-A18 WH-18 F1 F+-AVR25 WH-16 48 45
CUSTOMER EARTH BK E- VOLTS ADJ. POT.1

FUW 7320 MKII

104-A147 WH-18 108-A153 WH-18 37 GEN VOLTS SENSING L1 34 50
C90-A19 WH-18 F2 F--AVR26 WH-16 47
C90-A23 WH-18 49 GEN CURRENT SENSING COM 46
ETH-A160 GN-YL-16 N N-AVR27 WH-16
PANEL BODY FUW LC ALTERNATOR (OPTION) C50-A14 WH-18 47 GEN CURRENT SENSING L3 44 U U-AVR28 WH-16
G G G G
G G C30-A15 WH-18 46 GEN CURRENT SENSING L2 43 R2
C10-A16 WH-18 45 GEN CURRENT SENSING L1 42 R1
POT CUSTOMER MAINS
C90-A146 WH-18 L6-K4 BK-8
PANEL DOOR 48 45
CONNECTION
42 Page,

R120 AVR
C90-A156 WH-18 50
F1 F+-AVR1 WH-18
R121 AVR 47
GEN BREAKER
C90-A145 WH-18 C90-A157 WH-18 49 GEN CURRENT SENSING COM 46 F1 F+-AVR29 WH-16 CONNECTION
F2 F--AVR2 WH-18
F2 F--AVR210 WH-16
N N-AVR3 WH-18 C50-A154 WH-18 47 GEN CURRENT SENSING L3 44
N N-AVR211 WH-16
TRANSFER SWITCH OPTION REF [6,J] L4-K2 BK-8
U U-AVR4 WH-18 C30-A158 WH-18 46 GEN CURRENT SENSING L2 43 220/230/240 V
U U-AVR212 WH-16 REF [12,E] 184-E12 WH-18
N1 C10-A155 WH-18 45 GEN CURRENT SENSING L1 42
R2
V V-AVR5 WH-18 48 45 F F F F
R1
POT MCB 7
F 50 47 F
CONNECT TO 'N1' FOR 6P (220/127V , 60Hz)
CONNECT TO 'N1' FOR 6P (220/127V , 60Hz) TERM 13 ETH-E89 GN-YL-16
FUW M14 ALTERNATOR FRAMES (STANDARD)
CONNECT TO TERM 20 (WIRE 181) 187-E4 WH-18
TRANSFER SWITCH OPTION L6-K4 BK-8 CUSTOMER MAINS MSR
N/C 186-E5 WH-18
N2-K35 BK-8
GEN BREAKER CONNECTION CONNECT TO TERM 21 (WIRE 101)
12 N/C 185-E6 WH-18
GEN BREAKER CUSTOMER MAINS 171-E13 WH-18
TRANSFER SWITCH OPTION CONNECTION N2-K1 BK-8 14
H CONNECTION
L6-K34 BK-8
CONNECTION
REF [6,J]
L4-K2 BK-8
CONNECT TO MCB 2 (WIRE 108) MSR
A1 A2
115-E22 WH-18 115-E10 WH-18
22
11
111-E14 WH-18 181-E77 WH-18
TERM 20 H
REF [6,I] 108-E21 WH-18 108-E7 WH-18 115-E16 WH-18 REF [3,F] 184-E12 WH-18 (NOTE C)
L5-K36 BK-8 220/240 V E 24 21 E
E REF [11,D] 184-E12 WH-18 E 108-E11 WH-18 105-E15 WH-18 E
E REF [12,D] 184-E72 WH-18 E N
L4-K33 BK-8
L
104-A147 WH-18 MCB 7
MCB 7
REF [5,G]
TERM 13 ETH-E89 GN-YL-16 76-E18 WH-18 COM
108-A153 WH-18 TERM 13 2 ETH-E82 GN-YL-16
MSR 187-E4 WH-18 POS II
MSR 187-E57 WH-18 CONNECT TO TERM 20 (WIRE 185)
N/C 186-E5 WH-18 POS I
SEE NOTE C 186-E58 WH-18 CONNECT TO TERM 21 (WIRE 110)
SEE NOTE B 12 185-E6 WH-18 POS O
(SHEET 1) 12 185-E59 WH-18 171-E13 WH-18
MCB 2 (2A) 2 (SHEET 1) 171-E74 WH-18 14 11 GBCR
CONNECT TO MCB 2 (WIRE 108) MSR 115-E22 WH-18 115-E10 WH-18 111-E14 WH-18 181-E77 WH-18 TERM 4 5-E23 WH-18
14 11 D D
MSR 115-E63 WH-18 115-E69 WH-18 111-E75 WH-18 181-E71 WH-18 D TERM 20 D
D D A1 A2 22 7420 CONTROLLER GBCR
A1 A2 22
TERM 20 2 108-E21 WH-18 108-E7 WH-18 115-E16 WH-18 REF [3,E] 184-E12 WH-18 (NOTE C) 12
108-E62 WH-18 108-E60 WH-18 115-E61 WH-18 REF [3,D] 184-E72 WH-18 (NOTE C) 24 21 A1 A2 14
24 21 108-E11 WH-18 105-E15 WH-18 E
22-E26 WH-18 5-E24 WH-18 11
77-E19 WH-18
108-E70 WH-18 105-E76 WH-18 E
N 9 CLOSE GEN O/P F (POS)
N
L
L MBCR
76-E78 WH-18 7420 MKII CONTROLLER
A1 A2
50-E27 WH-18 5-E25 WH-18 MBCR
GBCR 76-E18 WH-18 COM 10 CLOSE MAINS O/P G (POS) 184-E1 WH-18 41 MAINS SENSING L1
COM CUSTOMER LOAD GBCR POS II 12 183-E2 WH-18 42 MAINS SENSING L2
12
POS II CONNECTION POS I
14 182-E3 WH-18 43 MAINS SENSING L3
POS I C 11 C
14 C 12 POS O C 76-E28 WH-18 78-E20 WH-18
11 181-E80 WH-18 44 MAINS SENSING N
C 77-E79 WH-18 POS O C 11 14
TERM 4 5-E23 WH-18 77-E19 WH-18
TERM 4 2 5-E64 WH-18
MBCR
7420 CONTROLLER GBCR CUSTOMER LOAD
7420 CONTROLLER GBCR CONNECTION
A1 A2
A1 A2 12 22-E26 WH-18 5-E24 WH-18 MBCR
22-E67 WH-18 5-E65 WH-18 9 CLOSE GEN O/P F (POS)
9 CLOSE GEN O/P F (POS) 11 14 220/230/240V
76-E83 WH-18 78-E81 WH-18 12
MBCR
MBCR 11 14
76-E28 WH-18 78-E20 WH-18 7420 MKII CONTROLLER
A1 A2
CUSTOMER LOAD 7420 MKII CONTROLLER
50-E27 WH-18
A1 A2
5-E25 WH-18
CONNECTION
G B
10 CLOSE MAINS O/P G (POS)
50-E68 WH-18 5-E66 WH-18
184-E54 WH-18
183-E55 WH-18
41 MAINS SENSING L1
42 MAINS SENSING L2 B
B
10 CLOSE MAINS O/P G (POS) 184-E1 WH-18
183-E2 WH-18
41 MAINS SENSING L1
42 MAINS SENSING L2
B B B
G
L10-K105 BK-8 182-E3 WH-18 43 MAINS SENSING L3
182-E56 WH-18 43 MAINS SENSING L3
L11-K106 BK-8 181-E80 WH-18 44 MAINS SENSING N
181-E73 WH-18 44 MAINS SENSING N L12-K107 BK-8
L10-K47 BK-8 N4-K108 BK-8
L11-K46 BK-8 N4-K101 BK-8 N4-K109 BK-8
38
L12-K48 BK-8 38 L12-K102 BK-8 L12-K110 BK-8 38 L10-K117 BK-8 39
N4-K45 BK-8 39 L11-K103 BK-8 L11-K111 BK-8 39 L11-K118 BK-8
40
N4-K40 BK-8 L10-K104 BK-8 L10-K112 BK-8 L12-K119 BK-8
N4-K41 BK-8 40 40
N4-K120 BK-8 41
41 41
L12-K42 BK-8 L12-K39 BK-8 A N4-K113 BK-8 N4-K121 BK-8 A
A A
A A L12-K114 BK-8 L12-K122 BK-8
L11-K43 BK-8 L11-K38 BK-8 L11-K123 BK-8
L11-K115 BK-8
L10-K44 BK-8 L10-K37 BK-8 L10-K116 BK-8 L10-K124 BK-8
FUW 7320 MKII FUW 7320 MKII FUW 7320 MKII
SHEET 8 SHEET 9
SHEET 7 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

F F
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
ATC OPTION (3 PHASE)

L
POWER SCHEMATIC (50Hz SINGLE PHASE) FUW C1-1, C1-5, C2-2 L
L 105-E260 WH-18
78-E262 WH-18
77-E266 WH-18
14
12
11

7420 CONTROLLER
TERM 4
GBCR
5-E217 WH-18
L

L ADDITIONAL INFORMATION L

LC FRAME ALTS ONLY 1 PHASE 2 WIRE SEE NOTE B

111-E317 WH-18

115-E267 WH-18
MBCR
9 OUTPUT F (GCBC) 22-E220 WH-18
A1 A2
5-E218 WH-18
DIN RAIL 1
(SHEET 1) MBCR
SINGLE PHASE N2-K48 BK-8
N3-K52 BK-8 A1 A2
GBCR GEN BREAKER CONNECTION L6-K50 BK-8 L9-K55 BK-8 10 OUTPUT G (MCBC) 50-E221 WH-18 5-E219 WH-18
REF SHEET 5-[6,I] L5-K49 BK-8 L8-K54 BK-8
K 12 L4-K51 BK-8 K
L7-K53 BK-8
K K 14 11 184-E261 WH-18 COMPONENT CURRENT RATING DESCRIPTION NOTE
L1-UA1 BR-8 L4-K2 BK-8
CUSTOMER LOAD 108-E264 WH-18
MCB 7
K
MCB 1 MCB 2 MCB 3 MCB 4 MCB 5 MCB 6 MCB 1 6A PANEL SUPPLY DC
K

7420 CONTROLLER MCB 2 2A GEN L1 SENSING

OPTIONAL TRANSFER SWITCH CONNECTION MCB 3 2A GEN L2 SENSING
77-E266 WH-18
187-E255 WH-18 184-E252 WH-18 MCB 4 2A GEN L3 SENSING
CONNECTION A1 A2 A1 A2 186-E256 WH-18 183-E253 WH-18
41 MAINS SENSING L1 38 TERM 21 - GEN NEUTRAL SENSING B
AC ALTERNATOR 78-E262 WH-18 42 MAINS SENSING L2 39 MCB 5 TBD BATTERY CHARGER SUPPLY
185-E257 WH-18 182-E254 WH-18 43 MAINS SENSING L3 MCB 6 TBD COOLANT HEATER SUPPLY
40
181-E258 WH-18 181-E259 WH-18 44 MAINS SENSING N
L3-WA1 BR-8 L6-K4 BK-8 41
TERM 20
J MC/AUX (NOTE C) J
SC/AUX
EXCITER
J J J J
E2

E T1 T2 T3 T4
A-C5
6 5 4 1 2 3 TERM 21
(NOTE B)
105-E260 WH-18
SC MC FUW 7320 MKII E
101-A48 WH-18 101-A10 WH-18
E1
TCP2000 / TCP3000 CONTROLLER
L10-K77 BK-8 CUSTOMER MAINS
MCB 4 (2A) 40 GEN VOLTS SENSING N L11-K79 BK-8 CONNECTION
L12-K82 BK-8
37
E N/C 102-A9 WH-18 110-A11 WH-18 39 GEN VOLTS SENSING L3
36 N4-K81 BK-8
N4-K83 BK-8
N4-K56 BK-8
DIN RAIL 2
MCB 3 (2A) I I
REF Sheet 2-[4,F] ETH-A91 GN-YL-16 L12-K80 BK-8 L12-K58 BK-8
I N/C 103-A47 WH-18 109-A12 WH-18 38 GEN VOLTS SENSING L2 I 171-E263 WH-18 SEE NOTE C
L11-K78 BK-8 L11-K59 BK-8 I I
CUSTOMER EARTH MCB 2 (2A)
35 (SHEET 1) COMPONENT WIRE ID DESCRIPTION
ETH-A90 GN-YL-16 L10-K76 BK-8 L10-K75 BK-8 TERM 1 7 FUSED PANEL SUPPLY
104-A46 WH-18 108-A13 WH-18 37 GEN VOLTS SENSING L1 TERM 2 7 FUSED PANEL SUPPLY
34 TERM 3 17A ESTOP COMMON
ONLY REQUIRED WITH TRANSFER SWITCH OPTION
ATC OPTION (1 PHASE 3 WIRE) TERM 4 5 BATTERY NEGATIVE
PANEL BODY ETH-A53 GN-YL-16 TERM 5 5 BATTERY NEGATIVE
TERM 6 5A RELAY COIL COMMON
R220/R221 AVR FUW TERM 7 17 E-STOP N/C
TERM 8 24 REMOTE START INPUT
C90-A17 WH-18 PANEL DOOR
CONNECT TO ALTERNATOR T1 RD 0V 7320 MKII H 105-E260 WH-18 14 11
H TERM 9 SA1 ANALOG INPUT
C90-A18 WH-18 TERM 4 5-E217 WH-18 TERM 10 5V 5V SENDER SUPPLY
H CONNECT TO ALTERNATOR T2 RD 110V H 78-E262 WH-18
C90-A19 WH-18 12 H TERM 11 SPARE H
E+ C90-A23 WH-18 49 GEN CURRENT SENSING COM 77-E266 WH-18 MBCR 7420 CONTROLLER GBCR
RD E+ VOLTS ADJ. POT. 46 TERM 12 SPARE
E- BK E- VOLTS ADJ. POT.1 111-E317 WH-18 A1 A2 TERM 13 EARTH
C50-A14 WH-18 47 GEN CURRENT SENSING L3 44 9 OUTPUT F (GCBC) 22-E220 WH-18 5-E218 WH-18 MCB 7 GENERATOR BREAKER TERM 14 ETH EARTH
C30-A15 WH-18 46 GEN CURRENT SENSING L2 CONNECT TO M4
43 115-E267 WH-18 TERM 15 - AUX NEUTRAL(N) SUPPLY AC
(WIRE 110)
C10-A16 WH-18 45 GEN CURRENT SENSING L1 42 MBCR CAR GRR MSR MBCR GBCR TERM 16 - AUX LIVE(L) SUPPLY AC
48 N3-K52 BK-8 TERM 17 134 WH OPTION LIVE(L) FEED
45 A1 A2
50 50-E221 WH-18 5-E219 WH-18 TERM 18 - AUX NEUTRAL(-) SUPPLY DC
47 GBCR GEN BREAKER CONNECTION L6-K50 BK-8 L9-K55 BK-8 10 OUTPUT G (MCBC)
TERM 19 - AUX LIVE(+) SUPPLY DC
REF SHEET 7-[6,I] N2-K48 BK-8 L8-K54 BK-8
G L4-K51 BK-8 G TERM 20 181 MAINS NEUTRAL SENSING (OPTION)
12
L7-K53 BK-8 TERM 21 101 GEN NEUTRAL SENSING (OPTON)
G G 14 11 184-E261 WH-18
108-E264 WH-18 G CAR - COMMON ALARM RELAY (OPTION) G
CUSTOMER LOAD MCB 7 GRR - GEN RUNNING RELAY (OPTION)
L6-K4 BK-8
CUSTOMER MAINS CONNECTION 7420 CONTROLLER MSR - MOTOR SUPPLY RELAY (OPTION)
CONNECTION 77-E266 WH-18 MBCR - MAINS BREAKER CLSOR RELAY (OPTION)

D GEN BREAKER
CONNECTION
220/240V
78-E262 WH-18
A1 A2 A1 A2 N/C
187-E255 WH-18
186-E256 WH-18
184-E252 WH-18
183-E253 WH-18
41 MAINS SENSING L1
42 MAINS SENSING L2
38
39
GBCR
MCB 7
-
-
GEN BREAKER CLOSE RELAY (OPTION)
MAINS SENSING MCB (2A) (OPTION) D
185-E257 WH-18 182-E254 WH-18 43 MAINS SENSING L3 GENERATOR N - GENERATOR NEUTRAL
110/120V 110/120V
40 GENERATOR LOAD CONNECTION
TRANSFER SWITCH OPTION REF [6,J] L4-K2 BK-8
181-E258 WH-18 181-E259 WH-18 44 MAINS SENSING N
41
CUSTOMER TERMINALS VFC VFC GENERATOR MCB - GENERATOR PHASES
220/230/240 V
REF [12,E] 184-E12 WH-18 TERM 20
F MC/AUX F
SC/AUX (NOTE C)
F F F F
MCB 7 110/120V 110/120V

105-E260 WH-18
SC MC FUW 7320 MKII
TERM 13 ETH-E89 GN-YL-16 220/240V
CONNECT TO TERM 20 (WIRE 181) MSR 187-E4 WH-18

CONNECT TO TERM 21 (WIRE 101)

N/C 186-E5 WH-18 L10-K77 BK-8 CUSTOMER MAINS
171-E13 WH-18
12 N/C 185-E6 WH-18 L11-K79 BK-8
L12-K82 BK-8
CONNECTION ATS OPTIONAL ATC OPTIONAL (TRANSFER CONTACTOR CONNECTIONS)
CONNECT TO MCB 2 (WIRE 108) MSR 115-E22 WH-18 115-E10 WH-18
14 11
111-E14 WH-18 181-E77 WH-18 N4-K83 BK-8 (TRANSFER SWITCH CONNECTIONS)
A1 A2 22
TERM 20 N4-K81 BK-8 N4-K56 BK-8
108-E21 WH-18 108-E7 WH-18 115-E16 WH-18 REF [3,F] 184-E12 WH-18 (NOTE C) E E
E 108-E11 WH-18
24 21
105-E15 WH-18 E E
L12-K80 BK-8
L11-K78 BK-8
L12-K58 BK-8
L11-K59 BK-8
171-E263 WH-18 CONNECT TO MCB 7 (WIRE 185) MAINS IN GEN IN
E E
N
L10-K76 BK-8 L10-K75 BK-8
L LOAD
76-E18 WH-18 COM
ATC OPTION (1 PHASE 2 WIRE)
POS II SC MC
POS I
POS O 105-E260 WH-18 14 11
TERM 4 5-E23 WH-18 GBCR D TERM 4 5-E217 WH-18 D
78-E262 WH-18 12
D GBCR D 77-E266 WH-18 7420 CONTROLLER GBCR D D
7420 CONTROLLER 12
A1 A2 111-E317 WH-18 MBCR A1 A2
22-E26 WH-18 5-E24 WH-18 11 14
77-E19 WH-18 9 OUTPUT F (GCBC) 22-E220 WH-18 5-E218 WH-18
9 CLOSE GEN O/P F (POS)
CONNECT TO TERM 21
(WIRE 101)
115-E267 WH-18
MBCR
MAINS
MBCR
N3-K52 BK-8
C 50-E27 WH-18
A1 A2
5-E25 WH-18 MBCR
7420 MKII CONTROLLER
GBCR GEN BREAKER CONNECTION
L6-K50 BK-8 L9-K55 BK-8 10 OUTPUT G (MCBC) 50-E221 WH-18
A1 A2
5-E219 WH-18 LOAD OUT C
10 CLOSE MAINS O/P G (POS) 184-E1 WH-18 41 MAINS SENSING L1 REF SHEET 8-[6,I]
L8-K54 BK-8
12 183-E2 WH-18 42 MAINS SENSING L2 12 L4-K51 BK-8
C L7-K53 BK-8 184-E261 WH-18 C
182-E3 WH-18 43 MAINS SENSING L3 14 11
11 14 108-E264 WH-18
C 76-E28 WH-18 78-E20 WH-18 C MCB 7
181-E80 WH-18 44 MAINS SENSING N CUSTOMER LOAD 7420 CONTROLLER
C
855 & 857 OPTION 890 & 892 OPTION C
CONNECTION
CUSTOMER LOAD 77-E266 WH-18
187-E255 WH-18 184-E252 WH-18 41 MAINS SENSING L1
CONNECTION 220/240V
A1 A2 A1 A2 N/C 186-E256 WH-18 183-E253 WH-18 42 MAINS SENSING L2
38 500mA 7 TERM 2 500mA 7 TERM 2
78-E262 WH-18 39
5 TERM 4 5 TERM 4
220/230/240V N/C 185-E257 WH-18 182-E254 WH-18 43 MAINS SENSING L3 40
181-E258 WH-18 181-E259 WH-18 44 MAINS SENSING N 41
TERM 20
MC/AUX (NOTE C) 890/892 MODULE
SC/AUX 857 MODULE
B B
1 BATTERY -VE 1 BATTERY -VE GSM GSM&GPS CONNECTIONS
B B B GPS NOT AVAILABLE ON MODEL 892
B
105-E260 WH-18 SC MC FUW 7320 MKII 8 2 BATTERY +VE 8 2 BATTERY +VE

220/240V CUSTOMER 3 RS485 A 3 I/O A USB CABLE

CUSTOMER TO CONTROLLER
CONNECTIONS 4 RS485 B 4 I/O B RS485 A 7
USB CABLE CONNECTIONS CUSTOMER
L10-K77 BK-8 CUSTOMER MAINS NOTE:RS485 CONNECTIONS 5 RS485 SCR TO CONTROLLER 5 I/O C RS485 B 8 CONNECTIONS
(-VE INPUT/+VE OUTPUT)
38 L11-K79 BK-8 CONNECTION NOT AVAILABLE ON MODEL 855 6 I/O D RS485 SCR 9

L10-K117 BK-8 L12-K82 BK-8

39 N4-K83 BK-8
L11-K118 BK-8
40 N4-K81 BK-8 N4-K56 BK-8
L12-K119 BK-8
N4-K120 BK-8 41 L12-K80 BK-8 L12-K58 BK-8
A 171-E263 WH-18 CONNECT TO MCB 7 (WIRE 181) A
N4-K113 BK-8 N4-K121 BK-8 L11-K78 BK-8 L11-K59 BK-8
A A A A
L12-K114 BK-8 L12-K122 BK-8 L10-K76 BK-8 L10-K75 BK-8
L11-K115 BK-8 L11-K123 BK-8
L10-K116 BK-8 L10-K124 BK-8
FUW 7320 MKII SHEET 11
SHEET 10 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
SHEET 12
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

B B
NOTES
NOTES DESCRIPTION
A WIRING NOT FACTORY SUPPLIED. REFER TO CONTROL MODULE OPERATION MANUAL IF REQUIRED.
B FOR 380-440V SYSTEM CONNECT TO TERM 21 (WIRE 101). FOR 200-240V SYSTEM CONNECT TO MCB 4 (WIRE 110)
C FOR 380-440V SYSTEM CONNECT TO TERM 20 (WIRE 181). FOR 200-240V SYSTEM CONNECT TO MCB 7 (WIRE 185)

SYMBOL DESCRIPTION ABBREV COLOR

CIRCUIT CONNECTED RD RED

WH WHITE
CIRCUIT NOT CONNECTED
OR ORANGE
ELECTRICAL CONNECTION TO
MACHINE STRUCTURE
YL YELLOW
INTERNAL ELECTRICAL CONNECTION
TO SURFACE OF COMPONENT PK PINK

CONNECTOR BK BLACK

Do not operate or work on this product unless you have H# CIRCUIT GROUPING DESIGNATION
GY GRAY
read and understood the instruction and warnings in the
PU PURPLE
relevant Operation and Maintenance Manuals and ATCH WIRE, CABLE, COMPONENT
relevant service literature. Failure to follow the instruc- BR BROWN
tions or heed the warnings could result in injury or / SPLICE
GN GREEN
death. Proper care is your responsibility. BLADE, SPADE, RING OR SCREW
TERMINAL BU BLUE

A A
THIS SCHEMATIC IS FOR THE C1.1, C1.5, C2.2, AND C3.3 GENERATOR SET
ELECTRICAL SYSTEM
VOLUME 2 of 3: 7410, 7420, AND 7320 CONTROL WIRING
MEDIA NUMBER: M0110005-01
SCHEMATIC PART NUMBER: 540-1537, CHANGE: 09, VERSION: DK
Components are shown installed on a fully operable generator set in a non powered state.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
Refer to the Parts Manual using a specific serial number prefix in SIS before ordering parts from this schematic.

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
 M0110005-01
April 2021 Harness And Wire Electrical Schematic Symbols
Symbols

Pressure Temperature Level Flow Circuit Breaker

Symbol Symbol Symbol Symbol Symbol

Symbols and Definitions

Fuse: A component in an electrical circuit that will open the circuit if too much current flows
through it.

Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
circle indicates that the component has screw terminals and a wire can be disconnected from it.

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.

Ground (Wired): This indicates that the component is connected to a grounded wire. The
grounded wire is fastened to the machine.

Ground (Case): This indicates that the component does not have a wire connected to ground.
It is grounded by being fastened to the machine.

C1.1, C1.5, C2.2, and C3.3

Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the
contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.

Generator Set
Sender: A component that is used with a temperature or pressure gauge. The sender
measures the temperature or pressure. Its resistance changes to give an indication to
T
the gauge of the temperature or pressure.

Electrical System Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.
It has a coil that makes an electromagnet when current flows through it. The
Y4B1-UP electromagnet can open or close the switch part of the relay.
Y5B1-UP
Solenoid: A solenoid is an electrical component that is activated by electricity. It has a
Y6B1-UP
coil that makes an electromagnet when current flows through it. The electromagnet
Y7B1-UP can open or close a valve or move a piece of metal that can do work.
GB81-UP
YMG1-UP Magnetic Latch Solenoid: A magnetic latch solenoid is an electrical component that is
GB91-UP activated by electricity and held latched by a permanent magnet. It has two coils (latch and unlatch)
that make electromagnet when current flows through them. It also has an internal switch that places
GBY1-UP
the latch coil circuit open at the time the coil latches.
TYB1-UP
YMH1-UP Harness and Wire Symbols
TYC1-UP
Wire, Cable, or Harness Harness Identification Letter(s):
TY21-UP Assembly Identification: Includes (A, B, C, ..., AA, AB, AC, ...)
Harness Identification Letters and
Harness Connector Serialization Code:
Harness Connector Serialization
The "C" stands for "Connector" and the
Codes (see sample).
number indicates which connector in the
AG-C4 L-C12 harness (C1, C2, C3, ...).
L-C12
111-7898 3E-5179 3E-5179
Part Number: for Connector Plug 1
Part Number: for Connector Receptacle
2
5A
Plug Receptacle Component
Pin or Socket Number Fuse (5 Amps) 9X-1123 Part Number

1 Deutsch connector: Typical representation

325-AG135 PK-14
of a Deutsch connector. The plug contains all
2 Harness identification code:
sockets and the receptacle contains all pins.
Volume 3 of 3: Option Wiring This example indicates wire group 325,
wire 135 in harness "AG".
Wire Gauge*
Wire Color
1 Sure-Seal connector: Typical representation
of a Sure-Seal connector. The plug and receptacle *Wire gauge is shown in AWG (American Wire Gauge)
PUBLICATIONS.CAT.COM 2 contain both pins and sockets. but could also be shown in metric denoted with mm

© 2021 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate Yellow”, the
“Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not
be used without permission.

M0110005-01 VOL 3 of 3
(Dimensions: 34 inches x 24 inches)
16 Page,
 7 6 5 4 3 2 1

PAC1 OR PGR1 FLSR SPARE ANALOG

WH
COMMON ALARM RELAY GEN RUNNING RELAY
INPUT NEUTRAL EARTH LINK
CAR GRR 9 2 4
M6
(M14 FRAME ALT)
115 108
4 NOTE A NOTE B NOTE C (16A)
A2 A1 A2 A1 3PH, 4P4W
E SA1 7 5 OPTIONAL 16
132 134
17 E
CAR / 1
HEATER L1 L2 L3
GRR / 1 CONNECTION JACKET
AUX SUPPLY NEUTRAL N
15 WATER (T1) (T2) (T3)
ETH HEATER LINK
14
SA1 7 5
: 12 : 11 : 14 : 12 : 11 : 14 LINK

VFC CONN VFC CONN

TERM 16 FOR WH AUX SUPPLY LIVE 110-240V AC

FL TERM 15 FOR WH AUX SUPPLY NEUTRAL AC E
FUEL
CUSTOMER CONNECTION
LEVEL
SENSOR
NEUTRAL / EARTH LINK

NEUTRAL EARTH LINK FTC (FUW FLSR)

PBCB2T/PBC48VT/9130/PBCBT
(LC FRAME ALT)
FUEL TRANSFER CONTROL RELAY
BATTERY CHARGER 3PH,3P4W P.STAR/ 1PH, 2W 1PH, 3W
D D
S.STAR 4 5 FT
T10 A2 A1
N T2/T3
DC CONN SUPPLY CONN T11 FTC / 1
T12 T1
T6/9 T3 T4 T3 T1 T3
+ - L N E
T5/8 T2 T2 T4 T2 : 12 : 11 : 14
VFC CONN
7 5 133 131 ETH
T4/7 T1
* CONNECT TO CONTROLLER
NEUTRAL / EARTH LINK NEUTRAL / EARTH LINK NEUTRAL / EARTH LINK
FOR 7XXX CONNECT FT TO CONTROLLER’S TERM 12
M5
(6A)

132
NEUTRAL EARTH LINK (M14 FRAME ALT)
C 1PH, 3W C
FUW 16 15 14 3PH, 3P4W 1PH, 2W
PBCB2T/ L1 L2 L3 L3 L1 L2 L1 L3 WS1
(19) (18)
PBCBT/ N (T1) (T2) (T3) (T4) (T1) (T2) (T1) (T4)
PBC48VT
LINK LINK + RD-18
2 A V+

LINK LINK

TERM 16 FOR PBCBT / PBCB2T / 9130 AUX SUPPLY LIVE 90-265V AC LINK

5 BK-18
TERM 15 FOR PBCBT / PBCB2T / 9130 AUX SUPPLY NEUTRAL AC 5 B GND
M0110005-01 VOL 3 of 3

E
E GN-18
E LCL
TERM 19 PBC48VT AUX SUPPLY POSITIVE (+) 40-60V DC * C ALARM
TERM 18 PBC48VT AUX SUPPLY NEGATIVE (-) DC CUSTOMER CONNECTION CUSTOMER CONNECTION
CUSTOMER CONNECTION
NEUTRAL / EARTH LINK
(Dimensions: 34 inches x 24 inches)

NEUTRAL / EARTH LINK

NEUTRAL / EARTH LINK

855 857 890 *

4520 CONTROLLER PIN 16

7410/20 CONTROLLER PIN 52

USB TO ETHERNET COMMS USB TO RS485 COMMS
USB TO ETHERNET COMMS
B B
7 7 7
500mA 2 500mA 2 3A
5 5 5
4 4

8 8 8
855 MODULE 857 MODULE 890 MODULE
1 BATTERY NEGATIVE

RS485 A

RS485 B

RS485 SCR
1 BATTERY NEGATIVE 1 BATTERY NEGATIVE
2 BATTERY POSITIVE 2 BATTERY POSITIVE 2 BATTERY POSITIVE RJ45 ETHERNET
3 3 RS485 A A 3

4 CUSTOMER 4 RS 485 B B 4
USB CABLE USB CABLE INPUT OR OUTPUT CONFIGURABLE -VE INPUT/+VE OUTPUT
CONNECTIONS C 5 GSM GPS
USB CABLE
5 TO 4520 5 RS 485 SCR TO 4520
RJ45 ETHERNET D RS232 ANTENNA ANTENNA
TO 7XXX
6

CUSTOMER
16 Page,

SYMBOL DESCRIPTION ABBREV COLOR

CONNECTIONS CIRCUIT CONNECTED RD RED

WH WHITE
CIRCUIT NOT CONNECTED
OR ORANGE
ELECTRICAL CONNECTION TO
MACHINE STRUCTURE
YL YELLOW
INTERNAL ELECTRICAL CONNECTION
TO SURFACE OF COMPONENT PK PINK

CONNECTOR BK BLACK

H# GY GRAY
CIRCUIT GROUPING DESIGNATION
Do not operate or work on this product unless you have

7 PANEL TERMINAL read and understood the instruction and warnings in the PU PURPLE
ATCH WIRE, CABLE, COMPONENT
relevant Operation and Maintenance Manuals and

A A
BR BROWN
relevant service literature. Failure to follow the / SPLICE
NOTE A: CONNECT TO CONTROLLER instructions or heed the warnings could result in injury
BLADE, SPADE, RING OR SCREW
GN GREEN

or death. Proper care is your responsibility.

CUSTOMER AC TERMINAL
BU BLUE

1 FOR 4520 CONNECT 88 TO CONTROLLER'S TERM. 9; TERMINAL

FOR 7XXX CONNECT 88 TO CONTROLLER'S TERM. 11

1 CUSTOMER DC TERMINAL THIS SCHEMATIC IS FOR THE C1.1, C1.5, C2.2, AND C3.3 GENERATOR SET
NOTE B: FOR 380-440 V SYSTEM CONNECT TO TERM. 20 (WIRE 101).
1 FOR 1 PHASE 3 WIRE 200-240 V SYSTEM CONNECT TO MCB 4 (WIRE 110); ELECTRICAL SYSTEM
DC CONNECTOR TERMINAL FOR 1 PHASE 2 WIRE 200-240 V SYSTEM CONNECT TO TERM. 20 (WIRE 101) VOLUME 3 of 3: OPTION WIRING
CUSTOMER VOLT FREE TERMINAL NOTE C: CONNECT TO MCB 2 (WIRE 108) MEDIA NUMBER: M0110005-01
SCHEMATIC PART NUMBER: 516-4125, CHANGE: 11, VERSION: DK
Components are shown installed on a fully operable generator set in a non powered state.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
Refer to the Parts Manual using a specific serial number prefix in SIS before ordering parts from this schematic.

7 6 5 4 3 2 1