INTERACTIVE SCHEMATIC

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 RENR2449-03
August 2014

C1.5 and C2.2 Marine Generator Set

Electrical System
C1.5: C2.2:
TAF1-UP TAG1-UP
JAW1-UP

© 2014 Caterpillar, All Rights Reserved Printed in U.S.A.

 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.

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.

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

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 electromagnet can open or close the switch part of the relay.

Solenoid: A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current
flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work.

Magnetic Latch Solenoid: A magnetic latch solenoid is an electrical component that is 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 the latch coil circuit open at the time the coil latches.

Harness and Wire Symbols

Wire, Cable, or Harness Assembly Identification: Harness Identification Letter(s): (A, B, C, ..., AA, AB, AC, ...)
Includes Harness Identification Letters and Harness
Connector Serialization Codes (see sample).
Harness Connector Serialization Code: The "C" stands for
"Connector" and the number indicates which connector in the
harness (C1, C2, C3, ...).
AG-C4 L-C12
111-7898 3E-5179 L-C12
3E-5179
Part Number: for 1 Part Number: for
Connector Plug
Connector Receptacle
2

Plug Receptacle
Pin or Socket Number

5A
1 Deutsch connector: Typical representation
Component
of a Deutsch connector. The plug contains all Fuse (5 Amps) 9X-1123 Part Number
2 sockets and the receptacle contains all pins.
325-AG135 PK-14
1 Sure-Seal connector: Typical representation Harness identification code:
of a Sure-Seal connector. The plug and receptacle This example indicates wire group 325, Wire Gauge
2 contain both pins and sockets. wire 135 in harness "AG". Wire Color
 7 6 5 4 3 2 1
PARALLEL CONNECTION SERIES CONNECTION
T3 T4 T1 T2 T3 T4

T1 T2

E E

L L L M L

VOLTAGE 50/60Hz OUTPUT

VOLTAGE 50/60Hz OUTPUT
L-L CONNECT L L
L-L L-M CONNECT L L M
110
T1-T3 220 110
115 T1-T3 T2-T4
230 115 T2-T3 T1 T4 T2-T3
T2-T4
120
240 120

DEDICATED SINGLE PHASE 4 LEAD GENERATOR.

DEDICATED SINGLE PHASE 4 LEAD GENERATOR.
VOLTAGE OUTPUT AT 50/60Hz
VOLTAGE OUTPUT AT 50/60Hz

AN AC BREAKER MUST BE FITTED IN LINE WITH AN AC BREAKER MUST BE FITTED IN LINE WITH
LOCAL REGULATIONS. LOCAL REGULATIONS.

D
SINGLE PHASE GENERATORS SINGLE PHASE GENERATORS D

L1(U) L1(U)

T1
T1 T7

REMOTE SHUTDOWN CONNECTION PINK

T4
T7

6 GREY 6
WATER TEMPERATURE SENDER
S
T4 T10
-

FOR COMBINED PRESSURE +

T10
SENDER/SWITCH COMBINED OIL PRESSURE 5 5
G YELLOW
SENDER (G) AND SWITCH (WK) M T11
G M ORANGE T12 T12 T5
WK WATER TEMPERATURE GAUGE
WK
T9 T8
C TERMINAL IDENTIFICATION TURQUOISE C
HIGH WATER TEMPERATURE SWITCH S T9 T11
SENDER AND SWITCH.
BLUE/ T6 T2
WK - SWITCH, TO - T6 T5
ALARM LAMP YELLOW
7 PINK 7
G - SENDER, TO +
OIL PRESSURE GAUGE T3 T2
M - -VE T3 T8
HIGH EXHAUST TEMPERATURE SWITCH L2(V)
ALARM/SHUTDOWN LIGHT
OIL PRESSURE GAUGE
L3(W) N L2(V) L3(W) N
8 RED/BLACK 8
12 BLACK
ENGINE CAN ONLY
BE STARTED AFTER 3 PHASE 4 WIRE SERIES STAR 3 PHASE 4 WIRE PARALLEL STAR
THIS UNIT IS ENERGIZED. D2 D1 ALARM/SHUTDOWN LIGHT
TO STOP ENGINE OPEN - LL VOLTAGE - 50Hz 380V-415V 60Hz 380V-480V LL VOLTAGE - 50Hz 190V-208V 60Hz 190V-240V
7 PINK
CIRCUIT SWITCH.
RED + AN AC BREAKER MUST BE FITTED IN LINE WITH AN AC BREAKER MUST BE FITTED IN LINE WITH
BLACK BLACK
8 RED/BLACK LOCAL REGULATIONS. LOCAL REGULATIONS.
ACTUATOR WHITE LINK BLACK TO VIOLET
WHITE/BLACK FOR 50Hz (1500 RPM) VOLT METER
BLUE LINK BLACK TO GREY 2 2 BROWN
BROWN 2
GREEN FOR 60Hz (1800 RPM)
OPERATION.
MAGNETIC PICKUP VIOLET L1(U) L1(U)
GREY ON
ON -
SYNCHRO-START YELLOW Tx SET
APECS 3100 ORANGE Rx 13
+
PROGRAMMABLE 14 RESET
OFF / STOP
ENGINE CONTROLLER SERVICE TOOL STOP
10
4 TURQUOISE 4 4
TURQUOISE
1 HOUR METER T1
9
ENGINE CIRCUIT SWITCH T12
ON/STOP
B B
5

LATCHING ENGINE CIRCUIT SWITCH MOMENTARY ACTION T12 T1

4
RELAY MOMENTARY ACTION
12
GLOW PLUG/START SWITCH T6 T7
8

12 BLACK 8 MOMENTARY ACTION T9 T4

12

GLOW PLUG/ WHITE

START SWITCH T6 T7 T9 T4
GLOW PLUG - CYL 1 HEAT
87 30 MOMENTARY ACTION T3 T10
9 9
GLOW PLUG - CYL 2 WHITE
86 85

T3 T10
GLOW PLUG - CYL 3 GLOW PLUG HEAVY T5 T2
DUTY RELAY HEAT
START
GLOW PLUG - CYL 4 10 GREEN
NOTE:THIS GLOW PLUG IS - + T11 T8
NOT INCLUDED ON 3 CYLINDER 11
HOUR METER RED
ENGINES T11 T8 T5 T2
87a

87
30 START
RUN LIGHT L3(W) L2(V) L3(W) L2(V)
86 85
10 GREEN 10 M
* VIOLET
ENGINE TO BE START RELAY 11 11 3 PHASE 3 WIRE PARALLEL DELTA
CONNECTECTED RED 3 PHASE 4 WIRE SERIES DELTA
TO BATTERY D4 D3 * AMP - 13
VIA BATTERY DEUTSCH - 3 SWITCH PANEL LL VOLTAGE - 50HZ 220V-240V 60Hz 220V-240V LL VOLTAGE - 50Hz 110V-120V 60Hz 120V
20A
ISOLATOR SWITCH. CIRCUIT
+ BREAKER
AN AC BREAKER MUST BE FITTED IN LINE WITH AN AC BREAKER MUST BE FITTED IN LINE WITH
+VE
2
LOCAL REGULATIONS. LOCAL REGULATIONS.
-VE STARTER 87a 4
6

30
87

THREE PHASE GENERATORS

1
86 85 5 3 VIOLET 3
3

A INSULATED EARTH SYSTEMS.

EARTH CONTROL RELAY
8 7
A
AC GENERATOR WINDING CONFIGURATIONS
THE EARTH CONTROL RELAY RUN LIGHT
RESISTOR
AND THE EARTH RELAY ARE RUN RELAY 12V-30 OHMS 6W
FITTED AS AN OPTION. 24V-330 OHMS 6W
THEY ALLOW THE ENGINE TO IND
+
BE GROUND MOMENTARILY
DURING THE OPERATION OF EARTH RELAY
THE STARTER AND THE GLOW -
ALTERNATOR
PLUGS. VIOLET
(MACHINE SENSED) INSTRUMENT PANEL
THIS SCHEMATIC IS FOR THE C1.5 AND C2.2 MARINE GENERATOR SET ELECTRICAL SYSTEM
REMOTE RUN INDICATION CONNECTION
MEDIA NUMBER: RENR2449-03

DC CIRCUITS FOR C2.2 & C1.5 MARINE GENSETS

Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
in neutral and with parking brake set.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.

7 6 5 4 3 2 1
INSTRUMENT PANEL
VIEW ALL CALLOUTS

The ‘DeluxePanel’ shown:

ALARM/SHUTDOWN
LAMP

ON/STOP
SWITCH
(ENIGNE CIRCUIT
SWITCH)
RUN LAMP

OIL PRESSURE
GAUGE

WATER TEMPERATURE
GAUGE

DC VOLTMETER HEAT/START
SWITCH
ENGINE RUN HOURMETER (GLOW PLUG/START
SWITCH)
THE BASIC START/STOP PANEL
VIEW ALL CALLOUTS

ALARM/SHUTDOWN LAMP

ON/STOP SWITCH
(ENIGNE CIRCUIT
SWITCH)

HEAT/START SWITCH
(GLOW PLUG/START
RUN LAMP
SWITCH)
CIRCUIT DIAGRAM FOR THE CONTROLLER

20 21 22 24
23

25

(20) Power Supply

(21) Switch
(22) Breaker
(23) Actuator
(24) Speed Sensor
(25) Controller
26 (26) Communicator Connector
DC BREAKER

A DC breaker is supplied to protect the wiring from accidental short circuit. This risk is highest when
the genset is being installed or when additional equipment is wired in and is negligible during normal operation.
To prevent accidental starting, always put the DC breaker to the off ‘O’ position and disconnect the battery
negative (-ve) before working on the genset.
A 20A breaker protects the main DC circuits. This is fitted with a toggle switch and it is recommended that this
be set to off "O" during servicing to prevent premature operation.
DC CIRCUITS FOR C2.2 AND C1.5 MARINE GENSETS WIRING

1 Blue/Yellow - Exhaust temp switch 16 Green - Starter solenoid

2 Black - Exhaust temp switch
3 Red - Glowplug
4 Blue - Magnetic Pickup
5 Green - Magnetic Pickup
6 Black - Cylinder block
7 Black - Cylinder block
8 Orange - Oil pressure switch
9 Black - Oil pressure switch -ve
10 Yellow - Oil pressure sensor
11 White - Apecs actuator
12 White/Black - Apecs actuator
13 Violet - Alternator ind
14 Red - Starter +ve
15 Red - Starter +ve
17 Grey - Water temp sender
18 Black - Water temp sender
19 Black - High water temp switch
20 Turquoise - Magnetic Pickup
21 Red - Starter +ve
22 Red - Alternator +ve 2
23 Coupling for instrumentation
24 Black - Earth relay
23 25 Black/red - Earth relay 3
1
16 22
21 19 20
14

18 17
4
11 15
7 13
6

12 25
5 24
8
9
10
DC CONTROL BOX FREQUENCY SELECTION

10

11 12

The frequency can be changed from 50Hz to 60Hz in the field. The speed is selectable by
jumper lead (10) on the circuit board.Attach the jumper (10) to pin (11) for 50Hz operation
at 1500rpm. Attach the jumper (10) to pin (12) for 60Hz operation at 1800rpm.
DC CONTROL BOX SPEED SELECTION

13

14

15 16

If the speed is reselected, the regulator installed in the generator must also be
reset. In order to reset the generator, remove the air inlet (13). The frequency link
ST3 (14) is set to match the speed of the engine. The link is installed for 50Hz (15).
Remove the link (16) for 60Hz operation.
DC CONTROL BOX

The controller is located within the DC control box.

GENERATOR SET WITH ENCLOSURE REMOVED FRONT AND
RIGHT SIDE VIEW
19 1 3 4

6
18

5
17

16 2

7
14

8
13

15

12
11 10 9

1 Coolant header tank / cooled exhaust manifold. 6 Injection pump. 11 Excess fuel return. 16 Dipstick.
2 Filler cap for the lubricating oil. 7 Sea water pump. 12 Sump drain take-off point. 17 Fuel filter.
3 Coolant filler cap. 8 Sea water inlet. 13 DC Control box. 18 Air intake.
4 Fuel Injector. 9 Oil pressure switch/sender. 14 Hourmeter. 19 Rear lifting eye.
5 DC Alternator. 10 Fuel inlet. 15 Fuel lift pump.
GENERATOR SET WITH ENCLOSURE REMOVED REAR AND
LEFT SIDE VIEW

20

25

21

24

23

22

20 Plenum chamber. 23 Heat exchanger.

21 AC Generator 24 Exhaust outlet.
22 Ground connection. 25 Water injection, exhaust.
INTERCONNECTING CABLES

2 1

Interconnecting cables are used to join the engine loom to the instrument panel(s). Cables are made in 6m
and 12m lengths and all cables have a male plug (1) at one end, and a female (2) at the other. Cables must
not be plugged together to give increased length. In general, if a longer cable is required, it should be
ordered as a special item, to be made into one piece.
INTERCONNECTING ‘Y’ HARNESS

A ‘Y’ harness is available, with a male plug at (1) and two female plugs (2). If necessary, more than one
‘Y’ harness may be used, to connect several Stop/Start instrument panels together. Any number of basic Stop/
Start panels can be connected with one Deluxe panel. Only "one" Deluxe panel may be used.
THREE PHASE MACHINES WITH REGULATOR

17

50Hz 60Hz
ST3
Frequency

19
18

Three-phase machines are installed with the regulator that is shown in the illustration
above.The frequency link (17) is set to match the speed of the engine. Link (18) is for 50Hz
operation. Link (19) is for 60 Hz operation.