MAIN HARNESS

CONNECTOR
RENR7695 MAIN HARNESS
May 2005 CONNECTOR LOCATIONS

ENGINE COOLANT
TEMPERATURE
SENDER
AMBIENT CONNECTOR
TEMPERATURE (REMOTE PANEL)
SWITCH
HIGH COOLANT
TEMPERATURE ENGINE COOLANT
SWITCH TEMPERATURE
SENDER

OIL ALTERNATOR MAGNETIC PICKUP

PRESSURE (SPEED/TIMING SENSOR)
GAUGE GENERATOR SET CONTROL
SHUTDOWN SPEED
COOLANT
RELAY CONTROL
TEMPERATURE MAIN HARNESS
GAUGE GLOW PLUG EXHAUST
CONNECTOR
CONNECTOR TEMPERATURE
SERVICE GENERATOR LOW SWITCH
METER HARNESS COOLANT CONNECTOR
CONNECTOR LEVEL
SWITCH FUEL PUMP STARTING
MOTOR
STOP
SOLENOID
STANDARD COLD START
ADVANCE
CONTROL PREMIUM SOLENOID
PANEL (NOTE A)

C4.4 Marine Generator Set

CONTROL
PANEL

Electrical System (Non MCS)

ALARM
MUTE OIL
RELAY PRESSURE CONTROL PANEL
GENERATOR SENDER (GENERATOR SET CONTROL)
RUN COMMON (REMOTE PANEL)
RELAY ALARM ALARM
CONTROLLER MUTE
RELAY OIL PRESSURE
AUDIBLE
RELAY L1K1-UP SWITCH/SENDER
ALARM
S1M1-UP
ALARM
DC MUTE
VOLTMETER SWITCH

EMERGENCY STOP
SWITCH BATTERY FUSE
DISCONNECT SPEED CONTROL
SWITCH 5A FAST

GENERATOR
RUN
SHUTDOWN RELAY MAGNETIC PICKUP
RELAY (SPEED/TIMING SENSOR) 24VDC to 12VDC
SPEED CONTROL CONVERTER
NOTE B

AUDIBLE 80 AMP
ALARM DC CIRCUIT
CONTROLLER
BREAKER
ALARM (GLOW PLUG)
MUTE RELAYS:
SWITCH 10 AMP FUEL/STOP
DC CIRCUIT GLOW PLUG
BREAKER SPEED CONTROL
(MAIN) START
EMERGENCY STOP
SWITCH

© 2005 Caterpillar Printed in U.S.A.

All Rights Reserved

LEFT SIDE VIEW

TYPICAL
(ENGINE WITHOUT TURBOCHARGER) RIGHT SIDE VIEW
TYPICAL
CONTROL PANEL
(ENGINE WITHOUT TURBOCHARGER)
(GENERATOR SET CONTROL)

GLOW PLUG
CONNECTOR
GENERATOR
HARNESS
CONNECTOR

ENGINE COOLANT
AMBIENT
MAIN HARNESS TEMPERATURE
TEMPERATURE
CONNECTOR SENDER
SWITCH

RENR7695
HIGH COOLANT
TEMPERATURE ENGINE COOLANT
SWITCH TEMPERATURE
SENDER
CONNECTOR
(REMOTE PANEL)

16 Page
LOW COOLANT
LEVEL SWITCH
ALTERNATOR
SPEED CONTROL

STOP SOLENOID
BATTERY
DISCONNECT
SWITCH

FUEL PUMP

24VDC to 12VDC
CONVERTER
NOTE B

OIL PRESSURE
SENDER RELAYS:
(REMOTE PANEL) FUEL/STOP
GLOW PLUG
SPEED CONTROL
START

10 AMP
DC CIRCUIT
BREAKER
(MAIN)

80 AMP
DC CIRCUIT
BREAKER
(GLOW PLUG) MAGNETIC PICKUP EXHAUST
FUSE
OIL PRESSURE COLD START ADVANCE MAGNETIC PICKUP (SPEED/TIMING SENSOR) STARTING TEMPERATURE
SPEED CONTROL
SWITCH/SENDER SOLENOID (NOTE A) (SPEED/TIMING SENSOR) GENERATOR SET CONTROL MOTOR SWITCH
5A FAST
SPEED CONTROL CONNECTOR
 ENGINE and STANDARD CONTROL PANEL WIRING

YELLOW (SHUTDOWN)
COMMON ALARM 2 19 SPARE UNIT

REMOTE CONTACTS 'E' REMOTE CONTACTS 'A' GENERATOR SET CONTROL (STANDARD) OIL COOLANT
FOR GENERATOR FOR GENERATOR 18 SPARE UNIT DC HOUR PRESSURE TEMPERATURE
RUN SHUTDOWN NOTE TO RESET UNIT SELECT 'OFF' POSITION ON MODE SWITCH. VOLTMETER METER GAUGE GAUGE

GREEN (RUN) 12 LAMP TEST + + + +

GENERATOR RUN 11
RED (+VE) - -

HIGH WATER TEMPERATURE

WHITE (LAMP TEST)
R1 11 L SERIES GOVERNOR FAILURE ALARM - - S S
R4 R2

RED (VOLTMETER)
LOW OIL PRESSURE
ALARM
REMOTE PANEL WIRING

COMMON SHUTDOWN
GENERATOR

REMOTE STARTER

EMERGENCY STOP
MUTE SHUT DOWN 8 WARNING LAMP
RUN RELAY
RELAY RELAY

NOT IN AUTO
VIOLET

MAG P +VE

MAG P -VE
2 2 2

PRE-HEAT
6 6 6

BLUE

STARTER
4 4 4
2 DC +VE EMERGENCY

FUEL

YELLOW
1 1 1 STOP ON

RED

GREY
5 5 5
3 3 3 CANOPY.

RED (AUDIBLE ALARM)

8 7 8 7 8 7 1 DC -VE 20 21 13 6 7 5 4 3 17 9 10 D2 OTHERWISE
AUDIBLE ALARM COMMON GENERATOR LINK
ALARM RUN 1A
MUTE ALARM PINK (COMMON TERMINALS
PINK (EMERGENCY STOP) DIODE

GREEN
SHUTDOWN)
R1 PINK (FUEL)
STOP

TO REMOTE PANEL
ALARM LAMP 150R PINK (EMERGENCY STOP)

(SHUTDOWN)
RUN
MUTE TEST

BLACK
D1

(AUDIBLE

GREEN

GREEN
RED (AUDIBLE ALARM)

WHITE
AUDIBLE ALARM 4 RED
AUDIBLE

ALARM)

YELLOW
BLACK

GREEN

GREEN

(RUN)
ALARM FIT LINK FOR 12V EMERGENCY

RED

RED

RED

TURQUOISE

PINK (OPG)

PINK (CTG)
1A STOP

PINK (HM)
ORANGE
RED FIT LINK FOR 24V
DIODE

BROWN

BLACK

BLACK

BLACK

BLACK
6 5 4 9 10 2 11

PINK

RED
REMOTE
WHITE (DEUTSCH J) CONTACTS
82R BLUE (MPU DSM) 'B'

VIOLET
BLACK
BLACK
24V SYSTEMS START
BLUE (MPU DSM) SIGNAL
ONLY
BLACK

R2
WHITE (DEUTSCH X) WHITE (DEUTSCH W) GREEN
OIL YELLOW
PRESSURE 7
SENDER

COMMON COOLANT GREY

ALARM TEMPERATURE
SENDER
8 12V SYSTEMS BLACK
LAMP ONLY
GENERATOR M N D T X J W C V B R S G P Q H E
AUDIBLE RUN BROWN
ALARM LAMP
REMOTE
CONTACTS
RED (MARKED ALARM MUTE) 'C'
ALARM MUTE 9
NOT IN
RED (MARKED ALARM MUTE) AUTO
ALARM MUTE 10
RED (+VE) SIGNAL
+VE 3
BLACK
-VE 6
GREEN
RUN 5

(GLOW RELAY)

(DEUTSCH J)
5A FAST 86 85
ACTING FUSE
RED RED RED (LSC1)
87 30

WHITE
RED
+VE DC CIRCUIT 87A

BLACK
FROM L SERIES
BREAKER 10A
RELAY
BATTERY
ALARM RED RED

MUTE VOLTAGE REGULATOR

PINK
BATTERY L SERIES
SWITCH 24V SYSTEMS ONLY. SPEED
DISCONNECT

GREEN

WHITE (-VE EARTH RELAY)

CONTROL

RED

RED
SWITCH 85

TURQUOISE
86
86 85 24v IN 87

YELLOW

ORANGE
30

BLACK
RED
12 1

GREY
87 30 87A
START 12v OUT FUEL/STOP 11 2

VIOLET
87a

BLUE
RELAY RELAY

BLUE (MPU DSM)

BLUE (MPU DSM)

GLOW PLUG HEAVY 10 3
86 85 AMBIENT
DUTY RELAY NOTE B
TEMPERATURE 9 4

PINK
REMOTE 87 30
SWITCH
NOTE A 8 5
START
GLOW PLUG
SWITCH MOMENTARY 7 6

RED
EARTH RELAY PINK

GREEN

START ADVANCE)
85 PINK

YELLOW
86

WHITE (COLD
GREY
B+ 87

BLACK

BLUE (LSC 11)

BLUE (LSC 3)
PINK
30

D+ 87a

GLOW PLUG - CYL 1

GLOW PLUG - CYL 3

GLOW PLUG - CYL 4

GLOW PLUG - CYL 2
B-

BLACK

WK
W

M
-VE CIRCUIT COLD FUEL/STOP FUEL
PUMP

BLACK

BLACK
BLACK

BLACK
FUSE 80A START SOLENOID COMBINED OIL
ADVANCE HIGH WATER COOLANT
-VE COOLANT OIL PRESSURE
STARTER ALTERNATOR NOTE A TEMPERATURE TEMPERATURE
FROM TEMPERATURE PRESSURE SWITCH AND SENDER
SENDER SENDER SWITCH
BATTERY SENDER

MAGNETIC MAGNETIC
PICKUP PICKUP

ENGINE and PREMIUM CONTROL PANEL WIRING L1

P1 P2
S1 S2 L2
P1 P2
S1 S2 L3

ORANGE (CT1)

ORANGE (CT2)

ORANGE (CT3)
P1 P2
S1 S2 N

RED (L3)

RED (L2)

RED (L1)
WHITE (CTE)

GREEN/YELLOW
AC ALTERNATOR
DC CIRCUIT 1 2 3 4 12
BREAKER 6.3A
3 OFF BLACK 10
34 N 25 26 27 29 30

CTL1

CTL2

CTL3

CTE

EARTH
RED (L1 LOAD) 9
33 L3

REMOTE PANEL WIRING with GAUGES RED (L2 LOAD) 8

32 L2
GENERATOR SET CONTROL (PREMIUM)
RED (L3 LOAD) 7
31 L1

L SERIES GOVERNOR FAILURE ALARM

GREEN (RUN)
GENERATOR RUN 11
REMOTE CONTACTS 'A' REMOTE CONTACTS 'E' REMOTE CONTACTS 'D'
FOR GENERATOR FOR GENERATOR FOR GENERATOR
ALARM RUN SHUTDOWN
- - - YELLOW (SHUTDOWN)
+ COMMON ALARM 2 RED
STOP (C0MM0N ALARM)

HIGH COOLANT TEMP

HIGH COOLANT TEMP

LOW COOLANT LEVEL

HIGH EXHAUST TEMP

19 COMMON ALARM

LOW OIL PRESSURE

LOW OIL PRESSURE

+ S S YELLOW (WATER SEPARATOR)

COMMON SHUTDOWN
START AUDIBLE COMMON GENERATOR

EMERGENCY STOP
ALARM

WATER IN FUEL
ALARM ALARM RUN STANADYNE

REMOTE START
MUTE DC OIL VIOLET WARNING LAMP

SYSTEM AUTO
8 FUEL/WATER
(AUDIBLE ALARM)

PRESSURE COOLANT R3 RED (WATER SEPARATOR)

ALARM MUTE
VOLTMETER TEMPERATURE
R1 R4
SEPARATOR

MAG P +VE

MAG P -VE
GAUGE

PRE-HEAT

SHUTDOWN

SHUTDOWN
GAUGE 2 2 2 (OPTION)

STARTER
6 6 6
(SHUTDOWN)

4 4 4 BLACK

ALARM

ALARM
RED

FUEL
2 DC +VE
1 1 1

0v
YELLOW

YELLOW

5 5 5
BLACK

GREEN

GREEN

(RUN)

(+VE)

3 3 3
GREY

DC -VE
RED

RED

RED

RED

8 7 8 7 8 7 1 13 5 6 18 24 4 3 17 20 21 22 15 16 23 14 12 10 9 7 11
COMMON GENERATOR SHUT DOWN
6 5 4 9 10 2 11 3 7 8 ALARM RELAY RUN RELAY RELAY
RENR7695

TO REMOTE PANEL

8 PINK (EMERGENCY STOP) EMERGENCY

STOP ON

(ALARM MUTE)
150R CANOPY.
16 Page, Color 2

PINK (EMERGENCY STOP) OTHERWISE

FIT LINK 19A D1 LINK TERMINALS
VIOLET

FOR 24V

BLUE (MPU DSM)

BLUE (MPU DSM)

R2

WHITE
1A DIODE
OIL FIT LINK

BLACK
RED
2 FOR 12V 8 17A RED (NOT IN AUTO)
6 19
PRESSURE RED (AUDIBLE ALARM) 4 REMOTE CONTACTS 'C' (+) BATTERY

TURQUOISE
RED (AUDIBLE ALARM)
NOT IN
GAUGE 4 1

YELLOW

ORANGE
AUDIBLE ALARM 5 TURQUOISE (HIGH EXHAUST TEMP) BLACK AUTO SIGNAL (+) BATTERY SWITCHED
3

GREY
RED
8 7
OIL RED 3 7 GREY (LOW COOL LEVEL)
YELLOW STARTING CIRCUIT
COOLANT PRESSURE 7 ALARM
MUTE GREEN
SENDER ALARM

BLACK
TEMPERATURE EMERGENCY REMOTE CONTACTS 'B' (-) BATTERY / RETURN
BLACK

AUDIBLE RELAY
MUTE STOP START
GAUGE COOLANT
ALARM BLACK SIGNAL
GREY
TEMPERATURE 8
SENDER SIGNAL PLUS TO GSC
SIGNAL MINUS TO GSC
RED (ALARM MUTE)
DC ALARM MUTE 9
CONTROL PLUS FROM GSC
VOLTMETER ALARM MUTE 10
RED (ALARM MUTE)
CONTROL MINUS FROM GSC
RED (+VE)
+VE 3
BLACK RUN / SHUTDOWN
-VE 6
GREEN
RUN 5

R2 82R
THIS SCHEMATIC IS FOR THE C4.4 MARINE GENERATOR SETS
24V SYSTEMS (S/N: L1K1-UP and S1M1-UP)
(DEUTSCH X)

ONLY
WHITE
GREEN

D3 D4 HARNESS DESCRIPTION
WHITE

12V SYSTEMS 269-5198 REMOTE PANEL 15'(4.57m)

ONLY
AUDIBLE 269-5199 REMOTE PANEL 25'(7.62m)
ALARM 269-5200 REMOTE PANEL 45'(13.72m)
M N D T X W F J C V B R S G P Q H E K L 269-5202 REMOTE PANEL 80'(24.39m)
5A FAST 271-3543 CONTROL PANEL 15'(4.57m) EXTENSION
86 85
ACTING FUSE
RED RED RED (LSC1) 273-2452 GENERATOR HARNESS (EXTERNAL / TO GENERATOR)
ALARM 87 30
273-2453 GENERATOR HARNESS (IN PREMIUM CONTROL PANEL)
BLACK

MUTE +VE
DC CIRCUIT L SERIES
FROM 273-4357 STANDARD CONTROL PANEL

TURQUOISE (HIGH EXHAUST TEMP)

SWITCH BREAKER 10A RELAY
BATTERY RED RED
273-6213 PREMIUM CONTROL PANEL
VOLTAGE REGULATOR
PINK

BATTERY L SERIES
24V SYSTEMS ONLY SPEED 274-1231 ALTERNATOR TO STARTER
DISCONNECT

GREY (LOW COOL LEVEL)

86 85 86 CONTROL
REMOTE SWITCH 85 274-1232 DISCONNECT SWITCH TO STARTER

PINK (LOW COOLANT LEVEL)

87 24v IN 87
WHITE (-VE RELAY)

START 30 BROWN 30
12 1 274-1233 MAIN HARNESS
(GLOW PLUG)

87a
WHITE (AMBIENT

SWITCH START FUEL/STOP

274-1991 REMOTE PANEL WITH GAUGES
VIOLET

GLOW PLUG HEAVY 12v OUT 11 2

TEMP SWITCH)

RELAY RELAY
BLUE

DUTY RELAY
NOTE B 10 3 BLUE (MPU DSM)

BLUE (MPU DSM)

86 85
PINK

5 4
AMBIENT 94
COMMON 50 2 TEMPERATURE

TURQUOISE
87 30 SWITCH 85 NOTE A: NOT INSTALLED ON GENSETS WITH TURBOCHARGER ASPIRATION.
ALARM
PINK

NOTE A NOTE B: FOR 24V SYSTEMS, CONNECT TERMINAL 87 OF FUEL/STOP RELAY TO

YELLOW

YELLOW

ORANGE
GLOW PLUG 76
RED

LAMP

BLACK
GENERATOR MOMENTARY THE INPUT OF THE CONVERTER, AND CONNECT THE OUTPUT OF THE
GREY

GREY
EARTH RELAY
RUN CONVERTER TO THE COLD START ADVANCE SWITCH, THE FUEL/STOP SOLENOID,
START ADVANCE)

85
86
AND THE FUEL PUMP. FOR 12V SYSTEMS, CONNECT TERMINAL 87 DIRECTLY
WHITE (COLD

LAMP B+ 87a
BLUE (LSC 11)

TO THE COLD START ADVANCE SWITCH, THE FUEL/STOP SOLENOID,

BLUE (LSC 3)
PINK
PINK

30
GLOW PLUG - CYL 1

GLOW PLUG - CYL 3

GLOW PLUG - CYL 4

GLOW PLUG - CYL 2

D+ 87
HIGH
AND THE FUEL PUMP.
B-
EXHAUST
COLD START LOW TEMP
W
G

WK

ADVANCE COOLANT
M

-VE CIRCUIT NOTE A FUEL/STOP FUEL PUMP LEVEL

BLACK

BLACK

BLACK

REMOTE PANEL REMOTE PANEL FUSE 80A SOLENOID COMBINED OIL

BLACK

BLACK

BLACK

BLACK

BLACK
HIGH WATER COOLANT
BLACK

BLACK

-VE COOLANT OIL PRESSURE

TEMPERATURE PRESSURE STARTER ALTERNATOR SWITCH AND TEMPERATURE TEMPERATURE
FROM SENDER SENDER SWITCH SENDER
BATTERY SENDER

MAGNETIC MAGNETIC
PICKUP PICKUP