Service Manual

C at e r p i l l a r
Service Manual
SR4 Generator

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

CT-S-SR4 GEN
SR 4 GENERATOR
SYSTEMS OPERATION
Generator and Regulator Components...... ..... .. . ..... 14
Generator Mounted Control Panel Attachments ........... 226
Ammeter ............................................. 233
Auxiliary Relay Module ................................ 233
Cycle Cranking Module ............................... 232
Governor Switch ...................................... 233
Heat Switch .......................................... 233
Identification and Location ............................ 226
Prealarm Module ...................................... 230
Remote Annunciator Panel ............................ 235
Synchronizing Lights Module .......................... 233
Wiring Diagrams .................................. 227-229
Generator Mounted Control Panel (Type 1) .............. 143
Automatic Start/Stop System .......................... 152
Components .......................................... 148
Identification ......................................... 143
Introduction .......................................... 143
Wiring ...................... " ........................ 143
Wiring Diagrams .................................. 144-147
Generator Mounted Control Panel (Type 2) .............. 164
Automatic Start/Stop System " ........................ 170
Components ................................ _ ......... 167
Identification ......................................... 164
Introduction .......................... " .............. 164
Wiring Diagrams .................................. 165, 166
Generator Mounted Control Panel (Type 3) .............. 182
Automatic Start/Stop System .............. , ........... 192
Components .......................................... 188
Identification ......................................... 182
Introduction .......................................... 182
Wiring Diagrams .................................. 183-187
TROUBLESHOOTING
Automatic Start/Stop System (Generator Mounted
Control Panel) . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. 72
Standby Current Supply Stops
Before Normal Current Returns. . . . . . . . . . . . . . . . . . .. 73
No Supply of Standby Current ..................... " 72
Operation of Standby System When
Standby Current is No Longer Needed .......... '" 74
Engine Division Data Sheets ................... '" ..... " 81
Brine Tank Load Test ................................. 126
Circulating Currents .................................. 122
Effect of Temperature on Voltage Regulation. ... . . . .. .. 99
Electrical/Mechanical Characteristics .................. 81
Electrical Voltages Available. . . . . . .. . . . . . . . . . . . . . . . . . .. 93
Flywheel Balance Weights ............................. 109
Grounding ............................................ 120
Linear Vibration ..................................... " 102
Linear Vibration Control ............................... 116
Remote Voltage Control .... '" ........................ 100
DISASSEMBLY AND ASSEMBLY
Alphabetical Index ........................ , ............. 128
Control Panel ........................................ " . 129
Generator Bearing ...................................... 130
Generator Installation ................................... 133
Generator Removal ..................................... 132
NOTE: The "C" is an indication of a change from the former issue.
INDEX
Generator Mounted Control Panel (Type 4) .............. 204
Automatic Start/Stop System .......................... 214
Components .......................................... 210
Identification ......................................... 204
Introduction .. , ....................................... 204
Wiring Diagrams .................................. 205-209
Glossary ............. , . ... .. ... . .... . ... .... ... . . . . .... 5
How to Read Control Panel DC Schematics .............. 140
Identification ........................................... 8
Operation of Generator ................................. 23
Excitation Circuit .................... , ............... , 26
Excitation Circuit Control. . ... . .. . . . .. ....... .. ... . ... 30
Flyback Circuit ....................................... 32
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Manual Voltage Control Attachment .............. , ., .. 50
Normal Voltage Generation. .. . . . . . . . . . . .. . . . . . . . . . . . .. 30
Output Voltage Sensing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34
Power Supply for Regulator Module Ai. . . . . . . . . . . . . . .. 36
Protection of Generator Circuits. ... .. .... . ... .. .. . . ... 41
Radio Frequency Interference (RFI) Suppression.. . .... 40
Regulator Adjustment. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42
Regulator Gain Circuit. .. . . . . . . . . . . .. . . . . . . .. . . . . . . . .. 38
Series Boost Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43
Start up Voltage Generation. . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Voltage Build-up Circuit ..................... .-.. . . . .. .. 28
Flashing the Field. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 80
General ............................... '" . " .. . . .. ... .. 52
Possible Causes & Verification Procedure. . . . . . . . . . . . . ... 62
Procedure for First Operation After Repair.. ...... .. ..... 79
Test Instruments ............ '" .. " .... ... . ..... . ....... 52
Test of Regulator Exciter Assemblies .................... 75
Testing Rectifiers... ........ ... . . ...... ... .............. 76
Troubleshooting Chart Index. . . . . .. . . .. . . . . . . . . . . . . .. . .. 61
Troubleshooting Procedures for Generator/Regulator ... " 54
AC Voltage Too High. ... . ... .... . ... .... .. .... .. ..... 59
AC Voltage Too Low .............. '" ............ ..... 58
Lack of AC Voltage Stability .... " . . . . . . . . . . .. . . . . . . . .. 60
No AC Voltage. ... . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 56
Voltage Regulator Module (Ai) .......................... 78
Rotor Assembly (Horizontal Method) ..................... 139
Rotor Assembly (Vertical Method) ....................... 137
Service Index ........................................... 128
Stator Assembly ........................................ 141
3
SR 4 GENERATOR INDEX

REWIND DATA

Connection Diagrams ............................... 253-257

Introduction ............................................ 236

PAGE NUMBER PAGE NUMBER

PART NO. GEN. EXCITER PART NO. GEN. EXCITER
5N1 237 259 5N47 248 262
5N2 237 259 5N48 246 262
5N3 238 259 5N49 247 262
5N4 238 257 5N50 249 258
5N5 239 257 5N51 237 259
5N6 239 257 5N52 249 259
5N7 238 257 5N53 250 258
5N10 240 260 5N54 250 259
5N11 238 259 5N55 251 259
5N12 239 257 5N56 247 262
5N13 239 257 5N57 251 262
5N14 240 260 5N58 252 261,262
5N15 237 259 5N59 252 261,262
5N16 241 259 5N60 246 261,262
5N17 240 260 5N61 248 262
5N18 238 259 5N62 252 261,262
5N19 241 259 5N63 243 259
5N20 242 258 5N64 239 257
5N21 238 257 5N65 239 257
5N22 242 257 5N66 243 258
5N23 243 258 5N67 246 257
5N24 239 257 5N68 239 257
5N25 243 257 5N69 243 258
5N26 238 257 5N70 243 257
5N27 243 260 5N71 239 257
5N28 243 259 5N72 242 257
5N29 245 259 5N73 242 258
5N30 242 258 5N74 238 257
5N31 238 257 5N75 238 257
5N32 242 257 5N76 237 261
5N33 243 258 5N77 249 260
5N34 239 257 5N78 237 261
5N35 246 257 5N79 249 261
5N36 243 258 5N80 250 260
5N37 239 257 5N81 250 261
5N38 243 257 5N82 251 261
5N39 243 258 5N83 243 258
5N40 239 257 5N84 239 257
5N41 243 257 5N85 246 257
5N42 239 257 5N86 239 257
5N43 246 262 5N87 243 258
5N44 247 262 5N88 239 257
5N45 247 262 5N89 243 257
5N46 248 262 5N90 239 257

4
IDENTIFICATION SYSTEMS OPERATION

3 PHASE 4 POLE GENERATORS

CATERPILLAR
GEN. GEN. VOLTAGE: BEGINNING BEGINNING
ENGINE GEN. ARRANGEMENT PART at 60 Hz freq. SEQUENCE SERIAL SEE
MODEL FRAME NO. NO. (at 50 Hz freq.) NO. NO. NOTE
3304 NA 365 - 5N1 M35BH300 (1)
*
3304 T - M44BH300 (1)
444 5N2 *
3304 T, 3306 T 5N5034 M44BH8000 5CA1 (1)
- M135BH100 (1)
3306 T 445 5N3 240-480
*
5N5035 M45BH8000 50A1 (1)
(200-400)
0334 447 - 5N4 M175BH100 (1)
*
0343 449 - 5N5 M250BH100 (1)
*
3406 PC TA 448 - 5N6 M48BH300 * (1)
340601 T 447 - 5N7 M47BH600 * (1)
- 5N10 208-416 T135B8100 (2)
0333 T 445 *
- 5N11 T135BH100 (2)
240-480
*
0343 449 - 5N12 T250BH100 * (2)
(200-400)
340801 T 449A - 5N13 MA49BH600 * (1)
3304 T - 44B8300 (3)
5N14 208-416 *
3304 T, 3306 T 5N5046 44B88000 5CA1
3304 T - 240-480 44BH300 * (3)
444 5N15
3304 T, 3306 T 5N5047 (200-400) 44BH8000 5CA1
3304 T - 300-600 44BG300 * (3)
5N16
3304 T, 3306 T 5N5048 (240-480) 44BG8000 5CA1
- 135B81
*
5N17 208-416
5N5049 45B88000 50A1
- 240-480 135BH1 *
3306 T 445 5N18
5N5050 (200-400) 45BH8000 50A1
- 300-600 135BG1 *
5N19
5N5051 (240-480) 45BG8000 50A1
- 5N20 208-416 175B81 *
240-480
0334 447 - 5N21
(200-400)
175BH1
*
300-600
- 5N22
(240-480)
175BG1 *
- 5N23 208-416 250B81
*
240-480
0343 449 - 5N24
(200-400)
250BH1 *
300-600
- 5N25 250BG1 *
(240-480)
240-480
0334 447 - 5N26
(200-400)
T175BH100 * (2)

- 46B8300 *
5N27 208-416
5N5059 46B88000 5EA1
- 240-480 46BH300 *
3306 TA 446 5N28
5N5060 (200-400) 46BH8000 5EA1
- 300-600 46BG300 *
5N29
5N5061 (240-480) 46BG8000 5EA1
- 5N30 208-416 47B8300
*
240-480
- 5N31 47BH300
340601 T 447 (200-400) *
300-600
- 5N32
(240-480)
47BG300 *

9
IDENTIFICATION SYSTEMS OPERATION

CATERPILLAR
GEN. GEN. VOLTAGE: BEGINNING BEGINNING
ENGINE GEN. ARRANGEMENT PART at 60 Hz freq. SEQUENCE SERIAL SEE
MODEL FRAME NO. NO. (at 50 Hz freq.) NO. NO. NOTE
5N8661 5N8908 208-416 C49BS500
240-480
3406 5N8662 5N8909 C49BH500
449S (200-400) 6BA1
300-600
5N8663 5N8910 C49BG500
(240-480)
3408 DI TAIPC TA 449 5N7087 5N8911 208-416 B49BS8000 5KA1

3208 NAIT 240-480

444 5N9141 5N9081 A44BH500 6NA1
(200-400)
3208 T 445 5N9143 5N9083 A45BS500 6JA1
208-416
3208 NAIT 444 5N9144 5N9084 A44BS500 6HA1
3208 T 445 5N9146 5N9086 300-600 A45BG500 6JA1
3208 NAIT 444 5N9147 5N9087 (240-480) A44BG500 6HA1

3208 T 240-480
445 5N9149 5N9089 A45BH500 6JA1
(200-400)

3412 300-600
589 5N9516 5N9432 P59BG500 6FA1
(240-480)
*Use Sequence No. for identification

GENERAL NOTES:

GENERATORS RATED: 3 PHASE, 60 HERTZ, 240-480 VOLTS ALSO USED FOR 3 PHASE, 50 HERTZ, 200-400. VOLTS AT NOMINALLY
5/6 OF 60 HERTZ KILOWATT RATING.

GENERATORS RATED: 3 PHASE, 60 HERTZ, 300-600 VOLTS ALSO USED FOR 3 PHASE, 50 HERTZ, 240-480 VOLTS AT NOMINALLY
5/6 OF 50 HERTZ KILOWATT RATING.
ALL GENERATORS SIN 3000 & UP WILL HAVE SERIES BOOST CAPABILITIES.

NOTE: (1)MARINE SOCIETY APPROVED GENERATORS. MEETS REQUIREMENTS OF ABS,LLOYD'S & DN V.

(2) TROPICALIZED GENERATORS THAT WERE BUILT TO CUSTOMER ORDERS PRIOR TO STANDARDIZING ON THIS INSULA-
TION SYSTEM FOR ALL GENERATORS. THIS CHANGE WAS EFFECTIVE WITH SIN 100 & UP.

(3) FIRST PRODUCTION RELEASE THAT USED THERMAL PROTECTOR (KLIXON BREAKER) IN REGULATOR ASSEMBLY.
STANDARD ON ALL SR 4 GENERATORS EFFECTIVE WITH SIN 300 & UP.

(4) GENERATOR TO INCLUDE SPACE HEATER IN ACCORDANCE TO MARINE SOCIETY SPEC.

13
SR 4 GENERATOR SYSTEMS OPERATION

GENERATOR AND REGULATOR COMPONENTS

COMPONENT SEE FIGURE(S) DESCRIPTION

Al 3 Sealed, non-serviceable, unit that controls the generator output.

A2 2,4 Holds SCR CR9, diode CRlO and resistance capacitance circuits to
give protection to these solid state components.
Cl,3 2,3 Capacitors that reduce voltage spikes that could cause radio
interference.
C2 2 Capacitor that accepts a charge when CR9 is "off" and gives first
current flow when CR9 turns "on".
CRI-6 6,7,8,9 Diodes that change the AC current from exciter armature L4 to DC
current.
CR7,8 6,7,8,9 Diodes that reduce voltage spikes that could damage CRI-6. Con-
ducts current around CRI-6 when the voltage gets to a certain level.
CR9 4 Silicon controlled rectifier (SCR) that acts as a valve to limit current
flow through exciter field L3.
CRlO 4 Diode that gives a path for current flow through the exciter field when
CR9 is "off".
CRll 2 Diode that decreases voltage spikes that could damage CR9 and
CRlO. Conducts current around CR9 and CRlO when the voltage
gets to a certain level.
EI-4 4,5,6,7,8,9,10 Heat sinks act as heat exchangers to lower the temperature of
rectifiers.
Fl 2 Fuse that gives protection to regulator circuit.
L1 3 Iron core suppression reactor decreases the shock load on the stator
windings when CR9 turns "on".
L2 2 Air core reactor that limits the current rise time when CR9 turns
"on".

L3 11 Copper windings on generator end housing. Current through these

windings causes an induced three phase AC current in exciter arma-
ture L4.
L4 5,10,11 Copper windings on the rotating field assembly. Rectified current
from this armature is the source for rotating field L5.
L5 5,10 Copper winding on poles attached to the rotating field assembly.
Current through these windings causes an induced three phase AC
current in stator L6.
L6 12 Copper windings attached to the generator housing. Current induced
in these windings is the power for the load.
TP 2 Gives protection against too much heat in the stator windings.
Rl 2 Rheostat that gives adjustment for voltage droop.
R2 2 Rheostat that gives adjustment for generator output voltage.

14