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Caterpillar sr4 Generator Service Manual
Caterpillar sr4 Generator Service Manual
C at e r p i l l a r
Service Manual
SR4 Generator
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 INDEX
SYSTEMS OPERATION
Generator and Regulator Components...... ..... .. . ..... 14 Generator Mounted Control Panel (Type 4) .............. 204
Automatic Start/Stop System .......................... 214
Generator Mounted Control Panel Attachments ........... 226 Components .......................................... 210
Ammeter ............................................. 233 Identification ......................................... 204
Auxiliary Relay Module ................................ 233 Introduction .. , ....................................... 204
Cycle Cranking Module ............................... 232 Wiring Diagrams .................................. 205-209
Governor Switch ...................................... 233
Heat Switch .......................................... 233 Glossary ............. , . ... .. ... . .... . ... .... ... . . . . .... 5
Identification and Location ............................ 226
Prealarm Module ...................................... 230 How to Read Control Panel DC Schematics .............. 140
Remote Annunciator Panel ............................ 235
Synchronizing Lights Module .......................... 233 Identification ........................................... 8
Wiring Diagrams .................................. 227-229
Operation of Generator ................................. 23
Generator Mounted Control Panel (Type 1) .............. 143 Excitation Circuit .................... , ............... , 26
Automatic Start/Stop System .......................... 152 Excitation Circuit Control. . ... . .. . . . .. ....... .. ... . ... 30
Components .......................................... 148 Flyback Circuit ....................................... 32
Identification ......................................... 143 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Introduction .......................................... 143 Manual Voltage Control Attachment .............. , ., .. 50
Wiring ...................... " ........................ 143 Normal Voltage Generation. .. . . . . . . . . . . .. . . . . . . . . . . . .. 30
Wiring Diagrams .................................. 144-147 Output Voltage Sensing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34
Power Supply for Regulator Module Ai. . . . . . . . . . . . . . .. 36
Generator Mounted Control Panel (Type 2) .............. 164 Protection of Generator Circuits. ... .. .... . ... .. .. . . ... 41
Automatic Start/Stop System " ........................ 170 Radio Frequency Interference (RFI) Suppression.. . .... 40
Components ................................ _ ......... 167 Regulator Adjustment. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42
Identification ......................................... 164 Regulator Gain Circuit. .. . . . . . . . . . . .. . . . . . . .. . . . . . . . .. 38
Introduction .......................... " .............. 164 Series Boost Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43
Wiring Diagrams .................................. 165, 166 Start up Voltage Generation. . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Voltage Build-up Circuit ..................... .-.. . . . .. .. 28
Generator Mounted Control Panel (Type 3) .............. 182
Automatic Start/Stop System .............. , ........... 192
Components .......................................... 188
Identification ......................................... 182
Introduction .......................................... 182
Wiring Diagrams .................................. 183-187
TROUBLESHOOTING
3
SR 4 GENERATOR INDEX
REWIND DATA
4
IDENTIFICATION SYSTEMS OPERATION
- 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 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.
(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.
13
SR 4 GENERATOR SYSTEMS OPERATION
14