REHS4494-02

03 August 2012

Special Instruction
i04967749 SR4B (S/N: ACA1-Up; AEB1-Up;
Installation Instructions for the AAD1-Up; ADD1-Up; ABH1-Up;
AAJ1-Up; ADL1-Up; ABM1-Up;
New Caterpillar Digital Voltage 2DM1-Up; 2GM1-Up; 3BM1-Up;
Regulator (CDVR) In Field 4DM1-Up; 5DM1-Up; 6GM1-Up;
Retrofit Applications 7GM1-Up; 8DM1-Up; 8HM1-Up;
1BN1-Up; 1HN1-Up; 2DN1-Up;
SMCS Code: 4467 2FN1-Up; 2GN1-Up; 2HN1-Up;
2SN1-Up; 3EN1-Up; 3FN1-Up;
Electric Power Generation 3GN1-Up; 3HN1-Up; 4EN1-Up;
3412 GENSET (S/N: 4BZ1-Up; 1EZ1-Up; 4FN1-Up; 4GN1-Up; 4WN1-Up;
3FZ1-Up) 5SN1-Up; 5WN1-Up; 6SN1-Up;
3512 GEN SET (S/N: ZAF1-Up) 7DN1-Up; 7TN1-Up; 8NN1-Up;
3512B GENSET (S/N: ZAH1-Up; 9CN1-Up; 9EN1-Up; ACP1-Up;
ZAJ1-Up) AAR1-Up; ADR1-Up; 8XS1-Up;
3516B GEN SET (S/N: ZAP1-Up) 5JW1-Up; 6DW1-Up; 8GW1-Up;
3516C GEN SET (S/N: SBK1-Up) ACX1-Up; AAY1-Up; ABY1-Up;
C175-16 GEN SET (S/N: WYB1-Up) AEZ1-Up; 2GZ1-Up; 8EZ1-Up;
SR4 (S/N: 5MA1-Up; 5RA1-Up; 8LZ1-Up; 8TZ1-Up; 9AZ1-Up;
5SA1-Up; 5TA1-Up; 5UA1-Up; 9GZ1-Up; 9MZ1-Up; 9WZ1-Up)
5VA1-Up; 5YA1-Up; 5ZA1-Up; SR4B HV (S/N: ABA1-Up; AEA1-Up;
6AA1-Up; 6FA1-Up; 6LA1-Up; A5A1-Up; G4A1-Up; ACB1-Up;
6MA1-Up; 6NA1-Up; 6PA1-Up; ADB1-Up; G4B1-Up; ABE1-Up;
6SA1-Up; 6WA1-Up; 1GD1-Up; ABG1-Up; ACG1-Up; AEG1-Up;
2ED1-Up; 5TD1-Up; 8FD1-Up; ADJ1-Up; AAL1-Up; AEL1-Up;
8ZD1-Up; 3EF1-Up; 8JF1-Up; ACN1-Up; G3N1-Up; PCP1-Up;
8KF1-Up; 8LF1-Up; 9EF1-Up; ACR1-Up; G3R1-Up; AES1-Up;
9FF1-Up; 6CG1-Up; 6DG1-Up; G3S1-Up; ABT1-Up; ADT1-Up;
6EG1-Up; 8HG1-Up; 9FG1-Up; G3T1-Up; ACW1-Up; G3W1-Up;
3KJ1-Up; 4SJ1-Up; 5NJ1-Up; A4X1-Up; G3X1-Up; AEY1-Up;
6EJ1-Up; 7AJ1-Up; 8MM1-Up; A4Y1-Up; G3Y1-Up; ACZ1-Up;
1MS1-Up) A4Z1-Up; G3Z1-Up)
SR4 HV (S/N: 8HS1-Up; 8JS1-Up; SR5 (S/N: G3M1-Up)
8KS1-Up; 8LS1-Up; 8MS1-Up; Engine
5HW1-Up; 5RW1-Up; 6CW1-Up) 3306B (S/N: B8D1-Up; 8NS1-Up;
LRW1-Up; 1CZ1-Up)
3408 CUSTOM T DI (S/N: 67U1-Up)
3408 TA DI (S/N: 78Z1-Up)
3408B T DI (S/N: 67U1-Up)
3408B (S/N: 78Z1-Up)
3408C (S/N: 67U1-Up; 78Z1-Up)
3412 (S/N: 2WJ1-Up)

1
3412 PC T DI (S/N: 38S1-Up) G3520C SI TA (S/N: CWW1-Up;
3412 T DI (S/N: 81Z1-Up) CWY1-Up)
3412C (S/N: 5FL1-Up; DJN1-Up; G3532 (S/N: 8BZ1-Up)
9EP1-Up) Generator Set
3412C TA DI (S/N: RLR1-Up) 3406 GEN SET (S/N: 4ZR1-Up)
3412C (S/N: 9BR1-Up; TFT1-Up; 3406C GEN SET (S/N: C2G1-Up;
BCW1-Up; LRY1-Up; RTY1-Up; C5G1-Up; C8G1-Up; KPS1-Up;
81Z1-Up; 3FZ1-Up) 9ES1-Up; LRX1-Up; C2Y1-Up;
3412E (S/N: TGC1-Up) 1DZ1-Up)
3508 (S/N: ZAA1-Up; ZAB1-Up; 3406C MARINE GS TA DI (S/N:
CNF1-Up; CAW1-Up; 5PW1-Up; PFH1-Up)
23Z1-Up; 70Z1-Up; 1JZ1-Up) 3406E GEN SET (S/N: 8AZ1-Up)
3508B (S/N: S2A1-Up; CNB1-Up; 3456 GEN SET (S/N: CCB1-Up;
S2B1-Up; ZAD1-Up; 3DM1-Up; C1G1-Up; C3G1-Up; C4G1-Up;
3DW1-Up; 5KW1-Up; BGX1-Up; CAH1-Up; GHJ1-Up; CBX1-Up)
1FZ1-Up) C15 GEN SET (S/N: C5E1-Up; C5H1-Up;
3512 (S/N: ZAE1-Up; CMJ1-Up; C5L1-Up; X4R1-Up; CYY1-Up)
FDR1-Up; 6WW1-Up; 24Z1-Up; C18 GEN SET (S/N: G4C1-Up; N1D1-Up;
67Z1-Up; 1KZ1-Up) STD1-Up; DKE1-Up; PEJ1-Up;
3512B (S/N: CMC1-Up; FDE1-Up; STM1-Up; EKW1-Up; M1Z1-Up)
BLF1-Up; S2G1-Up; S2H1-Up; C18 MARINE GS (S/N: MGS1-Up)
BRK1-Up; 8EM1-Up; 1PW1-Up; C27 GEN SET (S/N: DWB1-Up)
6GW1-Up; 1GZ1-Up) C32 GEN SET (S/N: SXC1-Up;
3512C (S/N: SBG1-Up; SLM1-Up) WDR1-Up)
3516 (S/N: CMD1-Up; 4XF1-Up; C9 GEN SET (S/N: C9E1-Up)
5SJ1-Up; ZAK1-Up; CAL1-Up; Industrial Engine
ZAL1-Up; 8TW1-Up; 25Z1-Up; 3412C IND (S/N: 38S1-Up)
73Z1-Up; 1LZ1-Up) Petroleum Engine
3516B (S/N: CPA1-Up; BMB1-Up; 3512C PETROLEUM (S/N: LLB1-Up)
CDE1-Up; BPJ1-Up; FDN1-Up; 3516C PETROLEUM (S/N: PES1-Up)
7RN1-Up; 9AN1-Up; S2P1-Up; C15 PET GS ENG (S/N: PET1-Up)
GAR1-Up; PBR1-Up; S2R1-Up; Petroleum Power Train Package
YAR1-Up; ZAR1-Up; GZS1-Up; TH35-C13P (S/N: PBJ1-Up)
2FW1-Up; 8NW1-Up; FDX1-Up; Power Module
S2Z1-Up; 1HZ1-Up) C32 POWER MODUL (S/N: MED1-Up;
3516C (S/N: SBJ1-Up; SBM1-Up) MEG1-Up)
3612 (S/N: 9RC1-Up) PM3412 (S/N: CAJ1-Up)
C9 (S/N: X3R1-Up) PM3456 (S/N: B3G1-Up)
G3306 (S/N: JCA1-Up; 07Y1-Up) PM3508 (S/N: BLM1-Up; BPY1-Up)
G3406 SI (S/N: R7E1-Up; KAR1-Up) PM3512 (S/N: BRF1-Up; BNR1-Up)
G3408 (S/N: 6RJ1-Up) PM3516 (S/N: CAC1-Up; BPD1-Up;
G3412 SI (S/N: R7A1-Up; KAP1-Up) KEN1-Up)
G3412C (S/N: 6ZM1-Up) PMG3516 TA DI (S/N: CFD1-Up)
G3512C (S/N: GNX1-Up) PP3516 (S/N: PPS1-Up)
G3516 (S/N: ZBA1-Up; 4EK1-Up;
25Z1-Up) Table of Contents
G3516B (S/N: ZBB1-Up)
G3516B SI TA (S/N: CSC1-Up) Introduction ........................................................... 3
G3516E (S/N: SLY1-Up) Important Safety Information ................................ 3
Mounting the CDVR .............................................. 3
G3520B SI TA (S/N: CWD1-Up) Wiring The CDVR ................................................. 3
G3520C (S/N: MAD1-Up; GZK1-Up; Operator Interface ................................................. 11
GZM1-Up; RLP1-Up)

2
Introduction Safety precautions and warnings are provided in
this instruction and on the product. If these hazard
warnings are not heeded, bodily injury or death could
occur to you or to other persons. Caterpillar cannot
anticipate every possible circumstance that might
involve a potential hazard. Therefore, the warnings
in this publication and the warnings that are on the
product are not all inclusive.

If a tool, a procedure, a work method, or operating

technique that is not recommended by Caterpillar is
used. Ensure that the tool, procedure, work method,
or operating technique is safe to use. Ensure that
the product will not be damaged or made unsafe by
the operation, lubrication, maintenance, or the repair
g01425620
procedures that are used.
Illustration 1

Mounting the CDVR

The CDVR, DVR, and VR6 use the same mounting
The Cat Digital Voltage Regulator presents an
holes. The parts kit includes the hardware that is
electrical shock/electrocution hazard. This hazard
required for mounting the CDVR. The following
will cause serious injury or death.
hardware is included in the kit: bracket, shorter bolts,
and additional hardware. The additional hardware
Service by trained personnel only.
required for the VR6 is shown in Table 4. Install the
CDVR with the heat sinks on the CDVR in the same
The terminals and heat sinks are live at hazardous
position as the display on the DVR or the heat sinks
voltages when power is applied and for up to 8
on the VR6. The CDVR may also be mounted in a
minutes after power is removed.
remote location.

These instructions are provided in order to assist Wiring The CDVR

in replacing an existing DVR or VR6 with a new
Caterpillar Digital Voltage Regulator (CDVR). Refer The CDVR requires connections that are similar
to the Specifications, Systems Operation, Testing to the DVR or VR6, although the harness and
and Adjusting, RENR7941-08, “Cat® Digital Voltage connectors will be different. A new wiring harness is
Regulator ” for complete information. provided with the parts kit. The part number for the
harness is 243-4271 Wiring Harness. One end of
Parts kit 329-4513 Conversion Kit is required to the harness is terminated with connectors that mate
complete this retrofit for both the DVR and the VR6 to the CDVR. The other end of the harness has a
voltage regulators. The VR6 also requires some label on each wire in order to identify the wire.
additional parts as called out in Table 4.
Table 1
Important Safety Information P6 Pin Functions

Work safely. Most accidents that involve product Pin Function

operation, maintenance, and repair are caused by P6-1 Power Input (single phase)
failure to observe basic safety rules or precautions.
An accident can often be avoided by recognizing P6-2 Power Input (single phase)
potentially hazardous situations before an accident P6-3 Power Input
occurs.
P6-4 F-
A person must be alert to potential hazards. This P6-5 F+
person should also have the necessary training,
skills, and tools in order to perform these functions P6-6 Chassis Ground
properly.

3
Table 2 Table 4
P9 Pin Functions Additional Parts Required for VR6
Pin Function Part Number Description Qty
244-0452 Wire End 3
P9-1 CAN bus - High
Electrical
2500 mm
P9-2 CAN bus - Low 153-2707 Cable (J1939
(98.42 inch)
communication)
P9-3 CAN bus - Drain (Shield)
Wire (Batt+ DC 2000 mm
P9-4 Contact Sense - Lower 5P-0653
power) (78.74 inch)
P9-5 Contact Sense - Raise Electrical Wire 2000 mm
6A-3361
P9-6 Contact Sense - Common (Batt- DC power) (78.74 inch)

P9-7 Contact Sense - Excitation Disable Electrical Wire 2000 mm

8C-8799
(Common) (78.74 inch)
P9-8 Contact Sense - Fault Reset
7X-0271 Bolt 1
P9-9 Contact Sense - Var/PF Enable
246-5764 Spacer 1
Table 3 314-9083 Terminal Block 3
P12 Pin Functions 328-4133 Terminal Marker 1
Pin Function 239-5260 Crimp Tool 1
P12-1 B-phase generator current sensing (“CT1”)
The CDVR has three multipin plug connectors.
P12-2 B-phase generator current sensing (“CT2”) The connectors have the following markings:
P12-3 ±10 DCV Input (B), - “P6”, “P9”, and “P12”. Connector “P6” mates with
a corresponding connector with six pins on the
P12-4 Alarm Output Driver (24V, 100mA) harness. Connector “P9” mates with a corresponding
P12-5 Fault Shutdown Driver (24 VDC, 100 mA) connector with nine pins on the harness. Connector
“P12” mates with a corresponding connector with 12
P12-6 ±10 DCV Input (A), + pins on the harness. Refer to the Tables 1, 2 or 3.
P12-7 18 to 30 V Control Power Input (B-) Each table corresponds to the connector number
in order to identify the function of each pin in the
P12-8 18 to 30 V Control Power Input (B+) connector.
P12-9 Driver Supply (50) (24 VDC, 100 mA)
P12-10 Generator Voltage Sensing - C (T3), lead 20
for SR4 and SR4B generators)(1)
P12-11 Generator Voltage Sensing - B (T2), lead 24
for SR4 and SR4B generators)(1)
P12-12 Generator Voltage Sensing - A (T1), lead 22
for SR4 and SR4B generators)(1)
(1) Refer to the generator set wiring diagrams.

4
 g03157977
Illustration 2
Illustration of changes to VR6 wiring Part 1

5
 g03157978
Illustration 3
Illustration of changes to VR6 wiring Part 2

6
 g01456243
Illustration 4
Illustration of changes to DVR wiring

7
 g01015474
Illustration 5
Illustration of a typical CDVR installation

The CDVR does not require a burden resistor. When

changing from a DVR, remove the resistor in parallel
with the CT for sensing droop. The CT connections
are polarized. One of the terminals has a dot. Confirm
that the CT connection with the dot is connected to
P12-1 on the CDVR. Refer to the Illustrations 2, 3,
and 4.

Note: Whereas the DVR and CDVR require 24V DC

power, the VR6 does not. When converting from
the VR6, two extra wires will be needed to jumper
from the existing battery power terminations to the
included terminal block. Refer to the Table 4 for the
recommended DC wiring.

Note: If the CDVR harness wires (1A and 2A) are

long enough for the installation, the recommended
battery jumper wires will not be necessary.

8
 g01455440
Illustration 6
Illustration of a terminal block with connections for RTDs

9
 g01455439
Illustration 7
Illustration of a terminal block with connections for thermocouples

10
Different labels and additional terminals are provided The CDVR requires a connection to a PC for
in the parts kit. These parts are required for the configuring the settings for the generator. The PC is
terminal blocks. These terminal blocks may be also used to monitor the parameters for the generator
located inside the generator terminal box or located and the faults from the generator.
in a remote location. Some labels may need to be
changed on the terminal blocks or added to the A nine pin RS232 cable is required to communicate
terminal blocks. These labels include the following: with the CDVR from a PC or a laptop computer.
“VAR/PF”, “Enable”, “Fault Reset”, and “Excitation
Disable”. Refer to the Illustrations 4 and 5. Install the Note: Do not use a null modem cable.
new terminals and labels that are required for your
specific application. Refer to the Illustrations 6 or 7. The following CDVR settings will need to be
configured in the CDVR: rated voltage, current,
A new momentary switch is provided in the parts frequency, PT Ratio, CT ratio, setpoints for VAR and
kit. The part number for the switch is 110-7884 PF, mode for load compensation, voltage adjustment
Toggle Switch. This switch is used to adjust the band, setpoints for soft start, setpoints for under
voltage on the CDVR output. The common wire to frequency, protective relay functions, and settings for
the switch will replace the following connections: pin PID. More parameters may need to be configured for
50 to “Excitation Disable”, “Fault Reset”, and pin 52a your specific application.
enable for VAR and PF. This switch also replaces the
rheostat that was used on the DVR and VR6. Refer to Note: If CAN datalink communication wires are
the Illustration 5. CAN datalink communication wires installed, Caterpillar Electronic Technician can also
(P9-1, 2 and 3) are not included in the 243-4271 be used to adjust voltage regulator settings. Refer
Wiring Harness. If datalink communication for the to the Specifications, Systems Operation, Testing
CDVR is desired, it will be necessary to install and Adjusting, RENR7941-08, “Cat® Digital Voltage
the additional 153-2707 Electrical Cable. Three Regulator ”, for more information.
244-0452 Wire Ends will also be needed. These
parts are included in Table 4, “Additional Parts
Required for the VR6”.

Note: When installing the CDVR on the J1939

datalink, please be aware of the terminating resistor
location and adjust as necessary.

Note: When converting from a VR6 to a CDVR,

an additional wire will be needed for the common
wire connection from the included terminal block
to the momentary switch. Refer to Table 4 for the
recommended wire part number and amount needed.

In the case of the DVR, the drivers for the alarm

output and the shutdown circuit will remain connected
between 24V DC, pin 50 and the output contacts.

The logic for the control circuit has changed in the

CDVR. The DVR supplies a signal unless a fault is
present. The CDVR signals only when the fault has
occurred. Refer to the Illustration 4.

Operator Interface
In order to configure the parameters of the CDVR, a
PC with the CDVR PC Software is required. Software
can be downloaded from the Service Information
System (SIS).

Refer to the Specifications, Systems Operation,

Testing and Adjusting, RENR7941-08, “Cat® Digital
Voltage Regulator ”, for more thorough information
on the CDVR software.

11
©2012 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.