85

Reference Information Section

Reference Materials

Service Manual Module, SENR3904, "VR3 Voltage

Regulator (416 Lead), Self-Excited SR4 Generator".

Service Manual Module, SEIVR3473, "VR3

Voltage Regulator (10112 Lead), Self-Excited SR4
Generator".

Service Manual Module, SENR5205, "VR3F Flat Top

Voltage Regulator".

Service Manual Module, SENR5829, "VR3F

Voltage Regulator Permanent Magnet Excited SR4
Generator".

Service Manual Module, SENR3906, "VR4 Voltage

Regulator".

Service Manuals
Service Manual, SENR8395, "SR4B Electric Set
Generator".

Service Manual, SENR6430, "524 and 1724

Electrically Powered Governor Systems for
Generator Set Engines".

Service Manual, SENR4676, "2301A Speed Control",

Service Manual, SENR3585, "2301A Electric

Governors (Load Sharing)".

Service Manual, SENR6565, " Generator Set Load

Sensor and Load Sharing Module".

Note: Specific generator set service manuals will

include the necessary service information for the
generator and for the control panel.

Special Instructions
Special Instruction, SEHS9124, "Cleaning and
Drying of Electric Set Generators".

Additional literature may have become available.

This literature may not be included above. Before
ordering any literature, contact a Caterpillar dealer.
Ask the Caterpillar dealer to check on the following
items: availability of the literature, form number of
the literature, and price of the literature.
 86
Reference Information Section
Reference Materials

Tools
SMCS Code: 0785; 4450

1
Table 12
part ~ u m k r +
p-ppppp-p
Description
-
-

TEST EQUIPMENT
1 8T-0900
h 5 5 - 5 1 7 5
Clamp-on Ammeter
Clamp-on Ammeter +i&urrent
Clamp-on, 0 to 500 Amp range, AC and DC
probe
---
o to 1000 Amp with 146-4080 multimeter
1
I Multimeter 1I voltage,
Digital, RS-232 output. true RMS, used for measuring
current, and resistance

1 1
911-7330 1 Multimeter Digital, for measuring voltage, current, and resistance I
Y r a l o - t imeter Digital, heavy-duty, used for measuring voltage, current, and resistance

i';:';;; Probe Group Used with Digital Multimeter

pppp-

Digital Thermometer For measuring temperature in degrees Celsius

L- --- p-pp

142-5055 Megohmmeter For measuring insulation resistance

1H-3110 ( ExciterIBearing Puller I For changing the bearings and exciter armature
1H-3107 I ExciterIBearing Puller 1 For changing the bearings and exciter armature
I 1 1 SPECIAL TOOLS 1
1 NIA ( Resistive Bridge ( For measuring resistance of windings i
I NIA 1 Protective Gloves Electrical, rubber, 13,800 V I
STANDARD TOOLS
-~ -

1 6V-3001 ( Crimping Tool ( For crimping Sure Seal connectors

1 Heavy duty crimping and stripping
---- 1
I For crimping Deutsch connectors 1
( Flashlight 1 As
(
required

For lubricating bearings

i
Lamp, fluorescent Safety light
d s , s , h i l l i p s and
d
ei ,:dra
d
nts
I
111-7248 J~rench
I 8T-9293 1 Wrench 1 Torque, 40 to 250 ft-lb, 112 inch drive
1 1U-7460 I Wrench set I Allen, 118 to 112 inch
1 111-7160 ) Socket set 1 Nine piece, 318 to 718 inch with 318 inch drive 1
I 111-8030 ) Socket set ) Twelve piece, 7/16 to 1 118 inch with 112 inch drive 1
Twelve piece, 8 to 19 mm with 318 inch drive
-pppp

Ten piece, 16 to 26 mm with 112 inch drive

' Thirteen piece, open-end combination sized -
- _ _ _ _ _ _ A
2_ _
1 set
L--
I Electric with nonmetallic nozzle
114 to 1 inch (standard)
-
1
(continued)
 87
Reference Information Section
Reference Materials

(Table 12, contd)

Part Number 1 Tooi Description 7
111-8809 Corrosion inhibitor Rust preventative
111-8803 Detergent , As required for cleaning, Hydrosolv 67
4C-5522 1 Gloves For chemical protection
N/A I plastic Protection for long-term storage

1 N/A 1 Rags I As required I

I N/A
- -
I water 1 For cleaning 1
N/A / Air 1 Compressed, dry
Covering material Waterproof desiccant bags, for protection from moisure during
long-term equipment storage
1 SEHS7332 "DO NOT OPERATE" For providing visual warnings and cautions
i Tags

Symbols
SMCS Code: 4450

SYMBOL DESCRIPTION SYMBOL DESCRIPTION SYMIIOL DESCRIPTION SYMBOL DESCRIP?ION SYMBOL DESCRIPTION

0 WARNtNG @
,--a
OIL FILTER LOW FUEL LEVEL @P LOW COOLANT lEUi @ ENGINE INTAKE AIR DAMPER CLOSED

@ DO N O T LIFT @, OIL PRESSURE

,--.
FUEL FILTER LOW COOLANT LEVEL fl SYSTEM BATTERY VOLTAGE

9 @ LOW OIL PRESSURE DIESEL FUEL & ENGINE COOLANT FILL LOW BATTERY VOLTAGE

@
LrT'NC

L A M P TEST
@ OIL LEVEL DIESEL FUEL FILL COOLANT DRAIN a 8 A T T E R I CHARGER MALFUNCTION

LPI;A:L @I @
ILLUMINATION COOLANT TEMPERATURE
.--. COOLANT FILTER ADJUSTABLE LOW-HIGH

A EMERGENCY STOP @( HIGH COOLANT TEMP P* REVERSE POWER ALARM

\
SYMBOL DESCRIPTION SYMBOL DESCRIP?ION SYMBOL DESCRlPllON SYMBOL DESCRIPTION

@ ALARM SlLENCE SERVICE HOURS

OAUT
8 S Y S l F U AUTO ENCINE START 2: HOT SURFACE

t
RAISE

LOWER
&
AUT
S T A R T I N G AID

Aurourrlc
- ETHER

@
OYERSPEEO

FAIL TO S T A R T , OVERCRANK
@
4 =
m NO SERVICE

F;:N
Iu:p",d",N
;-T
REAO M A N U A L

PRESSURE

:e;:R
1
MAN. MANUAL V-A VOLTMETER PHASE SELECTOR

I
0 OFF
.
-
0 GENERATOR SYNCHRONIZING INDICATOR
I
@ ENGINE STOP
@ :;g(NNEE
ENGINE START. OR
144-0848

Illustration 71
The control panel and modules utilize International Graphic Symbols to identify functions.
A typical list of the symbols that are used is shown above.
88
Reference Information Section
Reference Materials

i01207219 Continuity -Continuity provides a path for current

flow.
Glossary
Control - A control is a device that controls another
SMCS Code: 4450 device. A control is also a circuit that controls a
device.
Actuate - Actuation relates to putting something
in motion. Cross Current Compensation - Cross current
compensation is a method that is used for reactive
Alternating Current (AC) -Alternating Current is an power equalization.
electric current that reverses direction at regular
intervals (50 times per second in 50 Hz or 60 times Current Transformer (CT) - A current transformer is
per second in 60 Hz). used to step down higher line current.
Anode -An anode is the positive end of a diode or Direct Current (DC) - Direct current is current flow
an anode is the positive end of a rectifier. that moves in only one direction in a given circuit.
Blocking Rectifier - A blocking rectifier permits Damping - Damping refers to decreasing the
direct current flow in only one direction. amplitude of a signal.
Bolted - A bolted device uses a bolt to hold two De-energized - A de-energized input refers to
or more parts together. stopping the current that is going to a component.
Bridge - A bridge is a circuit that is used to Distribution Winding - Distribution windings go from
measure small quantities of current, voltage, or one end of the core to the other end of the core.
resistance. These windings are arranged in groups that are
located in several slots.
Bridge Rectifier - A bridge rectifier is a circuit that
is used to change alternating current (AC) to direct Droop - Droop refers to a decrease.
current (DC).
Excitation - Excitation is controlled direct current
Buildup - A buildup is a gradual increase in voltage. (DC) that is used to make a magnetic field.
Cathode - A cathode is the negative end of a diode Energized - A n energized input refers to activating
or a cathode is the negative end of a rectifier. a device.
Capacitance - Capacitance is the ability to store Electrostatic Charge - Electrostatic charge is
an electrical charge. electricity that is caused by induced voltage and
stored charge.
Capacitor - A capacitor is a device that will store
an electrical charge. Exciter - A n exciter supplies direct current (DC) to
the field windings of the generator.
Circuit Breaker - A circuit breaker is an automatic
switch that is used to open a circuit. Field - A field is a magnetic line of force that
surrounds a conductor. This force is caused by
Circulating Current - Circulating current is the flow current flow in the conductor.
of current between two or more generators that are
working in parallel. Circulating current is also the Field Windings - Field windings are many turns of
flow of current between two or more generators that wire that are wrapped around an iron core. When
are parallel with a utility line. direct current (DC) flows through the field windings,
a magnetic field is produced. This magnetic field is
Conduct - Conducting relates to allowing the flow comparable to the magnetic field of a bar magnet.
of current.
Flashing - Flashing is a process of putting direct
Constant Voltage Regulation - Constant Voltage current from an external source into the field
Regulation is one of the two methods of voltage windings. This process causes the generator to
regulation. In order to maintain the line voltage, produce an output voltage.
Constant voltage regulators allow the field to be
forced to the saturation point. This allows the engine Flux - Flux is magnetic lines of force.
to be overloaded. On large block load applications,
the engine may not recover.
 89
Reference Information Section
Reference Materials

Frequency - Frequency is the number of cycles KVAR - Kilovolt Amperes Reactive is abbreviated
that are completed in a one second period. The unit as KVAR. KVAR is associated with the reactive
of frequency is the Hertz (Hz). One hertz is equal power that flows in a power system. Reactive power
to one cycle per second. does not load the generator set's engine. Reactive
power will cause thermal loss in the generator.
Full-Wave Rectifier - A full-wave rectifier changes
the positive phase and the negative phase of KVAR Regulation - KVAR Regulation is one of the
alternating current to direct current. two methods that are used to regulate the reactive
power output. Regardless of the generator's real
Gain - Gain relates to the ratio of input magnitude power output, the voltage regulator causes the
to output magnitude. generator to produce a constant value of KVAR. In
this case, the generator's power factor will change
Gate - A gate is an electronic part of a controlled when the generator's real power output changes.
rectifier (thyristor). KVAR regulation is used when the generator is
connected in parallel with an infinite bus (utility) and
Generate - The production of electricity. it is not possible to change the system voltage.

Grounded - A device is grounded by making a Kilowatts (kW) - Kilowatt is the electrical rating
connection to ground. A device could also be of the generator. One kilowatt equals 1000 watts.
grounded by making a connection to a component Actual power is measured in kilowatts.
that is connected to ground.
Lead - A lead is a wire.
Hertz (Hz) -Hertz is the unit of measurement for
frequency. One hertz is equal to one cycle per Line Voltage - Line voltage is the output voltage
second. of the generator that is measured between the
generator leads (phases).
Humidity - Humidity is the water content that is
present in the air. Lock In - Lock in occurs when a contact closes in
order to keep a device in an energized state.
lmpedance - lmpedance is the resistance to
alternating current. Lock Out - Lockout occurs when a contact opens
in order to keep a device in a de-energized state.
Impulse Modulation - Impulse modulation changes
the following characteristics of a wave: amplitude, Magnetic - A magnetic device is a device that has
frequency, and phase. This is accomplished by the characteristics of a magnet.
impressirrg one wave on another wave that has
constant properties. Magnification - Magnification refers to the
enlargement of an item.
Induce - This refers to the transfer of power from
one device to another device. The transfer is done Module - A module is an assembly of electronic
via a magnetic field or via an electric field. components and electronic circuits.

lnterference - lnterference is an unwanted mixture Moisture - Moisture is the presence of water.

of electrical signals, lnterference is usually
associated with electrical noise. Oscillation - Oscillation is the flow of electricity that
periodically changes direction and/or magnitude.
lnstrumentation - lnstrumentation is a group of
instruments that are used for measuring a system Permanent Magnet (PM) - A permanent magnet
function. supplies the initial magnetism that is required to
start a PMPE generator.
Insulated -An insulated device is a device that is
covered with a nonconductive material. Permanent magnet pilot excited (PMPE) - A PMPE
generator receives power for the voltage regulator
kVA -This is the abbreviation for Kilovolt Amperes. from a pilot exciter. A PMPE generator consists of a
kVA is a term that is used when electrical devices permanent magnet and a pilot exciter.
are rated. In order to calculate a device's kVA
rating, multiply the rated output (amperes) by the PF Regulation - PF Regulation is one of the two
rated operating voltage. ways to regulate the reactive power output. PF
regulation is used when the generator is connected
in parallel with an infinite bus (utility) and it is not
possible to control the system voltage.
90
Reference Information Section
Reference Materials

Phase Winding - A phase winding is a group of Saturable Reactor - A saturable reactor has
generator stator coils. Electric power for one phase characteristics that are similar to a valve. As the
of the load is induced in the phase winding. load changes, a valve opens in order to give more
current to the output or a valve closes in order to
Polarity - Polarity is the positive characteristics or give less current to the output.
the negative characteristics of two poles.
Saturated - A device has been saturated when
Power Factor (PF) - Power factor is the ratio of the device has been magnetized in excess. When
apparent power (kVA) to total power (kW). 'The saturation occurs, a large increase in current results
power factor represents the portion of the current in a small increase in magnetic force.
that is doing useful work. Power factor is expressed
as a decimal number between 0 and 1 . SCR - An SCR is a silicon controlled rectifier. An
SCR is a semiconductor.
Pulsating - Pulsating relates to the characteristics
of current that are similar to mechanical vibration. SE - An SE generator is a self-excited generator.
An SE generator uses a small part of the generator
Radio Suppression - Radio suppression reduces output to provide excitation current back to the
the amplitude of radio frequency interference. generator. An SE generator uses residual magnetic
field for start-up.
Reactive Droop Compensation - Reactive Droop
Compensation is one of the two methods that are Semiconductor - A semiconductor is a component
used for reactive power equalization. In reactive such as one of the following components: a
droop compensation, the voltage regulator causes transistor, a diode, and a thyristor. Semiconductors
an individual generator output to change in have electrical characteristics that are between a
proportion to the reactive current. This reactive conductor and insulation.
current is measured with a current transformer.
Series Boost - A series boost is an attachment that
Reactive Power - Reactive power flows back allows generator output to continue for a short time
and forth between the inductive windings of the during a line failure. This allows the circuit breaker
generator. These windings are part of the electrical to trip in sequence.
load. The reactive power does not perform any
useful work in the electrical load. The reactive Short - A short is an undesired electrical connection
power only applies load to the generator. This limits that exists between two or more components.
the generator's capacity.
Shutdown - A shutdown occurs when the engine is
Reciprocating - Reciprocating motion is motion that stopped. This shutdown can occur manually or this
first moves in a straight line in one direction. The shutdown can occur automatically.
direction of this motion then varies by 180 degrees.
Simultaneous - A simultaneous occurrence refers
Rectifier - A rectifier is a diode circuit that converts to two actions that happen at the same time.
alternating current (AC) to direct current (DC).
Solid-State - A solid-state component is an
Regenerative Power - Regenerative power works electrical component that has no moving parts.
against primary power.
Stator - A stator is the windings of a generator that
Reset - A reset returns a switch to a ready do not rotate.
condition. In addition, a reset returns a circuit to
a ready condition. Surge - A surge is a sudden increase in voltage
or current.
Residual Magnetism - Residual magnetism is a
small amount of magnetism that is remaining in a Tap - A tap is a connection at the midpoint of a
device after excitation is removed. circuit. From this tap, power is taken from the circuit.

RFA - An RFA is a rotating field assembly. Transfer - A transfer refers to moving something
from one point to another point. A transfer also
Rotating Rectifier - A rotating rectifier is mounted to refers to converting something from one state to
a plate on a generator shaft. This plate then rotates another state.
with the generator shaft.
Transient Peak Voltage - A transient peak voltage is
Rotor - A rotor is the rotating windings of a a high voltage condition of limited duration.
generator.
 91
Reference Information Section
Reference Materials

Turn-on -When a device is turned on, the device is

activated or the device is started.

Varistor - A varistor is a device that loses resistance

as voltage increases.

Voltage Droop Resistor - A voltage droop resistor is

a variable resistor. This resistor is used to control the
change of voltage. This can occur when a generator
is paralleled with another generator. This can also
occur when the generator is paralleled with a utility.

Voltage Level Rheostat - A voltage level rheostat

gives a range of control that is used when the
voltage output level is adjusted.

Voltage Regulator - A voltage regulator is a circuit

that senses the generator's output voltage. The field
coil current is automatically adjusted in order to
maintain the desired output.

Voltage Spike - A voltage spike is a brief high

voltage.

Volts per Hertz Regulation - Under block loading

conditions, the Volts per Hertz Regulation provides
fast recovery. This regulation maintains close voltage
control over the normal load range. This regulation
also produces a rapid response of the generator
set. 'This control is maintained by matching the
generator output to the engine performance.

Windings -Windings are layers of wire on a core.

Wiring -Wiring relates to the wires of a circuit.

Wound -Wound refers to being circled.

92
lndex Section

lndex
Foreword................................................................ 4
Generator Identification........................................ 4
Automatic Operation..............................................56 Ordering Parts ..................................................... 4
An Engine Shutdown that is Caused by Faults .. 57
Restarting the Engine ........................................ 57
Standby Sets ......................................................57
Starting the Engine ............................................56
Stopping the Engine..........................................57 General Hazard Information .................................... 7
General Maintenance Information......................... 58
Space Heaters ................................................... 58
Generator .Clean .................................................. 69
Generator .Dry ..................................................... 70
Bearing . Inspect ...................................................64 Controlled Current Method................................. 70
Bearing (Ball) .Lubricate.....................................66 Oven Method ..................................................... 70
Lubricating Process ...........................................67 Self-circulating Air Method ................................ 70
Bearing (Spherical Roller) .Lubricate ................... 67 Generator Description ........................................... 11
Lubricating Process ...........................................67 Generator Identification......................................... 12
Bearing Temperature .MeasureIRecord ............... 68 Generator Identification...................................... 12
Before Starting Engine ............................................9 Output Lead Wiring ............................................ 12
Burn Prevention.....................................................7 Generator Installation ............................................ 52
Bearing Inspection ............................................. 52
Electrical Measurements ................................... 53
Location ............................................................. 52
Protective Devices ............................................. 53
Crushing Prevention and Cutting Prevention........... 8 Receiving Inspection.......................................... 52
Storage ............................................................. 52
Unpacking and Storage ..................................... 52
Generator Isolating for Maintenance ..................... 10
Generator Lead Connections ................................ 13
Electrical Connections .Check.............................. 68 Grounding the Frame ......................................... 15
Electrical System .................................................... 9 Lead Numbering ................................................ 13
Grounding Practices ............................................ 9 Multiple Units ..................................................... 15
Electronic Modular Control Panel II (EMCP 11) ...... 31 Neutral Connections .......................................... 15
Alarm Module (If Equipped) ............................... 36 Parallel to a Utility .............................................. 16
Display ............................................................34 Single Units...................................................... 15
Fault Indicators .................................................33 Generator Load .Check ........................................ 72
Generator Set Control (GSC).............................32 Generator Operation .............................................. 20
Keypad ...............................................................35 Block Loading .................................................... 20
Main Control Panel ............................................31 Excitation Systems............................................. 21
Synchronizing Lights Module (If Equipped) ....... 35 Generator Options ............................................ 22
Synchronizing Lights Module With Reverse Power Loading of the Generator ................................... 20
Relay (If Equipped) ..........................................35 Low Idle Adjustment........................................... 21
Electronic Modular Control Panel 11+ (EMCP 11+) .. 37 Oilfield Generators............................................ 22
Alarm Module.....................................................43 Power Factor ...................................................... 21
Custom Alarm Module (If Equipped).................. 44 Standby Electric Sets ......................................... 21
Generator Set Control +.....................................38 Generator Set .Test .............................................. 72
Main Control Panel ............................................37 Generator Set Control Panels ............................... 29
Synchronizing Lights Module (If Equipped) ....... 44 Generator Set Vibration .Inspect .......................... 73
Engine Starting .......................................................9 Generator Start-up Checklist ............................... 59
Engine Starting and Engine Stopping ................... 54 Glossary ............................................................... 88
Engine Stopping ...................................................9

Important Safety Information ................................... 2

Fire Prevention and Explosion Prevention............... 7 Installation ............................................................ 52
Fire Extinguisher .................................................8
 93
Index Section

Insulation .Test ..................................................... 74 Reference Numbers ..............................................12

Recommended Periodic Insulation Test Generator Set Information Sheet ....................... 12
Procedure......................................................... 74 Rotating Rectifier .Check...................................... 77
Recommended Periodic Insulation Tests ........... 74 Rotating Rectifier .Test .........................................78
Testing a Brushless Exciter Rotating Rectifier With
A Test Light ......................................................78
Testing A Brushless Exciter Rotating Rectifier With
An Ohmmeter................................................... 78
Maintenance Interval Schedule (Standard) ........... 62
Maintenance Interval Schedule (Standby)............. 63
Maintenance Recommendations........................... 58
Maintenance Section ............................................ 58
Manual Operation .................................................. 54 Safety Section .......................................................5
EMCP II And EMCP II+ Control Panels ............. 54 Safety Signs and Labels ..........................................5
Manual StartlStop Control Panel (130-3786)..... 55 Single Unit Operation ............................................28
Manual StartIStop Control Panel ........................... 29 Initial Start-up ....................................................28
Fault Indicators ..................................................30 Starting ..............................................................
28
Gauges And Meters ...........................................29 Stopping .............................................................28
Operator Controls ..............................................30 Space Heater .Check ...........................................79
Model View Illustrations.........................................11 Stator Lead .Check.............................................80
SR4B Generators (Typical Examples) ............... 11 Stator Winding Temperature .MeasuretRecord.... 80
Model Views ........................................................11 Symbols.................................................................87
Mounting and Dismounting...................................... 8

Table of Contents..................................................... 3
Operation ...............................................................20 Tools ......................................................................86
Operation Section ..................................................20

Varistor .Test.........................................................81
Parallel Operation .................................................. 22 Ohmmeter ..........................................................81
Circulating Currents ........................................... 25 Test Light............................................................81
Electric Governors ............................................. 26 Voltage Connections..............................................16
Frequency Adjustment ....................................... 23 Single-Phase Current From a Three-Phase
Governors That Are Operating In Parallel.......... 25 Generator .........................................................18
Initial Startup Requirements .............................. 22 Three-Phase Voltage Connections ....................16
Load Division ..................................................... 25 Voltage Regulator Options.....................................50
Paralleling Multiple Units.................................... 24 Electromagnetic InterferenceIRadio Frequency
Phase Rotation ................................................ 22 Interference Module .........................................50
Starting Multiple Units........................................24 Manual Voltage Control ......................................50
Stopping.......................................................... 28 Voltage Regulators ................................................46
Voltage Adjustment ............................................ 24 Adjustment Procedure for the Voltage
Power Factor .Check ............................................ 77 Regulators....................................................47
Product Identification Information.......................... 12
Product Information Section .................................. 11

Walk-Around Inspection ........................................82

Winding .Test ................................................... 83
Reference Information Section .............................. 84
Reference Material .............................................. 84
Operation and Maintenance Manuals ................ 84
Owner's Manuals ............................................ 84
Service Manual Modules ................................... 84
Service Manuals ................................................ 85
Special Instructions........................................... 85
Reference Materials .............................................. 84