SR4 Generator & Control Panel Maintenance

Generator Maintenance (SEBU6150-02)
SMCS -
Serial Numbers
You must read and understand the warnings and instructions contained in the
Safety section of this manual before performing any operation or maintenance
procedures.
Space Heaters
Space Heaters are recommended for SR4 generators that are installed in high
humid conditions.
The SR4 generator can operate in high humidity conditions without problems.
However, problems can occur when the generator is idle and the surrounding air is
warmer than the generator. Moisture can form on the windings and result in poor
performance and even result in damage to the windings. Whenever the generator
is not in use, insure that the space heaters are in operation.
Whenever the generator is operating, insure the space heaters are disconnected.
An external source of either 115 or 230 volts AC (200V at 50 Hz) is required to

operate the space heaters.
Space Heater Connection to External Source H1, H2, H3, H4 Terminal Strip
Terminals.
If 115 VAC source is available, connect both heaters in parallel across the source
(L1-L2). If 230 VAC source is available, connect both heaters in series across the
source (L1-L2).
Recommended Periodic Resistance Checks
Use a megohmmeter (megger) to check generator main stator winding insulation

resistance periodically. The frequency of the insulation resistance test is
determined by the generator's environment and by previous megohmmeter test
indicators.
NOTE: Test the main stator windings with a megohmmeter (megger) in the
following situations:
1. Before initial startup of generator set.

2. After generator storage.
3. Every three months if generator is operating in a humid environment or is not
protected from the elements by an enclosed area.
4. Every six months if the generator is installed in an enclosed area with relatively
low humidity and minimal temperature variations.
5. If generator has not been run under load for three months or more.
6. Test every week and use space heaters if the generator is exposed to a sea
water environment or if the surrounding conditions are very humid (relative
humidity above 75%) or if a recent test reading was less than three megohms. In
applications where salt and high humidity are present, space heaters must be
operated whenever the generator is not operating under load. This is the only way
to maintain megohmmeter test readings above one megohm.
The insulation resistance check is described in Special Instruction SEHS9124. A
reading of one megohm or less indicates that the winding has absorbed too much
moisture.
This is a guideline only. It may be necessary to megger more frequently if the

environment is extremely humid, salty or if the last megger test was close to one
megohm.
Clean and Inspect
Before working inside the generator, make sure that the starter motor
can not be activated by any automatic or manual signal.
When the engine-generator is operating, voltages up to 600V are

present in these areas near or on the regulator:
1. the regulator terminal strip.
2. the excitation transformer terminal strip (self-excited generator

only).
Do not short these terminals to ground with any part of the body or any
conductive material. Loss of life or injury could result from electrical
shock or injury from molten metal.
An electrical shock can be received from the regulator capacitor (C1)

when the engine-generator is not in operation. To avoid possible injury,
discharge the stored charge using an 100 ohm resistor across C1
terminals.
NOTICE
Electronic components in the regulator can be damaged during
generator operation if contact is made between the part and ground.
Periodically generators should be inspected for cleanliness. Contaminants such as

dirt, dust, grease, salt, or oil films should not be allowed to accumulate on the
windings.
If moisture is allowed to remain in contact with an electrical winding, some of the

moisture will eventually be retained in voids or cracks of the insulation. This will
lower the resistance of the winding insulation. The insulation used on the windings
of Caterpillar generators is moisture resistant, but constant exposure to moisture
will gradually lower the insulation's resistance.
Dirt can make the problem worse because it can hold the moisture in contact with
the insulation. Salt (from sea air) can also make the problem much worse. This is
because salt tends to absorb moisture from the air. When the salt and moisture
combine, they form a good electrical conductor.
Clean the voltage regulator and generator of dirt and debris. Use a brush to loosen
accumulations of dirt and a vacuum system for removal. Use of compressed air is
not recommended, because of moisture present in the form of condensation.
Carbon tracking on insulators can be caused by dirt or loose connections. These
carbon paths must be cleaned or the insulators replaced. Failure to correct a
carbon tracking problem will eventually result in a short in the electrical circuit.
Visually check for loose or broken wires and connections. Check the wires and
connections on the voltage regulator assembly. Check that all circuit boards are
fully plugged into their sockets. Check all wires and connections in the generator.
Clean heat sinks. Make any necessary repairs to the wiring as required. Refer to
the "Electric Set Generator Service Manual," Form SENR7958, for testing and
adjusting or disassembly and assembly procedures.
Generator Bearings
Bearing Lubrication
NOTE: Use Cat Special Purpose Grease (SPG) 2S-3230 for ball bearings. This is
a NLGI No. 2 Grade (without molybdenum disulfide) with thickener Polyurea, and a
temperature range of [-29 to 177°C (-20 to 351°F)]. Use NLGI No. 1 or 0 Grade for
extremely low temperatures.
NOTE: Use Cat 108-8611 Grease for spherical roller bearings. This is a NLGI No.
1 1/2 Grade (without molybdenum disulfide) with thickener Clay, viscosity 32cST at
40°C (104°F) and 5 cST at 100°C (212°F).
1. Remove the louver assembly or rear plate from the rear of the generator
housing.
2. Remove the top and lower grease pipe plugs.

3. Install a grease fitting in the top, threaded grease pipe.
4. Grease shielded ball bearings with 1.8 to 2.0 oz of 2S-3230 Grease at an
interval of every 2000 hours. Grease spherical roller bearings with 1 oz of 108-
8611 Grease at an interval of every 1000 hours. DO NOT MIX GREASES.
NOTE: Some two bearing generators have spherical roller bearings in the front
bracket and ball bearings in the rear bracket. These units should use a common
108-8611 Grease for front and rear bearings.
5. Wipe off excess grease. Remove the top grease fitting and install plug.
6. Operate generator for one hour. This allows the grease to expand, forcing the
excess grease out of the cavity relieving the internal pressure. The generator
should continue to operate until the grease stops purging. Grease may not purge
until later grease intervals.
7. Stop the engine. Install the plug in the bottom, grease pipe and wipe off excess
grease.
8. Install the louver assembly or rear plate.
Bearing Inspection
The following maintenance procedure for generator bearings should be followed at

every major engine overhaul:
1. Remove bearing bracket. Inspect the bracket bore and bearing outer race and
rolling elements. Standby Power units should have the bearing inspected and the
grease replaced every three years. The bearing bracket bore should be inspected
for out of roundness, excessive wear, and a bracket step less than 0.0762 mm
(.003 in). The bearing should be inspected for outer race damage, severe fretting,
and smoothness of operation. If possible, the bearing elements should be
inspected. Some double shielded ball bearings prevent visual inspection of the ball
bearing elements. Other double shielded ball bearings have a retaining ring, that
can be removed, to allow access for a visual inspection of the ball bearing
elements.
NOTE: Bearings being removed for failure analysis should not be cut off with a
torch.
2. Spherical Roller Bearing should be cleaned and repacked with 108-8611

Grease. Pack the bearing and cavity to one-third to one-half of the cavity volume.
(Approximately 3 - 4 oz. in the bearing and 4 - 5 oz. in the cavity.) Refer to the
chart that follows.
3. All ball bearings should be cleaned and the bracket cavity re-packed with 2S-
3230 Grease. The cavity should be filled to one-third to one-half of the cavity
volume. Refer to the chart that follows.
4. Make sure the grease supply tube to the bearing is filled with grease.
5. Remove the bracket drain plug and operate generator for one hour. This allows
the grease to expand, forcing the excess grease out of the cavity relieving the
internal pressure. The generator should continue to operate until the grease stops
purging. Grease may not purge until later grease intervals.
6. Stop the engine. Install the bracket drain plug and wipe off excess grease.
7. For future greasing intervals follow the recommendation on the lubrication plate
(if equipped) or the Maintenance Schedule in this manual. Repeat Step 5 each
time the bearings are greased. The grease amounts are not given in number of
grease pumps due to the differences in quantity each grease gun delivers. DO
NOT MIX GREASES.
Generator Maintenance Schedules

PPI-00000EA3
2024/06/26
13:28:06-05:00
SEBU61500023
© 2024 Caterpillar Inc.

SR4 Generator & Control Panel Maintenance

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Generator Maintenance (SEBU6150-02)

An external source of either 115 or 230 volts AC (200V at 50 Hz) is required to

Recommended Periodic Resistance Checks

Use a megohmmeter (megger) to check generator main stator winding insulation

1. Before initial startup of generator set.

This is a guideline only. It may be necessary to megger more frequently if the

Clean and Inspect

When the engine-generator is operating, voltages up to 600V are

1. the regulator terminal strip.

2. the excitation transformer terminal strip (self-excited generator

An electrical shock can be received from the regulator capacitor (C1)

Periodically generators should be inspected for cleanliness. Contaminants such as

If moisture is allowed to remain in contact with an electrical winding, some of the

2. Remove the top and lower grease pipe plugs.

The following maintenance procedure for generator bearings should be followed at

2. Spherical Roller Bearing should be cleaned and repacked with 108-8611

Generator Maintenance Schedules

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