Baldor Portable Generator BALDOR GENERATORS User Manual

PRESENTS YOUR  
BALDOR GENERATORS  
3815 OREGON STREET OSHKOSH WI 54902  
PHONE: 920–236–4200 FAX: 920–236–4219  
REVISED/EFFECTIVE MAY 1, 2003  
FORM#: S–PSG–002–48  
C:\ISO9001\FORMS\SPSG–002–48msw  
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SAFETY WARNINGS  
z Place protective covers and guards over the rotating parts, if rotating parts such as the drive shaft, pulley,  
belt, etc. are left exposed, they are potentially hazardous.  
z When cleaning, repairing or inspecting, make sure all moving parts have stopped.  
z Prior to working on the generator set, disconnect the spark plug and battery to prevent accidental starting.  
z Use only original equipment or authorized replacement parts. Use of correct parts will assure the operator  
of the safety integrity that was designed into the unit.  
z Unauthorized modifications to the generator set may impair the function and/or safety of the unit.  
z Do not operate the generator set without a muffler. Inspect periodically and replace if necessary.  
z Do not touch the hot exhaust components or the high voltage spark plug and coil terminals. While Spark  
Plug Voltages are not normally lethal, an involuntary jerk of the hand caused by a hot surface or by  
an electrical shock can result in injury.  
z Repair of electrical generating equipment requires specialized skills. Repair personnel must have a  
thorough understanding of generator and small engine repair procedures.  
z Never inhale exhaust gases. They contain carbon monoxide; a colorless, odorless and extremely  
dangerous gas that can cause unconsciousness or death. Symptoms of carbon monoxide poisoning  
can include: dizziness, nausea, headaches, sleepiness, vomiting or incoherency. If you or anyone else  
experiences any of these symptoms, get out into the fresh air immediately. Shut the unit down and  
do not operate it until it has been inspected and, if necessary, repaired.  
z Never Operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave.  
z CALIFORNIA PROPOSITION 65 WARNING: engine exhaust from this product contains chemicals known  
to the state of California to cause cancer, birth defects or other reproductive harm.  
z Know how to stop the engine quickly and understand the operation of all controls.  
Revised: 8/13/02  
Effective: 2/27/98  
Page 1 of 4  
FORM#: SPSG0013  
C:\ISO9001\FORMS\SPSG0013.msw.bbk  
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SAFETY WARNINGS  
z Never permit anyone to operate the generator set without proper instructions.  
z Never allow children to operate the generator set.  
z Children and pets must be kept away from the area of operation due to the possibility of burns from hot  
engine components or injury from any equipment the generator set is powering.  
z Always wear eye protection and Hearing protection when working near the generator set.  
z Operate the generator set only with the guards, shields and other safety items in place and working  
properly.  
z Do not put hands, feet, tools or other objects near rotating parts.  
z Use reasonable care when moving or lifting the unit. The generator set may move around inside the wrap  
frame creating Pinch Points.  
z Do not run the generator set while it is being moved.  
z Do not support the generator set from the top of the wrap frame.  
z Do not operate the generator set while under the influence of alcohol, drugs or medication.  
z When transporting or using a generator set with the wheel option, secure the unit to prevent it from moving  
around.  
z Do not tamper with or change the engine speed as it has been preset at the factory for proper operation.  
z Keep hands and face away from the carburetor when the air cleaner is being moved. A sudden backfire  
can cause serious burns.  
z Be careful of hot parts. The muffler and other generator parts become very hot while the engine is running.  
z Do not jump startthe generator set.  
z Sulfuric acid can cause severe injury and can give off gases, which are corrosive and potentially explosive.  
Avoid contact with skin, eyes, and clothing. In case of contact, flush area immediately with water.  
z When transporting a generator set, secure it to prevent it from moving or shifting.  
z Know how to stop the engine quickly and understand the operation of all controls.  
z Do not operate electrical equipment while standing in water, on wet ground or with wet hands or shoes.  
z Use extreme caution when working on electrical components. Potentially dangerous voltage is present  
when the engine is running.  
Revised: 8/13/02  
Effective: 2/27/98  
Page 2 of 4  
FORM#: SPSG0013  
C:\ISO9001\FORMS\SPSG0013.msw.bbk  
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SAFETY WARNINGS  
z Always treat the electrical circuits as if they were energized.  
z Disconnect all leads plugged into the unit Prior to working on it.  
z Have the electrical circuits serviced only by qualified technicians.  
z Inspect wiring frequently and replace frayed, broken or poor leads.  
z Do not connect this unit to any buildings electrical system unless you utilize an approved transfer switch or  
the main service entrance switch has been disconnected and locked open.  
z Circuit overload protection must be provided in accordance with national electrical codes and local  
regulations.  
z Check GFCI Receptacles monthly by using the Testand Resetbuttons designed into them.  
z Depending on your application it may be mandatory to ground or not ground this unit to earth ground.  
Comply with local electrical codes.  
```` FOR GASOLINE OR DIESEL POWERED GENERATOR SETS ````  
z Operate the generator set on a level surface. If the generator set is tilted, fuel spillage may result.  
z Handle fuel with care. It is highly flammable. Use only clean, properly marked and approved safety  
containers for refueling and storing fuel.  
z Stop the engine and allow it to cool before refueling.  
z Do not overfill the fuel tank. Only fill the tank to within 1/2of the top of the tank to allow space for fuel  
expansion.  
z If fuel is spilled, wipe it up carefully and wait until the fuel has dried before starting the engine.  
z Make sure the fuel cap is properly closed after refueling.  
z Never operate the generator set while smoking.  
z Never operate the generator set near an open flame.  
z Never store the generator set with fuel in the tank indoors or in an enclosed, poorly ventilated enclosure  
where fuel fumes may reach an open flame, electrical spark or pilot light as on a furnace, water heater,  
clothes dryer, etc.  
z When transporting over long distances or rough roads, drain the fuel tank to prevent leakage and spillage.  
Revised: 8/13/02  
Effective: 2/27/98  
Page 3 of 4  
FORM#: SPSG0013  
C:\ISO9001\FORMS\SPSG0013.msw.bbk  
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SAFETY WARNINGS  
```` FOR GASOLINE OR DIESEL POWERED GENERATOR SETS ````  
z Check all fuel supply piping and their connections on a monthly basis for fuel leaks.  
z Use only approved piping and componentry in your fuel supply system.  
z A professional, experienced technician should only install the fuel supply system.  
z Do not run the fuel line up against any sharp objects.  
z Comply with NFPA regulations and your local codes in regard to shutoff valves, regulators, etc. and any  
other recommendations or requirements they may have.  
z Keep the generator set at least three feet away from buildings or other structures.  
z Keep the generator set away from flammable and other hazardous materials (trash, rags, lubricants,  
explosives, paints, etc.)  
z Keep the generator set free of grass, leaves and excessive grease and oils.  
z Allow the generator set to cool before transporting it or storing it indoors.  
z Have fire extinguisher accessible and nearby while operating the generator set.  
z This generator set must not be used on or near any forest covered brush covered or grass covered land  
unless the engines exhaust system is equipped with a spark arrester and it must be maintained  
in effective working order by the operator.  
z Operation inside an enclosed compartment or building is a potential fire hazard and should not be done  
unless approval is obtained from Baldor Generators. Engine/Generator overheating can cause severe  
damage due to restricted, obstructed or improper airflow that is necessary for the proper cooling of the  
unit.  
z Hot exhaust gases being discharged by the engine must never be directed toward anything that could  
catch fire or explode.  
Revised: 8/13/02  
Effective: 2/27/98  
Page 4 of 4  
FORM#: SPSG0013  
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FORWARD  
This manual contains the information you need to safely and efficiently operate your generator  
set. During the preparation of this manual every effort was made to ensure the accuracy of its  
contents.  
Never operate this generator set without first carefully reading this manual and observing all the  
safety warnings it presents. While safety is built into every Baldor PowR Gard generator set,  
careless or improper operation could possibly result in mechanical failure, property damage, se-  
vere injury or death.  
Note that this manual covers only very basic information in regards to the engine. A separate  
owners manual for the engine is supplied with this unit for your use. Please refer to this manual  
for information relative to engine operation, maintenance, recommendations and additional  
safety warnings.  
As soon as you receive your generator set, inspect it closely for shipping damage. If you find  
some damage, notify the transportation company immediately and file a freight damage claim.  
Think of this manual as a tool to help you get the most out of your generator set. We strongly  
suggest that you keep this manual with your generator set and refer to it when questions arise  
in regards to its operation.  
Baldor Generators, formerly PowR Gard Generator Corporation has been in business since  
1965. The generator sets we manufacture have earned the reputation of being of high quality  
and a dependable product. We take pride in this fact and continue to keep our quality standards  
high on our list of priorities. We are also constantly researching new technological ideas to de-  
termine if they could be used to make our generator sets even better.  
Thank you for purchasing your Baldor PowR Gard Generator Set.  
Effective: February 26, 1998  
Revised 2/01/02  
Form#: SCSD0037  
C:\ISO9001\FORMS\SCSD0037.MSW  
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Effective: February 26, 1998  
Revised 2/01/02  
Form#: SCSD0037  
C:\ISO9001\FORMS\SCSD0037.MSW  
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6
Features & Specifications  
Model  
Standby output–  
TS25  
TS45  
TS80  
TS130  
TS175  
0
150 C Rise  
(KVA/KW):  
3 PH @ 480 Volt  
25/20  
25/20  
18/18  
48/38  
46/37  
27/27  
81/65  
72/58  
45/45  
134/107  
131/105  
70/70  
175/140  
169/135  
80/80  
3 PH @ 208/240 Volt  
1 PH @ 240 Volt  
Continuous Output–  
0
125 C Rise (KVA/KW):  
3 PH @ 480 Volt  
3 PH @ 208/240 Volt  
1 PH @ 240 Volt  
23/18  
23/18  
18/18  
44/35  
44/35  
25/25  
75/60  
69/55  
43/43  
121/97  
119/95  
66/66  
169/135  
156/125  
75/75  
G
E
N
E
R
A
T
O
R
Voltage 3 PH Adjustable  
208/220/240/  
416/440/460/480  
208/220/240/  
416/440/460/480  
208/220/240/  
416/440/460/480  
208/220/240/  
416/440/460/480  
208/220/240/  
416/440/460/480  
Voltage 1 PH Adjustable  
120/127/139/  
240/254/277  
120/127/139/  
240/254/277  
120/127/139/  
240/254/277  
120/127/139/  
240/254/277  
120/127/139/  
240/254/277  
Amperage (Continuous):  
3 PH 480 Volt  
27.1  
62.5  
52.6  
121.4  
90.2  
190.8  
145.8  
329.6  
203.0  
433.7  
3 PH 208 Volt  
3 PH 240 Volt  
54.1  
105.3  
165.4  
285.7  
275/550  
375.9  
1 PH 240 Volt/120 Volt  
Receptacles:  
75.0/150.0  
104.2/208.3  
179.2/358.3  
312.5/625.0  
120 Volt, 15 Amp GFCI  
4
2
6
3
6
3
6
3
6
3
120/240 Volt, 50 Amp,  
CS6369 Twistlock  
Voltage Regulation 1/2%  
Power Factor 3 Phase  
Frequency  
1/2%  
0.8  
1/2%  
0.8  
1/2%  
0.8  
1/2%  
.08  
1/2%  
.08  
50 or 60 Hertz  
<5%  
50 or 60 Hertz  
<5%  
50 or 60 Hertz  
<5%  
50 or 60 Hertz  
<5%  
50 or 60 Hertz  
<5%  
Total Harmonic Distortion  
Insulation  
Class F  
Class F  
Class F  
Class F  
Class F  
Engine Make/Model  
Design  
Isuzu  
4LE  
Isuzu  
4BG1  
John Deere  
TO4045T  
John Deere  
TO6068  
John Deere  
RG6081T  
Water Cooled  
4 Cycle Diesel  
Water Cooled  
4 Cycle Diesel  
Water Cooled  
4 Cycle Diesel  
Water Cooled  
4 Cycle Diesel  
Water Cooled  
4 Cycle Diesel  
Starting System  
Displacement (cid)  
Cylinders  
12 VDC  
133.0  
4
12 VDC  
264.2  
4
12 VDC  
276.0  
4
12 VDC  
414.0  
6
12 VDC  
498.0  
6
HP @ Rated Speed  
RPM  
34.5  
64.0  
100.0  
1800  
166.0  
1800  
211.0  
1800  
1800  
1800  
E
N
G
I
N
E
Safety Shutdowns:  
High Temperature  
Low Oil  
Std.  
Std.  
Std.  
Std.  
50  
Std.  
Std.  
Std.  
Std.  
80  
Std.  
Std.  
Std.  
Std.  
80  
Std.  
Std.  
Std.  
Std.  
160  
Std.  
Std.  
Std.  
Std.  
160  
Overspeed  
Overcrank  
Fuel Capacity  
Fuel Consumption (GPH):  
1/2 Load  
1.3  
2.0  
2.0  
3.4  
2.7  
4.9  
4.2  
8.1  
5.6  
Full Load  
10.5  
Approx. Run Time (Hrs.):  
1/2 Load  
38  
25  
40  
24  
30  
16  
38  
20  
29  
15  
Full Load  
Battery Recommendation Min. Cold  
Cranking Amps  
750  
900  
900  
(2) 750  
(2) 750  
(Battery not included)  
Dimensions (L x W x H):  
With Trailer  
Without Trailer  
Weight (Lbs.):  
123x 62x 70”  
74x 38x 52”  
139x 60x 81”  
84x 38x 61”  
139x 60x 81”  
84x 38x 61”  
163” x 66” x 94”  
108” x 42” x 74”  
163” x 66” x 94”  
108” x 42” x 74”  
Without Fuel  
2265  
1790  
3540  
2829  
3848  
3053  
5600  
4610  
6200  
5205  
Without Fuel & Trailer  
7
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SWITCHABLE  
ELECTRICAL CONNECTION INFORMATION  
WARNING: High voltage may be present at receptacles and load studs while engine is  
operating – DANGER of electrical shock is present. Use extreme care.  
LOAD RECEPTACLES  
1. Voltage is present in 120/240 volt switch position only.  
2. Load wires may be brought into receptacle compartment through access door at control station.  
HARD WIRE LOAD TERMINAL BLOCK  
1. Voltage available at load block is outlined in chart below.  
2. Cables must be brought into load block compartment through access hole in base of trailer.  
3. Opening load block door will cause load disconnect to trip.  
4. Do not start engine with load turned “on”. Allow engine to come up to speed and warm up (1).  
5. If left unattended, lock all doors to prevent tampering or injury.  
AVAILABLE VOLTAGE:  
SWITCH POSITION  
STUD  
277/480  
123 = 480 VAC, 3 Phase  
1N, 2N, 3N = 277 VAC, 1 Phase  
123 = 240 VAC, 3 Phase  
23 = 240 VAC, 1 Phase  
2N, 3N = 120 VAC, 1 Phase  
1N = 180 200 VAC, Wild Leg  
123 = 208 VAC, 3 Phase  
23 = 208 VAC, 1 Phase  
120/240  
120/208  
1N, 2N, 3N = 120 VAC, 1 Phase  
NOTE: To prevent damage to loads and generator, select voltage switch position prior to starting  
engine.  
NOTE: Upon switching voltage selector switch, adjust voltage and adjust rheostat (located on engine  
control panel) for proper voltage.  
Revised: October 3, 2002  
Effective: April 23, 1999  
Form#: S–PSG–001–15  
D:\ISO9001\FORMS\MSW’98bbk  
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CONNECTION INFORMATION  
Your new Baldor Generator has all interconnecting wiring terminated at a junction box. All wiring will be  
clearly labeled as being load; remote start contacts and AC input terminals and are to be connected as  
described below.  
Load These connections are rated and sized according to the KW of the generator. Proper lead  
wire from these points to the automatic transfer switch (or load switching device) is mandatory.  
See enclosed transfer switch information for corresponding generator input terminals.  
Remote Start Contacts This twowire connection, once connected to an appropriate switch,  
will start the generator and perform as described in the remote start/stop literature. These  
contacts are connected to the Engine Start Contactsof the automatic transfer switch.  
A Two Pole normally open, closed to operate switch may also be used to start the generator.  
AC Input These connections are for units with float type battery chargers or engine block  
heater combinations. A Constant supply of 120 volts AC (or as specified) is needed at these  
terminals to power these devices.  
NOTE: Power is not required when the unit is in operation. Internal battery charging and radiant heat  
during operation eliminate the need for these devices.  
NOTE: It is recommended that units utilizing an automatic transfer switch with adjustable time delays  
have the initial adjustments made prior to startup.  
Factory recommendations are; allow a 2 second delay on startup, 15second delay on emergency to  
normal.  
Revised: March 20,2001  
Effective: April 23, 1999  
Form#: SPSG00119  
D:\ISO9001\FORMS\MSW98bbk  
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CONTROL PANEL OPERATION  
AND FUNCTION  
A. MASTER CONTROL SWITCH This switch controls the starting and stopping of the engine via  
the engine control logic circuitry.  
With this switch in the Manualmode, the engine will start and run immediately after a  
10 20 second time delay.  
CAUTION: Please note that once the engine has been told to start, the gen set  
should be treated as though it is operational, even though the start  
delay has not yet allowed the engine to crank.  
With this switch in the Automaticmode, the engine can be started and stopped from a remote  
contact. (Standard switch, transfer switch, etc.) There is a time delay, to cool down, of 6090  
seconds when the unit is shut down from the remote contacts while the Master Control Switch is in  
the Automatic Mode.  
With this switch in the Offposition, the engine will immediately stop. The position must also be  
utilized to clear fault shutdown conditions.  
B. PANEL LIGHTS By turning on the panel light switch, the panel lights will be energized and will  
illuminate the control panel. The fuse next to the switch is to protect this circuit from damage due to  
excessive current.  
C. FIELD AND CONTROLLER FUSES These fuses protect the internal workings of the generator  
set.  
D. GAUGES These gauges monitor some of the more critical operating parameters of the engine as  
well as the run time of the generator set.  
The Voltmeter displays the charging rate that is currently being produced by the engines alternator to  
facilitate the charging of the battery. This gauge should normally be above 12.5V whenever the unit is  
running. If you ever notice the gauge is reading below 12V while the engine is running please contact  
the service department at Baldor Generators.  
The Temperature Gauge monitors and displays the operating temperature of the engines coolant. The  
point at which a fault shutdown will occur is approximately 230°F.  
The Oil Pressure Gauge displays and monitors the current operating pressure of the engines oil  
system. The trip point at which a fault shutdown will occur is approximately 15 PSI or below.  
Fuel level is checked by the owner or is usually a separately supplied fuel tank.  
The Hour Meter accumulates and displays the total running time of the generator set.  
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E. VOLTAGE ADJUST The rheostat allows the user to fine tunethe generator sets voltage  
output. It is normally used to adjust output voltage after switching the output of the generator set to a  
different voltage.  
F. METERS These meters monitor and display the current operating parameters of the generator set.  
The Voltmeter monitors and displays the current operating AC output of the generator set.  
The Hertz Meter monitors and displays the current operating frequency of the generator set.  
The ammeter monitors and displays the amount of current that is being delivered by the generator set.  
This meter works in conjunction with the Voltmeter Switch (Item G) in determining which output leg  
to monitor.  
G. AMMETER SWITCH The switch allows the user to switch between L1, L2 and L3 to monitor the  
current in each output leg of the generator.  
H. PANEL LIGHT By turning on the panel light switch, the panel lights (Not pictured on diagram)  
will be energized and will illuminate the control panel.  
I SYSTEM FAULT INDICATORS These lights will come on when a fault condition or a warning  
condition develops.  
The Low Oil Pressurelight will come on when the engines oil pressure drops below 15 PSI. This  
condition will trigger a fault shutdown and the unit will stop.  
The Overcranklight will come on when the engine has failed to start after four attempted crank  
cycles. Each crank cycle consists of a 12 second time period followed by a 12 second rest time  
period.  
The Overspeedlight will come on when the engines operating speed rises above its normal  
operating parameters. This condition will trigger a fault shutdown and the engine will stop.  
High Temperature light will come on when the engines operating temperature exceeds the safety  
setpoint.  
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OPERATION PRESTART PROCEDURE  
1. Fill system fuel tank with clean, fresh diesel fuel.  
CAUTION: Wipe up any and all fuel spillage.  
2. Fill engine crankcase to full mark with clean, fresh lubricating oil per attached engine operating guide.  
3. Radiator coolant should be checked at the beginning of each day and filled in compliance with the engine  
manufacturers guidelines.  
4. Secure the generator for operation.  
Skid mounted the power generating system should be mounted to a smooth,  
hard surface suitable for supporting the system under all stress conditions.  
Trailer mounted block wheels to prevent accidental movement.  
Adequate clearance must be provided for access doors to fully open.  
NOTE: The generating system exhaust also exits radiator end. When  
positioning a generator system ensure position does not cause a  
concentration of toxic emissions.  
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OPERATION STARTING  
1. Conduct Prestart Procedures.  
2. Switch the generator set to the applicable voltage setting.  
3. Connect the load(s) to the circuit breaker.  
WARNING: High voltage is present when the generator set is running.  
4. Move the Master Control Switchto the appropriate position.  
5. Adjust the voltage if necessary by turning the voltage adjustment knob located on the control panel.  
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OPERATION  
The prime mover utilized in this power generating system is controlled via an engine control module.  
Starting is accomplished by commanding the control to startthe engine. This command can be  
given by a number of controls.  
? The operator control mounted on the front panel.  
? The remote controls via the transfer switch or remote start terminal closure.  
Initially, the system may be started and operated by placing the operator control in the manual/run”  
position. To cease operation, return the switch to the offposition.  
NOTE: Clear unit of all loose objects and perform all prestartprocedures before operating  
generator system.  
ENGINE CONTROL MODULE:  
The engine control module (ECM) is a microprocessorbased module that monitors the control and  
safety inputs and provides all the required START and STOP functions automatically.  
The following front panel controls and instruments are wired into the microprocessor through the  
ECM terminal blocks:  
1.  
RunOffAuto Switch  
a. * Run” – run position causes the generator set to start and run immediately.  
b. * Auto” – auto position allows unit to be controlled via any remote singlepole drycontact  
(transfer switch, etc.). Contact closure causes the unit to start and run, while contact opening causes  
unit to shut down after a preset cool down period.  
c. Off” – unit operation is terminated.  
* units equipped with Isuzu engines may have a time delay glow plug cycle before starting.  
Lamp Test  
2.  
Push button energizes all alarm lights simultaneously. This feature is disabled with the  
runstopauto switch in the stopposition, and has no other effect on unit operation.  
SAFETY INPUTS  
1. Low Oil Pressure Shutdown (LOP)  
Monitoring of oil pressure begins for a preset time after unit starts and remains in effect until  
unit is shut down (except as noted in loss of frequency inputbelow). The LOP signal is derived  
from an oil pressure switch gauge mounted on the control panel  
2. High Temperature Shutdown (HT)  
The engine temperature monitoring begins immediately with the start signal. However, if engine  
temperature is excessive prior to start (i.e., heat soak after shutdown), the unit is permitted to  
start.  
The high temperature condition is permitted to exist for up to 60 seconds after the unit is running  
before shutdown when alarm occurs. If the excessive temperature condition is corrected within  
that time period, the HT circuit reverts to normal monitoring. The HT signal is derived from a  
monitoring device located on the prime mover.  
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3. Overspeed Adjustment (OS) Over Frequency  
Overspeed protection is provided by a frequency sensing network within the controller. The trip  
point of the frequency network is adjustable via a rheostat located on the top of the controller at  
the right hand side. Clockwise (CW) rotation increases the trip frequency and, thereby, raises the  
shutdown speed.  
CRANKING CONTROL  
1. Overcrank Protection  
This feature provides a preset second crank cycle. Failure of the engine to start by the end of the  
crank period results in an Overcrankshutdown and alarm indication.  
2. Cranking Disconnect Adjustment (CDS Adjustment)  
The cranking disconnect signal is obtained by a frequency network within the controller. The trip  
point of the frequency network is not adjustable.  
LOSS OF FREQUENCY  
Internal protection against loss of frequency input to the cranking disconnect circuit is programmed in  
after the unit has started normally. In the event the frequency goes to zero (engine runs out of fuel,  
frequency signal source fails, etc.) the LOP shutdown circuit is bypassed and a 12second wait  
period is initiated. If frequency returns within this time period, LOP monitoring resumes and operation  
continues normally. If frequency has not returned at the end of this time period, the engine oil  
pressure status is observed to determine whether the engine is actually running or stopped. If the  
engine has stopped (i.e., air in fuel, etc.), the cranking cycle will begin in an effort to restart the  
engine. If the engine has not stopped (loss of input signal, etc.), the unit is shutdown with an  
Overcrankindication and alarm.  
WARNING:  
Overcrank indication can mean a loss of crankdisconnect signal during the  
previous run period. Attempting to restart the engine with no crankdisconnect signal can  
destroy the starter motor, which can cause serious personal injury.  
This is of particular note since the tendency is to pursue only cranking and start related faults. The  
cranking disconnect signal source is a key component in this system and must be checked out  
thoroughly whenever an Overcrankshutdown occurs.  
NOTE:  
The controller does not provide protection against loss of signal during startup. A  
shutdown with alarm, due to any of the above conditions, will prevent any subsequent  
operation of the generator set. The runstopauto selector switch on the control panel  
must be momentarily placed in the stop position to reset these functions.  
CAUTION: If a dead battery is suspected, remove controller fuse, charge battery (or replace), and  
then attempting starting. Damage to engine control may result from jump starting.  
17  
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TROUBLESHOOTING GENERATOR  
As with any machine, trouble may develop in electrical generators. It may be due to long service  
or neglect of regular maintenance. Servicing, and checking. Should trouble develop, the follow-  
ing instructions will be helpful in tracing the cause and making repairs.  
SPEED DEVIATIONS:  
The generator speed should be maintained at rated nameplate speed. The frequency and volt-  
age of the generator output depends on speed. If the generator runs slower than rated speed,  
the voltage will drop off.  
NO VOLTAGE  
CAUSE  
CHECK AND REMEDY  
Flash Field.  
Loss of residual magnetism in  
exciter field poles.  
Open in stator windings  
Check for continuity in windings. Return to factory  
for repair if open  
Open or short in rotating rectifiers.  
Short Circuited.  
Check rectifiers.  
Clear lead to restore voltage buildup.  
Open in alternator field  
Check for continuity and return rotor to factory for  
repair if field coils are open.  
Shorted exciter armature  
Check for short and replace if faulty.  
Test and repair  
Shorted leads between exciter  
armature and generator field.  
LOW VOLTAGE  
CAUSE  
CHECK AND REMEDY  
Excessive load.  
Reduce load. With 3 phase generators, the load on  
each leg should be as evenly balanced as possible  
and should not exceed the rated current on any leg.  
Low Speed.  
Line loss.  
Check engine for malfunction or system for over-  
load.  
Increase size of line lead wire.  
18  
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LOW VOLTAGE (Continued)  
CHECK AND REMEDY  
CAUSE  
High resistance connections–  
Connections will be warm or hot  
Make better connection electrically and  
mechanically.  
Shorted field.  
Test field coils for possible short by checking resist-  
ance with an ohmmeter or resistance bridge. Re-  
turn rotor assembly to factory for repair if alternator  
field coils are shorted.  
Low power factor  
Reduce inductive (motor) load. Some AC motors  
Draw approximately the same current regardless of  
load. Do not use motors of larger horsepower rating  
than is necessary to carry the mechanical load.  
FLUCTUATING VOLTAGE  
(May be indicated by flickering lights.)  
CAUSE  
CHECK AND REMEDY  
Irregular speed of engine.  
Fluctuating speed.  
Check engine for malfunction or load for fluctuation.  
Stabilize load. The addition of a lamp load (resist-  
ance load) may compensate partially for load  
changes caused by intermittent motor operation.  
Do not overload.  
Loose terminal or load connections.  
Make better connection mechanically and electri-  
cally.  
Defective bearing causing uneven air gap. Replace worn bearing.  
HIGH VOLTAGE  
CAUSE  
CHECK AND REMEDY  
Excessive speed.  
Check engine for malfunction.  
OVERHEATING  
CAUSE  
CHECK AND REMEDY  
Generator overloaded.  
Reduce load. (Check with ammeter and compare  
with nameplate rating.)  
Clogged ventilating screens.  
Clean air passages.  
19  
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OVERHEATING (continued)  
CHECK AND REMEDY  
Improve ventilation.  
CAUSE  
High room temperature.  
Insufficient circulation.  
Low power factory.  
Provide crossventilation.  
Reduce inductive loads or install power factor im-  
provement capacitors.  
Unbalanced load  
Dry bearing.  
The load on each leg should be as evenly balanced  
as possible and should not exceed the rated cur-  
rent on any leg.  
Replace bearing.  
MECHANICAL NOISE  
CAUSE  
CHECK AND REMEDY  
Replace bearing.  
Defective bearing.  
Rotor scrubbing on stator.  
Bad bearing; replace. Bent shaft, return to factory.  
Loosen end bell, tighten; loose drive discs, tighten.  
Loose laminations.  
Return to factory.  
Tighten or align.  
Loose or misaligned coupling.  
GENERATOR FRAME PRODUCES SHOCK WHEN TOUCHED  
CHECK AND REMEDY  
CAUSE  
Static charge.  
Ground generator frame.  
Grounded armature or field coil.  
Return to factory for repair.  
20  
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TROUBLESHOOTING ENGINE  
CODE LIST OF POSSIBLE CAUSES  
1. Battery capacity low.  
33. Piston rings not free or are worn or broken.  
2. Bad electrical connections.  
3. Fault in starter motor.  
4. Fault in starter motor.  
5. Wrong grade of lubricating oil.  
6. Low engine speed from starter motor.  
7. Stop control fault.  
34. Valve stems and/or guide worn.  
35.West type air cleaner too full or wrong oil used.  
36. Crankshaft bearings worn or damaged..  
37. Not enough lubricating oil in the pump.  
38. Gauge not correct.  
39. Lubricating oil pump worn.  
8. Restriction in fuel lift pipe.  
9. Fault in fuel lift pump.  
10. Dirty fuel filter element.  
40. Relief valve not free to close.  
41. Relief valve not free to open.  
42. Relief valve spring broken.  
11. Restriction in air filter or induction system.  
12. Air in fuel system.  
43. Fault in suction pipe of lubricating oil pump.  
44. Dirty lubricating oil filter element.  
45. Piston damaged.  
46. Piston height not correct.  
47. Fan damaged.  
48. Fault in engine mounting (housing).  
49. Flywheel housing or flywheel not aligned  
correctly.  
50. Fault in thermostat or wrong type.  
51. Restriction in coolant passages.  
52. Water pump drive belt loose.  
53. Restriction in radiator.  
54. Fault in water pump.  
55. Restriction in breather pipe.  
56. Damaged valve stem oil seals (where used).  
57. Not enough coolant in system.  
58. Restriction in sump strainer.  
13. Fault in fuel injection pump.  
14. Fault in atomizers or not correct type.  
15. Cold start equipment not used correctly.  
16. Fault in cold start equipment.  
17. Broken fuel injection pump drive.  
18. Fuel injection pump timing not correct.  
19. Valve timing not correct.  
20. Bad compression.  
21. restriction in fuel tank vent.  
22. Type or grade of fuel not correct.  
23. Restriction of engine speed control movement.  
24. Restriction in exhaust pipe.  
25. Cylinder head gasket leaks.  
26. Engine temperature too high.  
27. Engine temperature too low.  
28. Valve tip clearances not correct.  
29. Valves not free.  
59. Valve spring broken.  
60. Fault in exhaust or vacuum pipe leakage.  
61. Turbo charger impeller damage, or dirty impeller.  
62. Turbo charger lubricating oil seal leaks.  
63. Induction system leaks (turbo charged engines.)  
30. Wrong high pressure pipes.  
31. Worn cylinder bores.  
32. Valves and seats do not seal correctly.  
21  
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22  
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MAGNAPLUS GENERATOR  
280 -- 430 Frame  
Installation, Operation and Maintenance  
Manual  
Marathon Electric  
A Subsidiary of Regal-Beloit Corp.  
100 East Randolph Street  
P.O. Box 8003  
Wausau, WI 54402-8003  
Phone: (715) 675 3311  
Fax:  
(715) 675 6361  
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TABLE OF CONTENTS  
SAFETY ..............................................................................................................................................................................................4  
RECEIVING AND STORAGE .........................................................................................................................................................4  
UNPACKING AND HANDLING ...................................................................................................................................................4  
STORAGE........................................................................................................................................................................................4  
PRINCIPLES OF OPERATION ......................................................................................................................................................5  
FIGURE 1 -- MAGNAPLUS CIRCUIT DIAGRAM ...............................................................................................................................5  
FIGURE 2 -- TYPICAL MAGNAPLUS LAYOUT DIAGRAM.................................................................................................................5  
VOLTAGE REGULATION .....................................................................................................................................................................6  
MOTOR STARTING.......................................................................................................................................................................6  
PARALLEL OPERATION ..............................................................................................................................................................6  
NONLINEAR LOADING................................................................................................................................................................6  
INSTALLATION................................................................................................................................................................................6  
PREPARATION FOR USE .............................................................................................................................................................6  
GENERATOR MOUNTING ...........................................................................................................................................................7  
Single Bearing Units. ...................................................................................................................................................................7  
Two Bearing Generators -- Direct Drive .....................................................................................................................................7  
Two Bearing Units -- Belt Driven.................................................................................................................................................7  
END PLAY TESTING.....................................................................................................................................................................7  
TORSIONAL VIBRATION.............................................................................................................................................................7  
ENVIRONMENTAL CONSIDERATIONS.....................................................................................................................................8  
WIRING CONNECTIONS................................................................................................................................................................8  
OPERATION....................................................................................................................................................................................11  
PRE-START INSPECTION ..........................................................................................................................................................11  
START-UP.....................................................................................................................................................................................11  
SHUTDOWN PROCEDURE.........................................................................................................................................................12  
MAINTENANCE .............................................................................................................................................................................12  
DRYING WINDINGS ...................................................................................................................................................................13  
Space Heaters.............................................................................................................................................................................13  
Forced Air ..................................................................................................................................................................................13  
TESTING ..........................................................................................................................................................................................13  
VISUAL INSPECTION ........................................................................................................................................................................13  
CONSTANT EXCITATION TEST .........................................................................................................................................................13  
CONTINUITY / RESISTANCE TEST.....................................................................................................................................................13  
INSULATION TEST............................................................................................................................................................................14  
DIODE TESTING..........................................................................................................................................................................14  
SERVICE ..........................................................................................................................................................................................14  
GENERAL .....................................................................................................................................................................................14  
FIELD FLASHING ........................................................................................................................................................................14  
BEARING REMOVAL ........................................................................................................................................................................15  
Opposite Drive End Bearing Bracket Removal..........................................................................................................................15  
Drive End Bearing Bracket Removal, ........................................................................................................................................15  
Two Bearing Units......................................................................................................................................................................15  
BEARING REPLACEMENT ........................................................................................................................................................15  
RECTIFIER ASSEMBLY REMOVAL ....................................................................................................................................................15  
DIODE REPLACEMENT .....................................................................................................................................................................15  
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RETURNED GOODS ......................................................................................................................................................................16  
TROUBLESHOOTING...................................................................................................................................................................16  
GENERATOR PRODUCES NO VOLTAGE................................................................................................................................17  
GENERATOR PRODUCES LOW VOLTAGE, NO LOAD.........................................................................................................17  
GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD APPLIED ..................................................................................18  
GENERATOR PRODUCES FLUCTUATING VOLTAGE..........................................................................................................18  
GENERATOR PRODUCES HIGH VOLTAGE............................................................................................................................18  
GENERATOR BUILDS VOLTAGE FROM STARTUP, THEN GOES TO LOW (RESIDUAL) VOLTAGE...........................19  
GENERATOR IS OVERHEATING..............................................................................................................................................19  
GENERATOR PRODUCES MECHANICAL NOISE ..................................................................................................................19  
EQUIPMENT RUNS NORMALLY ON UTILITY POWER, BUT WILL NOT RUN ON GENERATOR.................................19  
SPECIFICATIONS ..........................................................................................................................................................................20  
PARTS LIST – SINGLE BEARING...............................................................................................................................................21  
Typical Generator Cross Section ...............................................................................................................................................21  
PARTS LIST – DUAL BEARING ..................................................................................................................................................22  
Typical Generator Cross Section ...............................................................................................................................................22  
3
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When in doubt, ask. Questions are much easier to handle  
than mistakes caused by a misunderstanding of the  
information presented in this manual.  
SAFETY  
PLEASE REMEMBER SAFETY FIRST. If you are not sure  
of the instructions or procedures contained herein, seek  
qualified help before continuing.  
RECEIVING AND STORAGE  
This service manual emphasizes the safety precautions  
necessary during the installation, operation, and  
maintenance of your MagnaPLUS generator. Each section  
of this manual has caution and warning messages. These  
messages are for your safety, and the safety of the  
equipment involved. If any of these cautions or warnings is  
not readily understood, seek clarification from qualified  
personnel before proceeding.  
RECEIVING AND STORAGE  
Upon receipt of the generator, it is recommended that it be  
carefully examined for possible shipping damage. The  
generator was given to the freight carrier in good condition;  
thus, the carrier is responsible for the product from the  
factory dock to the destination. Any damage should be  
noted on the freight bill before accepting the shipment. Any  
claims for damage must be promptly filed with the delivering  
carrier.  
Before any service work is done, disconnect all power  
sources and lock out all controls to prevent an unexpected  
start-up of the generator set driver. Proper grounding  
(earthing) of the generator frame and distribution system in  
compliance with local and national electrical codes and  
specific site requirements must be provided. These safety  
precautions are necessary to prevent potential serious  
personal injury, or even death.  
UNPACKING AND HANDLING  
Carefully read all instruction tags shipped with the unit.  
When lifting, attach an overhead crane to the lifting lug(s) on  
the generator frame. Apply lifting forces in a vertical  
direction. When transporting single bearing generators, the  
generator’s rotor must be adequately supported to prevent  
damage.  
The hazards associated with lifting or moving your  
MagnaPLUS generator are pointed out in the installation and  
maintenance sections. Incorrect lifting or moving can result  
in personal injury or damage to the unit.  
Prior to start-up of the unit ensure that all generator leads  
are properly connected to the generator link board located  
inside the connection box. Always assume that there will be  
voltage present at the generator terminals whenever the  
generator's shaft is rotating, and proceed accordingly.  
Residual voltage is present at the generator terminals and at  
the automatic voltage regulator panel connections even with  
the regulator fuse removed. Caution must be exercised, or  
serious injury or death can result.  
WARNING  
THE LIFTING LUG (S) ON THE GENERATOR ARE  
DESIGNED TO SUPPORT THE GENERATOR ONLY.  
DO NOT LIFT A COMPLETE GENERATOR AND  
DRIVER ASSEMBLY BY MEANS OF LIFTING LUG (S)  
ON THE GENERATOR. PERSONAL INJURY OR  
EQUIPMENT DAMAGE MAY RESULT.  
This manual is not intended to be a substitute for properly  
trained personnel. Installation and repairs should only be  
attempted by qualified, trained people. The cautions and  
warnings point out known conditions and situations that are  
potentially hazardous. Each installation may well create its  
own set of hazards  
STORAGE  
In the event that the generator is not immediately installed  
on its prime mover, it is recommended that the unit be stored  
indoors in a clean, dry area, which is not subject to rapid  
changes in temperature and humidity. If the generator is  
stored for a long period of time, the generator should be  
tested, cleaned and dried as required before being put into  
service. See the maintenance section of this manual for  
further information. If the unit has been stored in an area  
where it has been subject to vibration, it is recommended  
that the bearing(s) be inspected and replaced as necessary.  
4
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PRINCIPLES OF OPERATION  
PMG (optional)  
Rotating Assembly  
PMG Field  
(rotor)  
Exciter Field  
(stator)  
Exciter Armature  
Main Field  
(rotor)  
Main Armature  
(stator)  
L1  
L2  
L3  
(rotor)  
N
S
(+)  
(+)  
DC  
(in)  
DC  
(in)  
(-)  
(-)  
3 Phase AC (out)  
3 Phase AC (out)  
PMG  
Armature  
(stator)  
Rotating Rectifier Assembly  
3 Phase -- Full Bridge  
Exciter Field Power  
(DC out)  
Input Power -- Single Phase  
(shunt powered regulator)  
Automatic  
Voltage  
Regulator  
PMG Input Power (optional)  
(1 phase, 300/250 hertz)  
Sensing Input -- Single Phase  
3 phase (optional)  
FIGURE 1 -- MagnaPLUS Circuit Diagram  
FIGURE 2 -- Typical MagnaPLUS Layout Diagram  
5
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generators generally supply .3 to .4 horsepower per  
generator kW in motor starting capability. For specific data  
contact Marathon Electric.  
PRINCIPLE OF OPERATION  
MagnaPLUS generators are a brushless, self excited, and  
externally voltage regulated, synchronous AC generator.  
The generator is made up of six major components: main  
stator (armature), main rotor (field), exciter stator (field),  
exciter rotor (armature), rectifier assembly, and voltage  
regulator. In understanding the above terminology, note the  
following: stators are stationary, rotors rotate, a field is an  
electrical input, and an armature is an electrical output.  
These system components are electrically interconnected as  
shown in figure 1 and physically located as shown in  
figure 2.  
PARALLEL OPERATION  
All MagnaPlus generators are built with 2/3 pitch main stator  
windings and full amortisseur (damper) windings. These  
features make the MagnaPlus generators suitable for parallel  
operation when equipped with the proper voltage regulators  
and voltage regulator accessories. Consult with the factory  
for further information relative to parallel operations.  
The generator’s exciter consists of a stationary field and a  
rotating armature. The stationary field (exciter stator) is  
designed to be the primary source of the generator’s residual  
magnetism. This residual magnetism allows the exciter rotor  
(armature) to produce AC voltage even when the exciter  
stator (field) is not powered. This AC voltage is rectified to  
DC by the rotating rectifier assembly and fed directly to the  
main rotor (field). As the generator shaft continues to rotate,  
the main rotor (field) induces a voltage into the generator's  
main stator (armature). At rated speed, the main stator’s  
voltage produced by the residual magnetism of the exciter  
allows the automatic voltage regulator to function. The  
regulator provides voltage to the exciter resulting in a build-  
up of generator terminal voltage. This system of using  
residual magnetism eliminates the need for a special field  
flashing circuit in the regulator. After the generator has  
established the initial residual voltage, the regulator provides  
a controlled DC field voltage to the exciter stator resulting in  
a controlled generator terminal voltage.  
NONLINEAR LOADING  
Solid state electronic control devices (variable frequency  
drives, precision motor controls, battery chargers, etc.) utilize  
electronic switching circuits (thyristors, SCRs, Diodes, etc.).  
These switching circuits introduce high frequency harmonics,  
which distort the normal waveform of the generator. This  
creates additional heat in the generator windings and may  
cause the generator to over-heat. Problems that can occur  
are not limited to the generator. Poor wave shape may  
adversely effect various loads connected to the generator.  
Consult Marathon Electric for further information relative to  
nonlinear loads.  
INSTALLATION  
Voltage Regulation  
PREPARATION FOR USE  
In the standard configuration (shunt excited), the automatic  
voltage regulator receives both its input power and voltage  
sensing from the generator's output terminals (See Figure 1).  
With the optional PMG configuration, the regulator receives  
input power from the PMG. The regulator automatically  
monitors the generator's output voltage against an internal  
reference set point and provides the necessary DC output  
voltage to the exciter field required to maintain constant  
Although the generator has been carefully inspected and  
tested in operation prior to shipment from the factory, it is  
recommended that the generator be thoroughly inspected.  
Check all bolts for tightness and examine the insulation on  
lead wires for chafing prior to proceeding with installation.  
Remove all shipping tapes, bags, skids and rotor support  
blocking. For two bearing units, rotate the shaft by hand to  
ensure that it rotates smoothly without binding.  
generator terminal voltage.  
Adjusting the regulator's  
reference set point changes the generator's terminal voltage.  
Consult the regulator manual for specific adjustment and  
operating instructions.  
MOTOR STARTING  
When a motor is started, the motor draws a large surge of  
current. This starting current is equivalent to the motors  
locked rotor or stall current and is 5 to 10 times' normal full  
load current. When the generator supplies this in-rush of  
starting current, the generator voltage dips temporarily. If  
the motor is too large for the generator, the generator’s  
voltage dips greater than 30 percent. This may result in the  
motor starter de-energizing or the motor stalling. MagnaPlus  
6
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driver and the generator's shaft. Aligning the generator and  
its driver as accurately as possible will reduce vibration,  
increases bearing life, and ensure minimum coupling wear.  
It may be necessary to shim the generator feet for proper  
support and alignment. Secure the feet of the generator with  
grade 5 or greater bolts through the holes provided in the  
WARNING  
DISABLE AND LOCKOUT ANY ENGINE CRANKING  
DEVICES BEFORE ATTEMPTING TO INSTALL OR  
SERVICE THE GENERATOR.  
START SETS, DISCONNECT THE CRANKING  
BATTERY. FOR AIR START, DISCONNECT THE AIR  
SUPPLY. FOR MOTOR GENERATOR SETS, OPEN  
THE POWER SUPPLY TO THE DRIVE MOTOR.  
FAILURE TO COMPLY WITH THESE SAFETY  
PROCEDURES COULD RESULT IN SEVERE  
PERSONAL INJURY OR EQUIPMENT DAMAGE.  
FOR ELECTRIC  
mounting feet.  
Consult the coupling manufacturer's  
instructions for alignment specifications and procedures.  
GENERATOR MOUNTING  
Two Bearing Units -- Belt Driven  
Two bearing MagnaPLUS generators can be belt driven  
provided belts are sized and applied correctly. Please refer  
to your supplier of belts and sheaves for correct sizing and  
tensioning specifications. A bearing life calculation should  
be performed. Marathon Electric recommends a minimum  
B-10 life of 40,000 hours. If cog type belts are used, a  
vibration may be introduced which could lead to premature  
failure of the bearings.  
NEVER "BAR OVER" THE ENGINE GENERATOR  
SET USING THE GENERATOR'S FAN. THE FAN IS  
NOT DESIGNED FOR THIS PURPOSE. BARRING  
OVER THE SET WITH THE FAN COULD DAMAGE  
THE FAN AND RESULT IN PERSONAL INJURY OR  
EQUIPMENT DAMAGE.  
GENERATOR MOUNTING  
Single Bearing Units.  
END PLAY TESTING  
Refer to the engine manual for recommended endplay  
specifications and measurement procedures. If endplay is  
not to specification, it is an indication that the generator shaft  
is not moving freely in the assembly, and normal life of the  
thrust bearing could be impaired. Probable causes of this  
problem are:  
Single bearing units are provided with an SAE flywheel  
housing adapter flange and flexible drive discs. Coupling the  
generator's shaft to the engine flywheel is accomplished with  
special steel drive discs bolted to the shaft. In addition to the  
drive discs, there may be a hub spacer, spacer discs, or a  
combination of hub spacer and spacer discs inserted  
between the drive discs and the shaft to achieve the proper  
shaft extension ("G" dimension per SAE J620c). Holes are  
provided in the periphery of the coupling discs, which  
correspond to tapped holes in the prime mover's flywheel.  
The outside diameter of the drive discs fit in a rabbet in the  
flywheel so that concentricity is assured.  
1. Improper seating of drive discs in the flywheel resulting in  
misalignment.  
2. Improper mating of generator frame to engine flywheel  
housing resulting in misalignment.  
3. Improper "G" dimension per SAE J620c on either the  
Grade  
8
place bolts and hardened washers are  
engine or generator.  
recommended to mount the drive discs to the flywheel. DO  
NOT USE SPLIT TYPE LOCK WASHERS. Split lock  
washers when biting into the drive disc cause stress risers,  
which may result in the disc fracturing.  
TORSIONAL VIBRATION  
The SAE flywheel housing adapter ring and the engine  
flywheel housing are designed to match each other with no  
further alignment necessary.  
Torsional vibrations are generated in all rotating shaft  
systems. In some cases, the amplitude of these vibrations  
at critical speeds may cause damage to the generator, its  
driver, or both. It is therefore necessary to examine the  
torsional vibration effect on the entire rotating system. IT IS  
THE RESPONSIBILITY OF THE GENERATOR SET  
Use grade 5 or greater  
mounting bolts. MagnaPLUS generator frames are  
constructed with two or three boltholes per foot. The feet  
should be shimmed where necessary to obtain solid contact  
with the sub-base. With the frame securely bolted to the  
engine flywheel housing, there is no side thrust or pull on the  
generator frame, thus no real need to secure the feet with  
more than one bolt per foot.  
ASSEMBLER  
TO  
ASSURE  
THE  
TORSIONAL  
COMPATIBILITY OF THE GENERATOR AND ITS DRIVER.  
Drawings showing pertinent dimensions and weights of the  
rotating assembly will be supplied by Marathon Electric upon  
request.  
GENERATOR MOUNTING  
Two Bearing Generators -- Direct Drive  
Two bearing generators are provided with a keyed shaft  
extension.  
For direct drive generators, the assembler  
furnishes a flexible coupling, which is installed between the  
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with the conduit. To minimize the transmission of vibration, it  
is essential that flexible conduit be used for all electrical  
entrance to the generator conduit box.  
ENVIRONMENTAL  
CONSIDERATIONS  
All MagnaPLUS generators are equipped with link boards  
(terminal strips) for both internal and external connections.  
All connections made to the studs of the link board should be  
made with high quality ring terminals. Ring terminal sizes  
are 6 mm (280 Series Frames) and 10 mm (360 and 430  
Series Frames). Torque link board connections to the  
following specifications: 280 frame -- 5.4 NM (4 Ft LB); 360 &  
430 frame -- 27 NM (20 Ft LB).  
The MagnaPLUS generator is designed for heavy-duty  
industrial applications; however, dirt, moisture, heat and  
vibrations are enemies of rotating electrical machinery.  
Excessive exposure to the elements may shorten generator  
life. The temperature of the cooling air entering the intake  
openings of the generator should not exceed the ambient  
temperature shown on the generator’s nameplate.  
Generators intended for outdoor application should be  
protected with housings having adequate ventilation.  
Although the standard insulation systems are moisture and  
humidity resistant, space heaters are recommended for  
extreme conditions. If the generator is to be installed in an  
area where blowing sand and dust are present, the  
enclosure should be fitted with filters. Filters reduce erosion  
on the generator's insulation by blocking high velocity  
abrasive particles generated by the flow of cooling air  
through the generator. Consult the factory for appropriate  
filters and generator deratings required.  
Refer to the connection diagram supplied with the generator  
and / or the proper diagrams shown in this manual. Install all  
inter-component and external wiring in accordance with  
national and local electrical codes. The neutral in the  
following connection diagrams shown below may be either  
grounded (earthed) or left above ground potential (floating).  
See national and local codes and / or the system distribution  
wiring schematic diagram for the proper connection of the  
neutral.  
The following connection diagrams are shown for twelve  
lead generators. Ten lead generators have the same  
terminal designations except for leads T10, T11, and  
T12. These three leads are internally connected inside  
the generator and brought out as a single lead (T0). Ten  
lead generators can only be connected in a wye  
configuration  
WIRING CONNECTIONS  
Wiring of the generator and accessories should be  
done in accordance with good electrical practices.  
Follow government, industry and association  
standards.  
The generator conduit box construction allows cable entry  
from multiple sides. A hole saw or other appropriate tool  
may be used to provide for conduit entrance. Protect the  
interior of the generator from shavings when drilling or  
sawing. An approved connector must be used in conjunction  
HIGH WYE CONNECTION  
L1  
T1  
VOLTAGE (HIGH WYE)  
Hz  
60  
L-L  
480  
460  
440  
416  
380  
416  
400  
380  
L-N  
277  
266  
254  
240  
219  
240  
231  
219  
T4  
T7  
L - L  
T10  
T11  
T12  
50  
T9  
T6  
T8  
T3  
L3  
T5  
T2  
L2  
L - N  
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LOW WYE CONNECTION  
L1  
T7  
T1  
T4  
VOLTAGE (LOW WYE)  
Hz  
L-L  
240  
230  
220  
208  
190  
208  
200  
190  
L-N  
139  
133  
127  
120  
110  
120  
115  
110  
60  
L - L  
T10  
T12  
T5  
T9  
L3  
T2  
T6 T11  
50  
L2  
T3  
T8  
L - N  
HIGH DELTA CONNECTION  
L1  
T12  
T1  
T4  
`
VOLTAGE (HIGH DELTA)  
T9  
Hz  
L-L  
277  
240  
240  
220  
200  
L-N  
139  
120  
120  
110  
100  
L - L  
T6  
60  
50  
T7  
T3  
L3  
T10  
L2  
T11  
T8  
T5  
L - N  
T2  
LOW DELTA CONNECTION  
L1  
T12  
T1  
VOLTAGE (LOW DELTA)  
L - L  
Hz  
L-L  
120  
110  
110  
100  
L-N  
NA  
NA  
NA  
NA  
T6 T7  
60  
T9  
T4  
T3  
T11  
T10  
50  
T8  
L3  
L2  
T5  
T2  
L - L  
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DOUBLE DELTA -- SINGLE PHASE CONNECTION  
T3  
T11  
T5  
T9  
VOLTAGE (DOUBLE DELTA)  
Hz  
60  
L-L  
240  
220  
220  
L-N  
120  
110  
110  
T6  
T8  
T2  
T4  
T12  
T7  
50  
L2  
L1  
T1  
T10  
L - N  
L - N  
Note: Single-phase KW/KVA ratings are approximately  
equal to 50% of the generator’s three phase ratings.  
L - L  
LOW ZIG ZAG -- SINGLE PHASE CONNECTION  
T6  
T2  
VOLTAGE (LOW ZIGZAG)  
Hz  
60  
L-L  
240  
220  
220  
200  
L-N  
120  
110  
110  
100  
T12 T8  
T3  
T5  
T9  
T11  
50  
T4  
T1  
T7  
L2  
T10  
L1  
Note: Single-phase KW/KVA ratings are approximately  
equal to 50% of the generator’s three phase ratings.  
L - N  
L - N  
L - L  
HIGH ZIG ZAG -- SINGLE PHASE CONNECTION  
T12  
T1  
T4  
T9  
VOLTAGE (HIGH ZIGZAG)  
T6  
Hz  
60  
L-L  
480  
460  
415  
380  
L-N  
240  
220  
208  
190  
T7  
T3  
L2  
T10 T11  
T8 T5  
T2  
50  
L1  
L - N  
L - N  
Note: Single-phase KW/KVA ratings are approximately  
equal to 50% of the generator’s three phase ratings.  
L - L  
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DEDICATED SINGLE PHASE CONNECTION  
VOLTAGE (DEDICATED)  
Hz  
60  
L-L  
240  
220  
220  
200  
L-N  
120  
110  
110  
100  
L1  
L2  
T1  
T2  
T3  
T4  
L - N  
L - N  
50  
L - L  
8. Review all prime mover prestart-up instructions, and  
ensure that all recommended steps and procedures  
have been followed.  
OPERATION  
9. Remove any masking materials affixed during painting.  
Inspect the generator, prime mover, and any accessory  
equipment to ensure that nameplates, and all safety  
warning / caution signs and decals provided with the  
equipment are in place and clearly visible.  
PRE-START INSPECTION  
Before starting the generator for the first time, the following  
inspection checks are recommended:  
1. A visual inspection should be made for any loose parts,  
Note: It is strongly recommended that the authority  
having jurisdiction over the installation site be  
consulted to determine if any additional warning or  
caution notices, or additional safety devices are  
required by local codes / standards. Any such  
required notices or devices should be installed prior  
to initial startup.  
bad connections, or foreign materials.  
2. Bar the set over by hand for at least 2 revolutions to be  
sure that there is no interference and that the set turns  
freely. If the set does not turn freely, check for  
clearance in the generator and exciter air gap.  
3. Check all wiring against the proper connection  
diagrams, and ensure that all connections and  
terminations are tight and properly insulated.  
START-UP  
WARNING  
The following procedure should be followed when starting  
the generator set for the first time.  
MAGNAPLUS GENERATORS MAY HAVE VOLTAGE  
PRESENT AT THE LEAD TERMINALS WHEN THE  
1. The generator output must be disconnected from the  
load. Be sure that the main circuit breaker or fused  
disconnect is in the open position.  
SHAFT IS ROTATING.  
DO NOT PERMIT  
OPERATION OF THE GENERATOR UNTIL ALL  
LEADS HAVE BEEN CONNECTED AND INSULATED.  
FAILURE TO DO THIS MAY RESULT IN PERSONAL  
INJURY OR EQUIPMENT DAMAGE  
2. Open the input power to the automatic voltage regulator.  
Remove the fuse or disconnect and insulate one of the  
regulator input power leads. (See separate regulator  
manual)  
4. Verify that all equipment is properly grounded (earthed).  
3. Verify that all prime mover start-up procedures have  
been followed.  
5. Clear the surrounding area of any materials that could  
be drawn into the generator.  
4. If the unit is provided with space heaters, ensure that  
they are de-energized. In some installations, a set of  
auxiliary contacts on the main circuit breaker or transfer  
switch will automatically open the space heater circuit  
when the generator is connected to the load.  
6. Check all fasteners for tightness.  
7. Check all access plates, covers, screens and guards. If  
they have been removed for assembly or inspection,  
reinstall and check for security.  
5. Start the prime mover, and adjust it for proper speed.  
See generator nameplate.  
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6. The purpose of this initial test with the regulator out of  
the circuit is to detect any wiring mistakes without  
exposing the unit to undue risk. Check all line to line  
and line to neutral voltages for balanced voltage. If  
voltages are balanced shut down the set and reconnect  
the regulator. If voltages are unbalanced, shut down the  
equipment and check for improper wiring. If the problem  
persists, consult the factory.  
3. If the unit is equipped with space heaters, verify that the  
heater circuit is energized.  
MAINTENANCE  
The following maintenance procedures should be followed to  
ensure long equipment life and satisfactory performance.  
Maintenance intervals will depend upon operating conditions.  
With the regulator de-energized, the residual voltage  
should be 10 - 25% of rated value. It is recommended  
that this residual voltage and driver RPM be recorded for  
use as a future troubleshooting benchmark.  
1. Routinely check intake and exhaust air screens to  
ensure that they are clean and free of debris. Clogged  
intake air screens will reduce cooling airflow and result  
in higher operating temperatures. This will reduce  
generator life and may result in generator damage.  
WARNING  
QUALIFIED ELECTRICAL PERSONNEL MUST  
2. All MagnaPLUS generators are equipped with double  
shielded ball bearings lubricated for the life of the  
bearing. Every 1,000 hours check the bearing(s) for  
CONDUCT THE FOLLOWING TEST.  
VOLTAGE MAY BE PRESENT AT BOTH THE  
GENERATOR AND VOLTAGE REGULATOR  
LETHAL  
smooth, quiet operation.  
For continuous duty  
generators, recommended practice is to replace the  
bearing during major overhauls of the engine.  
TERMINALS DURING THIS PROCEDURE. CAUTION  
MUST BE EXERCISED NOT TO COME INTO  
PERSONAL CONTACT WITH LIVE TERMINALS,  
LINKS, OR STUDS. SERIOUS INJURY OR DEATH  
COULD RESULT.  
3. Periodically inspect the unit for any buildup of  
contamination (dirt, oil, etc.) on the windings. If the  
wound components have become coated with heavy  
concentrations of oil and grime, the unit should be  
disassembled and thoroughly cleaned. This operation is  
not one that can be accomplished effectively on site, but  
rather one that should be conducted by an authorized  
service center equipped with the appropriate apparatus  
and solvents necessary to properly clean and dry the  
generator.  
7. Start the set and adjust the terminal voltage to the  
desired value by means of the regulator voltage  
adjustment. If the regulator is equipped with a stability  
adjustment, follow the instructions in the regulator  
manual to adjust the stability. Again, check all line to  
line and line to neutral voltages for balance. It is  
recommended practice to record the no load excitation  
(DC voltage to the exciter stator), generator terminal  
voltage, and driver speed as a benchmark for future  
troubleshooting.  
WARNING  
QUALIFIED ELECTRICAL PERSONNEL MUST  
CONDUCT THE FOLLOWING TEST.  
VOLTAGE MAY BE PRESENT AT BOTH THE  
GENERATOR AND VOLTAGE REGULATOR  
LETHAL  
8. Close the main circuit breaker to the load.  
9. Monitor the generator output current to verify that it is at  
TERMINALS DURING THIS PROCEDURE. CAUTION  
MUST BE EXERCISED NOT TO COME INTO  
PERSONAL CONTACT WITH LIVE TERMINALS,  
LINKS, OR STUDS. SERIOUS INJURY OR DEATH  
COULD RESULT.  
or below nameplate value.  
10. Check generator speed (frequency) under load. Adjust  
as necessary. (Refer to prime mover or governor  
manuals)  
SHUTDOWN PROCEDURE  
4. Every 2,000 operating hours or in conjunction with  
scheduled engine maintenance check the DC no load  
excitation voltage per item #7 in the startup procedure.  
Compare this voltage with the value recorded during  
initial startup. If this value of no load excitation voltage  
is markedly higher than the benchmark reading, it is an  
indication of problems in the exciter, main field, or the  
rotating rectifier assembly. Ensure that RPM is the  
same as initial test.  
There are no specific instructions for shutting down the  
generator; however, several good practices should be  
observed to prolong equipment life.  
1. It is advisable to disconnect all loads (open main circuit  
breaker or disconnect) prior to shutdown. This is  
especially important if loads can be damaged by low  
voltage or low frequency conditions during generator  
"coast down".  
5. Monitor and record insulation resistance with a 500 volt  
mega-ohm meter. The minimum acceptable reading is  
2 mega-ohms. If the reading drops below the minimum,  
the generator should be cleaned and dried at an  
authorized service shop. Consult Marathon Electric for  
more information.  
2. Isolate all conditions that could apply voltage to the  
generator terminals while the generator is at rest.  
Failure to comply could result in personnel injury or  
equipment damage.  
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DRYING WINDINGS  
Generators in service may inadvertently have their windings  
exposed to splashing or sprayed water. Units that have  
been in transit or storage for long periods of time may be  
subjected to extreme temperature and moisture changes  
causing excessive condensation. Regardless of the source  
of moisture, wet windings should be thoroughly dried out  
before operating the unit. If this precaution is not taken,  
serious damage to the generator can result. The following  
procedures may be utilized in drying the generator’s  
windings. Winding wetness and situation limitations will  
influence the method selected.  
WARNING  
QUALIFIED ELECTRICAL PERSONNEL MUST  
CONDUCT THE FOLLOWING TEST.  
VOLTAGE MAY BE PRESENT AT BOTH THE  
GENERATOR AND VOLTAGE REGULATOR  
TERMINALS DURING THIS PROCEDURE. CAUTION  
MUST BE EXERCISED NOT TO COME INTO  
PERSONAL CONTACT WITH LIVE TERMINALS,  
LINKS, OR STUDS. SERIOUS INJURY OR DEATH  
COULD RESULT.  
LETHAL  
Space Heaters  
An electric heater may have been supplied with the  
generator. When energized from a power source other than  
the generator, the heater will gradually dry the generator.  
Enclosing the unit with covering and inserting additional  
heating units can accelerate this process. A hole should be  
left at the top of the covering to permit the escape of  
moisture. Care should be taken not to overheat various  
accessory equipment mounted with the generator.  
Constant Excitation Test  
(12V BATTERY TEST)  
The generator “no load” voltage is dependent on exciter  
input voltage and generator speed. With the generator  
operating at rated speed and 12 volts dc applied to the  
exciter field, the generators terminal voltage will be near  
rated value.  
Forced Air  
Another method to dry the generator is to run the set with no  
excitation (see startup procedure item #2). The natural flow  
of ambient air through the generator will tend to dry the  
windings. This method can be accelerated by adding a  
source of heat at the air intake to the generator. Heat at  
1. Shutdown the generator set and connect a voltmeter on  
the generator terminals.  
°
point of entry should not exceed 80 C (180 F).  
2. Disconnect the regulator’s F+ (F1) and F- (F2) leads  
and connect them to a 12V battery. Caution should be  
taken to ensure that the battery is not exposed to any  
potential arcing.  
TESTING  
3. With no load on the generator (main breaker open) run  
the generator at rated speed. Measure the generator’s  
terminal voltage and compare this value with values  
recorded during installation.  
Visual Inspection  
If voltage readings are normal, the main generator and  
excitation are operating properly. Troubleshooting should  
continue with the regulator. If readings are not normal the  
problem is in the generator. Continue testing diodes, surge  
suppressor, and windings.  
Remove covers and look for any obvious problems: burnt  
windings, loose connections, broken wires, frayed insulation,  
cracked brackets, missing hardware, etc. Check for foreign  
objects that may have been drawn into the generator. Verify  
that the generator’s air gaps (main rotor and exciter) are free  
from obstructions. If possible, rotate the generator manually  
to ensure free rotation. Never “bar over” the engine  
generator set using the generator fan.  
Continuity / Resistance Test  
The generator has four components that can be checked  
using an ohmmeter: exciter stator, exciter rotor, main stator  
and main rotor. Each of these components is comprised of  
various windings that form a complete electrical path of  
relatively low resistance. Using an ohm meter measure the  
loop resistance of each component.  
Compare these  
measured values with the values listed in the specification  
section of this manual. Note that very small resistance  
values require precision equipment to make accurate  
measurements; however, a standard ohmmeter will provide  
a good indication of winding continuity.  
13  
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When the positive test probe is connected to the diode's  
anode and the negative test probe is connected to the  
diode's cathode (forward biased), the diode will switch on  
and conduct electricity (figure 3). This is observed by a low  
resistance reading when using an ohm meter or the lighting  
of the bulb when using a battery light continuity tester.  
Reversing the test leads (reverse biased) will result in the  
diode switching off and no electricity will be conducted. The  
results of these tests should indicate one of three conditions:  
Insulation Test  
Insulation resistance is a measure of the integrity of the  
insulating materials that separate the electrical windings  
from the generator’s steel core. This resistance can degrade  
over time or be degraded by contaminants: dust, dirt, oil,  
grease, and especially moisture. Most winding failures are  
due to a breakdown in the insulation system. In many cases,  
low insulation resistance is caused by moisture collected  
when the generator is shutdown  
1. Good diode: Will have a much greater resistance in  
one direction than the other. Typical reverse biased  
resistance will be 30,000 ohms or greater, while forward  
biased resistance will be less than 10 ohms. The  
battery-light tester will have the light "on" in one  
direction and "off" in the other.  
Insulation resistance is measured with a megger (mega-ohm  
meter). A megger measures insulation resistance by placing  
500 volts between the winding and the frame of the  
generator. Caution must be taken to remove all electronic  
devices (regulators, diodes, surge protectors, capacitors,  
protective relays, etc.) from the winding circuit before  
checking the insulation. Winding insulation can be checked  
on the main stator, main rotor, exciter stator, and exciter  
rotor. Minimum resistance is 2 mega-ohms. If the winding  
resistance is low it must be dried (see maintenance section)  
or repaired.  
2. Shorted condition: Ohmmeter reading will be zero, or  
very low in both directions. The continuity tester will  
have the light "on" in both directions.  
3. Open condition: Ohmmeter will have a maximum  
(infinity) reading in both directions. Continuity tester  
light will be off in both directions.  
Diode failure after a 25 hour "run-in" period is generally  
traceable to external causes such as a lightning strike,  
reverse current, line voltage spikes, etc. All 6 diodes are  
essentially in the same circuit. When a diode is stressed to  
failure, there is no easy method to determine remaining life  
in the other diodes. To avoid possible continued failures, it  
is recommended that the entire rectifier assembly be  
replaced rather than replacing individual diodes.  
DIODE TESTING  
If the generator is close coupled to an engine, it may be  
necessary to "bar over" the engine in order to gain access to  
a given area of the rectifier assembly. NEVER use the  
generator's fan as a fulcrum to accomplish this. Use the  
engine manufacturer's recommended practice to manually  
turn over the engine.  
To prevent possible injury to  
personnel, and damage to the equipment, ensure that the  
engine cannot start during this procedure.  
SERVICE  
Remove the two main rotor leads and the three exciter rotor  
leads from the rectifier assembly (figure 4). The rectifier  
assembly is now electrically isolated from the generator.  
The diodes remain mounted and the diode leads remain  
connected to the terminal posts. Using an ohmmeter or a  
battery light continuity tester, place one test probe on the  
diode lead terminal post. In succession, touch the other test  
probe to the lead screw hole in each heat sink. Reverse the  
probes and repeat the procedure. You have now tested the  
three diodes connected to this terminal post in both the  
forward and reverse direction. Repeat the procedure using  
the other diode terminal post.  
GENERAL  
The service procedures given in this section are those which  
can reasonably be conducted on-site with a minimum  
number of special tools and equipment.  
maintenance personnel should conduct all service  
procedures. Replacement parts may be ordered through an  
authorized service center or directly from the factory.  
Qualified  
FIELD FLASHING  
Restoring Residual Magnetism  
(not applicable on PMG equipped generators)  
Forward  
Reverse  
Terminal End  
Anode Cathode  
To restore residual magnetism to the generator, connect a  
12 volt battery to the exciter field while the generator using  
the following procedure:  
(+)  
(-)  
Stud End  
Cathode  
(-)  
Anode  
(+)  
1. Shutdown the generator set. Remove the exciter field  
leads F+ and F- from the regulator.  
FIGURE 3: DIODE POLARITY  
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CAUTION:  
                                                                                                                                  
Continue to pull the bracket free from the bearing. Visually  
inspect the bearing bore for damage or wear. If worn or  
damaged, sleeve or replace prior to reassembly.  
Failure to remove the exciter field leads from the  
automatic voltage regulator during flashing  
procedures may destroy the regulator.  
Reassembly note: Before the bearing bracket is seated  
against the frame, a threaded rod may be used to help align  
the inner bearing cap with the bearing bracket.  
2. Connect the F+ and F- leads to the battery’s  
corresponding positive and negative terminals. This  
should be done using an appropriate length of lead wire  
to separate the battery from the point of connection  
(batteries may explode when exposed to an electric arc).  
After 3 to 5 seconds, remove the F- lead. An inductive  
arc should result. If no arc is drawn, repeat the  
procedure.  
BEARING REPLACEMENT  
Using a bearing puller, remove the existing bearing. It is  
strongly recommended that the bearing be replaced any time  
it is removed from the shaft. ALWAYS install the same type  
and size bearing that was supplied as original equipment.  
Order by part number from the parts list, and include the unit  
serial number and part number when ordering. Heat the  
3. Reconnect the F+ and F- leads to the regulator. Restart  
the generator and verify that terminal voltage is  
developed. If terminal voltage does not develop, repeat  
the field flashing procedure and / or consult the trouble  
shooting section.  
o
o
bearing to a maximum of 100 C (212 F) in an oven. Apply  
a thin coat of clean lubricating oil to the press-fit area of the  
rotor shaft. Using suitable heat resistant gloves, install the  
bearing over the end of the shaft until it seats against the  
shaft shoulder. The bearing should slide on the shaft and be  
seated without excessive force. Should the bearing bind on  
the shaft prior to being seated against the shoulder, a piece  
of tubing slightly larger than the press fit area can be used to  
drive the bearing to its final position. Using light taps with a  
soft mallet, apply pressure to the inner race only.  
Bearing Removal  
Prior to performing this operation, it is suggested that the  
alternator's shaft be rotated until two of the main rotor poles  
are in a vertical position. Once the bearing bracket is  
backed out, the rotor will drop on the main stator core.  
Having the rotor in this position will limit the amount of rotor  
drop to that of the air gap. Visually inspect the bearing bore  
for damage or wear. If worn or damaged, replace prior to  
reassemble.  
Rectifier Assembly Removal  
Opposite Drive End Bearing Bracket Removal.  
Prior to proceeding with bracket removal, disconnect exciter  
field leads F+ and F- from the automatic voltage regulator  
and ensure that they are free to move when the bearing  
bracket is removed. Remove the bearing bracket retaining  
bolts. Using a pair of screw drivers, wedge the bracket off  
the frame. After approximately 1/8 inch, the bracket will  
clear the locating register on the frame and will drop until the  
rotor is resting on the main stator core. Continue to pull the  
bracket free from the bearing. Visually inspect the bearing  
bore and o-ring (if equipped) for damage or wear. If worn or  
damaged, repair or replace prior to reassembly.  
The rectifier assembly cannot be removed until the opposite  
drive end bearing bracket and bearing have been removed  
(see bearing removal procedure). Remove the three exciter  
rotor leads from the heat sinks and the two main rotor leads  
from the main rotor posts (see Figures 4). Remove the  
screws securing the rectifier assembly and pull the assembly  
free from the shaft.  
Diode Replacement  
Drive End Bearing Bracket Removal,  
Two Bearing Units.  
Prior to installing a replacement diode on the heat sink,  
apply a thin film of conductive heat sink compound around  
the base of the diode (do not coat the threads). When  
installing a diode on the heat sink, care should be taken not  
to over torque the retaining nut, which could cause damage  
to the device. Torque to 28 pound-inches. If not damaged,  
the existing diode lead wire may be unsoldered from the  
failed diode, and resoldered on the replacement.  
Remove any drive arrangement from the generator shaft  
extension. Remove the bearing lock ring retaining screws.  
There is no o-ring in the drive end bearing bracket. The  
shaft extension must be supported before proceeding  
further. A hoist and sling, jack, or some other means of  
support with a capacity of 2 tons should be used.  
Remove the bearing bracket retaining cap screws. Using a  
flat bladed screw driver or chisel, pry the bracket back from  
the frame. After approximately 1/8 inch, the bracket will  
clear the locating register on the frame. Lower the shaft  
extension until the rotor is resting on the main stator core.  
15  
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430 FRAME  
280 / 360 FRAME  
A - Exciter Rotor Lead, B - Main Rotor Lead, C - Red (+) Suppressor Lead, D - Black (-) Suppressor Lead  
FIGURE 4: ROTATING RECTIFIER ASSEMBLY  
checks first and prevent further damage when  
troubleshooting a disabled machine.  
RETURNED GOODS  
The first step of troubleshooting is to gather as much  
information as is possible from operating personnel and  
individuals present during the failure. Typical information  
includes: how long the unit had been operating; what loads  
were on line; weather conditions; protective equipment that  
did or did not function. In addition, information as to the  
operating condition of the generator's prime mover is vital.  
Has the prime mover been maintaining constant speed? If  
not, have there been extended periods of under speed  
operation? Has the prime mover experienced an over-speed  
condition? If yes, what was the maximum speed, and how  
long did the unit operate at that elevated speed?  
Contact Marathon Electric Manufacturing Corporation for  
authorization before returning any product. We can not be  
responsible for any items returned without authorization.  
CAUTION  
Single bearing generators must have their rotor  
assembly properly secured to prevent damage during  
transit to the factory, or to an authorized service center.  
The generator speed should be maintained at rated  
nameplate value during all operating tests. The frequency of  
TROUBLESHOOTING  
the generator depends upon rotational speed.  
Most  
This section is intended to suggest a systematic approach to  
locating and correcting generator malfunctions. The section  
is arranged according to the symptoms of the problem. The  
steps have been arranged in an attempt to do the easy  
regulators used with MagnaPLUS generators have built in  
under frequency protection such that if the speed is reduced  
more than 5%, the voltage will drop off rather rapidly with  
further reductions in speed.  
16  
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WARNING  
HIGH VOLTAGES MAY BE PRESENT AT THE GENERATOR’S TERMINALS WHEN THE UNIT IS RUNNING.  
SOME ACCESSORY EQUIPMENT SUCH AS SPACE HEATERS MAY BE ENERGIZED FROM AN OUTSIDE  
POWER SOURCE WHEN THE UNIT IS AT REST. TOOLS, EQUIPMENT, CLOTHING AND YOUR BODY MUST  
BE KEPT CLEAR OF ROTATING PARTS AND ELECTRICAL CONNECTIONS. SPECIAL PRECAUTIONS MUST  
BE TAKEN DURING TROUBLESHOOTING SINCE PROTECTIVE COVERS AND SAFETY DEVICES MAY BE  
REMOVED OR DISABLED TO GAIN ACCESS AND PERFORM TESTS. BE CAREFUL. SERIOUS PERSONAL  
INJURY OR DEATH CAN RESULT FROM THESE HAZARDS. CONSULT QUALIFIED PERSONNEL WITH ANY  
QUESTIONS.  
GENERATOR PRODUCES NO VOLTAGE  
CAUSE  
CHECK AND REMEDY  
Voltmeter off or defective  
Incorrect or defective connections  
Check voltage with a separate meter at the generator terminals.  
Verify generator connections. See drawings supplied with the generator or lead  
connection diagrams in this manual. Inspect all wiring for loose connections, open  
circuits, grounds, and short circuits.  
Loss of residual  
Flash the field. Refer to field flashing in the service section. If the generator is equipped  
with a PMG, field flashing is not necessary -- check regulator fuse and input power from  
the PMG.  
Defective diodes, suppressor, or  
windings  
Test the generator using the 12 volt battery test as specified in the testing section. If the  
results indicate generator problems, perform insulation, continuity, and diode tests as  
specified in the testing section.  
Regulator protection operating  
Regulator inoperative  
Adjust regulator. Consult regulator manual.  
Adjust or replace regulator. Consult regulator manual.  
GENERATOR PRODUCES LOW VOLTAGE, NO LOAD  
CAUSE  
CHECK AND REMEDY  
Underspeed operation  
Check speed using a tachometer or frequency meter.  
Check voltage with a separate meter at the generator terminals.  
Voltmeter off or defective  
Incorrect or defective connections  
Verify generator connections. See drawings supplied with the generator or lead  
connection diagrams in this manual. Inspect all wiring for grounds, open circuits and short  
circuits.  
Loss of regulator power  
Check regulator fuse and input power. Input power is produced by the generator’s  
residual voltage or from an optional PMG.  
Regulator adjustment  
Adjust regulator settings. Consult regulator manual.  
Regulator incorrectly connected  
Review the generator connection diagram or reference the regulator manual.  
Defective diodes, suppressor, or  
windings  
Test the generator using the 12 volt battery test as specified in the testing section. If the  
results indicate generator problems, perform insulation, continuity, and diode tests as  
specified in the testing section.  
Regulator inoperative  
Adjust or replace regulator. Consult regulator manual.  
17  
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GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD APPLIED  
CAUSE  
CHECK AND REMEDY  
Excessive load  
Reduce load. The load on each leg should be evenly balanced, and rated current should  
not be exceeded on any leg.  
Large motor starting or low load  
power factor  
Motor starting currents are too large for the generator. When starting multiple motors,  
sequence the motors and start the largest motors first. Reduce lagging power factor load.  
Driver speed droop or belt slip  
Reactive droop  
Check driver. If belt driven, check belt tension. Check under frequency setting on  
regulator. Under frequency voltage roll-off may be activated.  
If the generator is equipped for parallel operation, some droop is normal as reactive load  
increases. When operating as a single unit, the parallel CT can be shorted to eliminate this  
effect. Refer to Regulator manual.  
Line drop  
If voltage is proper at generator terminals but low at load terminals, increase external wire  
size.  
Defective diodes, suppressor, or  
windings  
Test the generator using the 12 volt battery test as specified in the testing section. If the  
results indicate generator problems, perform insulation, continuity, and diode tests as  
specified in the testing section.  
GENERATOR PRODUCES FLUCTUATING VOLTAGE  
CAUSE  
CHECK AND REMEDY  
Fluctuating engine speed  
Regulator stability  
Check engine and governor systems for malfunctions. Check load for fluctuation.  
Adjust Regulator stability. Refer to Regulator manual.  
Regulator external rheostat  
Defective rectifier assembly  
Loose terminal or load connections  
Defective regulator  
Replace defective or worn rheostat. Use shielded cable to minimize electrical noise.  
Check assembly for loose connections. Test the diodes as specified in the test section.  
Improve connections both mechanically and electrically.  
Replace regulator.  
GENERATOR PRODUCES HIGH VOLTAGE  
CAUSE  
CHECK AND REMEDY  
Faulty metering  
Check voltage with separate meter at generator terminals.  
Incorrect connections  
Verify generator connections. Refer to drawings supplied with the generator or connection  
diagrams in this manual.  
Regulator adjustments  
Leading power factor  
Adjust regulator. Consult regulator manual.  
Check the power factor of the load. If power factor is leading, change load configuration.  
Excessive leading power factor (capacitors) can cause voltage to climb out of control.  
Incorrect regulator connection  
Defective regulator  
Verify regulator voltage sensing is connected correctly. Consult regulator manual.  
Replace regulator.  
18  
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GENERATOR BUILDS VOLTAGE FROM STARTUP, THEN GOES TO LOW (RESIDUAL)  
VOLTAGE  
CAUSE  
CHECK AND REMEDY  
Regulator protective circuit operating Check indicators on regulator. Correct problems and adjust regulator as is required. Refer  
to regulator manual.  
GENERATOR IS OVERHEATING  
CAUSE  
CHECK AND REMEDY  
Reduce load. Check with ammeter and compare with nameplate rating.  
Clean air passages.  
Generator is overloaded  
Clogged ventilating screens  
High room temperature or altitude  
Insufficient circulation of cooling air  
Improve ventilation or reduce load.  
Generator location and enclosure design must provide adequate airflow and minimize  
recirculation of hot air.  
Unbalanced load  
The load on each leg should be as evenly balanced as possible and should not exceed  
rated current on any one leg.  
GENERATOR PRODUCES MECHANICAL NOISE  
CAUSE  
CHECK AND REMEDY  
Defective bearing  
Replace bearing.  
Loose or misaligned coupling  
Belt slap or loose guards  
Tighten, realign, or replace coupling.  
Check belt tensioning. Check belt guard fasteners.  
EQUIPMENT RUNS NORMALLY ON UTILITY POWER, BUT WILL NOT RUN ON GENERATOR  
CAUSE  
CHECK AND REMEDY  
Distorted voltage waveform  
Analyze load. Excessive SCR (thyristor) loading will cause distortion. Some equipment  
may be sensitive to distorted waveforms. Refer to Marathon Electric.  
Improper generator voltage or  
frequency  
Check nameplates of devices comprising the load. Compare required voltage and  
frequency with that of the generator. Adjust driver speed and/or generator voltage as  
necessary to match generator output to load requirements.  
CAUTION: Compare required voltage, frequency, and kVA with generator nameplate to ensure adequate generator  
capacity. If in doubt, consult Marathon Electric for information regarding generator capacity.  
19  
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SPECIFICATIONS  
MODEL / FRAME SIZE  
EXCITER RESISTANCE  
STATOR  
ROTOR  
281, 282, 283, 284  
23.0  
23.5  
23.0  
20.33  
18.0  
.120  
.120  
.135  
.076  
361, 362, 363 -- three phase  
361, 362, 363 -- dedicated single phase  
431, 432, 433 -- three phase  
431, 432 -- dedicated single phase  
.105  
EXCITER FIELD  
NO LOAD VOLTS  
480 V / 60 HZ  
NO LOAD TERMINAL VOLTAGE  
WITH 12 VDC FIXED EXCITATION  
HIGH WYE / 60 HZ HIGH WYE / 50 HZ  
MODEL  
GENERATOR RESISTANCE  
STATOR*  
ROTOR  
281PSL1500  
281PSL1501  
281PSL1502  
282PSL1503  
282PSL1504  
282PSL1505  
283PSL1506  
283PSL1507  
284PSL1508  
361PSL1600  
361PSL1601  
361PSL1602  
362PSL1604  
362PSL1606  
363PSL1607  
431PSL6202  
431PSL6204  
431PSL6206  
431PSL6208  
432PSL6210  
432PSL6212  
433PSL6216  
433PSL6220  
4.20  
4.15  
3.20  
2.00  
1.51  
1.00  
.681  
.480  
.346  
.381  
.264  
.181  
.400  
.400  
.439  
.470  
.512  
.575  
.654  
.758  
.875  
.750  
.810  
.990  
1.05  
1.20  
1.37  
.8114  
.6373  
.6793  
.715  
.8114  
.8656  
1.0672  
.9743  
11.0  
11.0  
9.0  
485  
490  
528  
500  
490  
515  
495  
480  
480  
485  
475  
460  
480  
500  
475  
440  
455  
455  
475  
440  
445  
425  
430  
400  
404  
435  
415  
400  
415  
400  
390  
375  
400  
385  
370  
380  
405  
380  
360  
385  
370  
390  
360  
385  
345  
350  
10.4  
11.3  
10.1  
11.0  
12.0  
12.0  
11.8  
12.5  
14.1  
12.2  
10.8  
12.2  
15.1  
13.6  
13.82  
12.20  
15.1  
14.1  
16.2  
15.6  
.138  
.0980  
.0692  
.0214  
.0477  
.0371  
.0133  
.0214  
.0226  
.01215  
.01214  
* Stator resistance measured line to line in a high wye connection.  
DEDICATED  
GENERATOR RESISTANCE  
EXCITER FIELD  
SINGLE PHASE  
STATOR  
1.420  
1.106  
.632  
.436  
.240  
ROTOR  
.381  
.395  
.430  
.450  
.520  
.620  
.760  
.857  
.750  
.857  
.926  
1.20  
1.35  
.516  
.615  
.643  
.852  
NO LOAD VOLTS / 60 HZ  
281PSL1511  
281PSL1512  
281PSL1513  
282PSL1514  
282PSL1515  
283PSL1516  
284PSL1517  
284PSL1518  
361PSL1611  
361PSL1612  
361PSL1613  
362PSL1615  
363PSL1617  
431PSL1811  
431PSL1813  
432PSL1814  
432PSL1815  
8.3  
8.1  
8.7  
9.2  
9.7  
13.3  
12.2  
16.6  
17.5  
16.1  
13.6  
17.0  
23.0  
9.9  
.160  
.0918  
.0610  
.0695  
.0434  
.0369  
.0191  
.0119  
.0248  
.0129  
.00931  
.00723  
13.8  
15.1  
11.2  
20  
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PARTS LIST – SINGLE BEARING  
Typical Generator Cross Section  
Reference  
Part Name  
Reference  
Part Name  
Number  
Number  
11  
1
2
End Bracket (under end cover 360 & 430 frames)  
Bearing  
Main Stator  
Main Rotor  
12  
3
4
O-ring (280 frame only)  
Rectifier Assembly  
13  
14  
Rotor Integral Keyway  
Fan  
5
6
Air Intake Screen (280 frame only)  
Exciter Rotor  
15  
16  
Mounting Adapter (SAE)  
Shaft  
7
Exciter Stator  
17  
Drive Hub  
8
9
10  
Link Board (terminal block)  
Conduit Box  
Generator Frame  
18  
19  
20  
Drive Disk (SAE)  
Exhaust Screen (drip cover not shown)  
Mounting Base  
Note:  
Illustration above is a 280 frame MagnaPlus. Other Frame sizes are typical. Optional PMG not shown.  
The generator model and serial numbers are required when ordering parts.  
21  
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PARTS LIST – DUAL BEARING  
Typical Generator Cross Section  
Reference  
Part Name  
Reference  
Part Name  
Number  
Number  
11  
1
2
3
End Bracket (under end cover 360 & 430 frames)  
Bearing (nondrive end)  
O-ring (280 frame only)  
Rectifier Assembly  
Main Stator  
Main Rotor  
Rotor Integral Keyway  
12  
13  
14  
4
Fan  
5
6
Air Intake Screen (280 frame only)  
Exciter Rotor  
15  
16  
End Bracket (drive end)  
Bearing (drive end)  
7
Exciter Stator  
17  
Shaft  
8
9
Link Board (terminal block)  
Conduit Box  
18  
19  
Key  
Exhaust Screen (drip cover not shown)  
Mounting Base  
10  
Generator Frame  
20  
Note:  
Illustration above is a 280 frame MagnaPlus. Other Frame sizes are typical. Optional PMG not shown.  
The generator model and serial numbers are required when ordering parts.  
22  
SB 504 2/94 (Revised 8/98)  
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RULES FOR SAFE TRAILER OPERATION  
CAUTION – Before you start:  
S
S
S
S
Make sure vehicle is capable of towing the load.  
Be sure hitch capacity is equal to or greater than the load when mounted on the vehicle.  
See that hitch ball rated capacity is equal to or greater than the load.  
Make sure your safety chain(s) is rated equal to or greater than twice the maximum  
gross trailer weight rating of your trailer.  
S
S
S
It is against the law to carry passengers in the back of any trailer.  
Reduce weight in car trunk and rear seat areas by the amount of tongue weight of your trailer.  
Any alterations or changes made to the trailer void any express or implied warranties on the trail-  
er or towing equipment.  
SELECTING THE PROPER TOWING EQUIPMENT  
When selecting the proper towing equipment, the two most important factors that must be considered are  
the M.G.T.W. (Maximum Gross Trailer Weight) and the Tongue Weight. The M.G.T.W. is the total weight of  
the trailer plus the payload in the trailer. The tongue weight is the downward pressure exerted at the cou-  
pler.  
The easiest way to measure the gross trailer weight is to place the loaded trailer on a vehicle scale mak-  
ing sure that the scales are supporting the entire weight of the loaded trailer.  
The easiest method for measuring tongue weight (up to 300 lbs.) is to place the trailer tongue on a set of  
bathroom scales making sure the trailer is level. For heavier tongue weights, place a board across the  
bathroom scales and a solid object of the same thickness as the scales with a piece of pipe between  
each. The trailer tongue should be level and in its normal towing position. Multiply the scale reading by  
three (3) to obtain the tongue weight. Tongue weight should be 10% of trailer weight and not over 10% of  
M.G.T.W.  
TOWING VEHICLE  
Make sure the vehicle you are using to tow the trailer is capable of towing the weight. Check the vehicle  
Owner’s Manual for towing capability of the towing vehicle or contact the car dealer for this information.  
Table 1 – Hitch Towing Capacity  
Hitch  
Class  
Sub Class I  
Maximum  
Towing Cap.  
1000 Lbs.  
Maximum  
Tongue Wt.  
100 Lbs  
Normally  
Installed  
Foreign or U.S. Sub–  
compact vehicles  
Compact Vehicles  
Mid–size & Full Size  
Vehicles  
Class I  
Class II  
2000 Lbs.  
3500 Lbs.  
200 Lbs.  
300 Lbs.  
Class III  
5000 Lbs. Plus  
500 Lbs. Plus  
Full Size Vehicles,  
Pick–up Truck  
23  
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ELECTRICAL TRAILER WIRING  
All trailers must have taillights, brake lights and turn signals connected in with the towing ve-  
hicle’s electrical system. It is also recommended that a heavy–duty turn signal flasher be  
installed since the trailer lights place an extra load on the car flashers.  
TOWING HEAVY TRAILER LOADS  
1. Trailer brakes – In all cases refer to your Vehicle Owner’s Manual and the Trailer Operating Manual  
to be certain you have an adequate braking system to handle the vehicle/trailer combination. Also,  
state requirements, road and weather conditions and grade of road, etc. should be taken into consid-  
eration when assessing the need for trailer brakes.  
2. Additional equipment – the following items may be helpful for towing heavy loads. Consult your ve-  
hicle Owner’s Manual for recommended towing accessories.  
(A) Overload Springs  
(B) Overload or air shocks  
(C) Transmission Oil Cooler  
(D) Engine Oil Cooler  
(E) Coolant recovery System  
(F) Heavy Duty Fan  
(G) Side View Mirrors  
(H) Sway Control  
SAFE DRIVING  
(1) Loading Trailer – The trailer should be loaded so that the downward tongue weight is approximately  
10% of the gross trailer weight.  
(2) Driving – The following precautions should be taken when towing a trailer:  
(A) Following and stopping distance – the rule of thumb for the minimum distance that should be  
maintained between you and the preceding car is one car and trailer length for every 10 MPH you  
are traveling. The distance should be increased accordingly depending on road and weather  
conditions. Avoid sudden stops if possible.  
(B) Passing – Accelerating and passing should be done slowly to allow extra distance for passing. Signal  
well in advance when passing and returning to the proper lane.  
(C) Turning – Drive slightly beyond normal turning power to avoid running over curbs and soft shoulders.  
(D) Uphill and Downhill Grades – Reduces speed and use a lower transmission gear for steep or long  
up or down hill grades.  
(E) Parking –  
S
S
S
S
Avoid parking on uphill or downhill grades  
Place transmission in “PARK”  
Apply parking brake.  
Use wheel chucks.  
(F) Trailer Sway – If trailer sways, reduce speed; apply trailer brakes rather than car brakes to control  
sway. If excessive sway persists, consult your local dealer for help.  
24  
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SAFETY CHECKS  
The following items should be checked before each use and once every 100 miles of towing:  
(1) Check lighting to be sure stop, tail and turn signals are working properly. Replace any broken lenses,  
reflectors or bulbs.  
(2) Check wires for good connections and possible fraying or wearing of insulation.  
(3) Check and properly maintain the trailer, hitch, ball and coupler.  
(4) Inspect hitch and ball for damage in every day use. Ball or hitch can be damaged in parking, hitting  
curbs, dragging when crossing ditches or railroad tracks.  
(5) Check and properly tighten all bolts on trailer, hitch, ball and coupler (including wheels).  
(6) Check safety chains for wear and do not allow them to drag on ground.  
(7) Towing vehicle tires – check tires for wear and proper inflation (Consult Vehicle Owner’s Manual for  
proper level of inflation of tires for towing a trailer).  
(8) Trailer Tires– Check tires for wear and proper inflation. If it becomes necessary to change a tire,  
replace only with a tire of the same size rating and capacity.  
(9) Carry emergency flares and fire extinguisher (required in some states).  
(10) Carry extra light bulbs and fuses.  
(11) Wheel bearings should be checked and replaced after the first 100 miles, and every 4000 miles  
thereafter or at least once a year. Wheel bearing grease or a good grade of multi–purpose grease  
should be used for packing wheel bearings. If you don’t know how to repack your wheel bearing,  
take your trailer to a garage for advice.  
(12) Vehicle maintenance – For proper vehicle maintenance while towing a trailer, refer to your Vehicle  
Owner’s Manual and manufacturer’s specifications.  
25  
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TRAILER LIGHT KIT  
WIRING INSTRUCTIONS  
Connect the wires of the short trunk connector to the vehicle wiring. Connect the brown wire to  
the tail light wire, the yellow wire to the left–hand stop and turn, and the green wire to the  
right–hand stop and turn wire. Attach the white ground wire to the vehicle frame. If vehicle has  
rear turn signals separated from stoplights, you will need an Anderson 5403 electronic  
converter.  
TRAILER LIGHT MOUNTING AND CONNECTION  
Mount the light with license window on the left rear of the trailer with side marker to the outside  
of the trailer. Mount the light without license window on the right rear of the trailer with side  
marker to the outside. Mount the license bracket with the left–hand light.  
Using frame clips, mount each half of the harness down each side of the trailer, with yellow and  
brown wires down left side and green and brown wires down right side. Connect yellow and  
brown wires to left side and green and brown wires down right side. Connect yellow and brown  
wires to left–hand light by stripping harness ends $” and inserting yellow wire into hole marked  
“Stop and Turn (yellow)”. Insert brown wire into hole marked “Tail (brown)”. (Extra holes are  
spares for auxiliary use.) Connect green and brown harness ends to the right–hand light in the  
same manner. Attach white ground wire to trailer tongue or frame.  
Mount the front side marker lights in the area shown. Attach wire to brown harness wire with 3M  
Scotchlok connector. (Kits 540,545, 547).  
Mount the three red marker lights to rear of trailer making sure that the lamps are no less than  
6” and no more than 12” from center of lamp to center of lamp. (Kit 547)  
After lamps are mounted, use 3M Scotchlok connectors to connect all three leads together and  
then plug into the extra hole marked brown in the back of taillight (either side).  
NOTE: Smaller holes above or below circuit holes on all lights are relief holes to be used for  
removal of wires. By inserting nail or paper–clip into these small holes the strain on the wires  
can be relieved so they can be moved.  
Connect harness plug to trunk connector plug. Turn on car headlights – both tail and all four  
side markers should come on. The brighter stoplights should come on only when the brake  
pedal is depressed, or when turn signal is activated, (Key must be in “on” position.) If lights do  
not light, check all ground connections. If turn signals do not operate properly, check  
connections between vehicle wiring and trunk connector.  
NOTE: All lights used in these kits comply with D.O.T. standards. Some kits do not contain all  
of the lights needed to meet vehicle requirements.  
26  
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Limited Warranty  
Unless otherwise provided, Baldor generators are warranted against defects in Baldor workmanship  
and materials for a period of time as set forth in the Warranty Period chart below. If a Baldor product is  
defective due to Baldor workmanship or materials and the defect occurs during the warranty period,  
then Baldor will either repair the product or replace it with a new one, whichever Baldor believes to be  
appropriate under the circumstances. Service for warranty issues regarding any Baldor Generators  
Products Warranty is available by contacting Baldor Generators’ Customer Service Department in  
Oshkosh, Wisconsin. A list of Baldor’s generator repair facilities may be obtained by contacting Bal-  
dor Generators at: Customer Service, Baldor Generators, 3815 Oregon Street, Oshkosh, Wisconsin  
54902, 920–236–4200 (telephone), 920–236–4219 (facsimile). All Baldor products requiring war-  
ranty service shall be transported or shipped freight pre–paid, at the risk of the party requiring warran-  
ty service, to a Baldor Generator repair facility, or to Baldor Generators’ Customer Service Depart-  
ment in Oshkosh, Wisconsin. Written notification of the alleged defect in addition to a description of  
the manner in which the Baldor generator is used, and the name, address and telephone number of  
the party requiring warranty service must be included. Baldor is not responsible for removal and ship-  
ment of the Baldor product to the service center or for the reinstallation of the Baldor product upon its  
return to the party requiring warranty service. Customers who are unable to take or ship the Baldor  
product to a Baldor Generator repair facility, or who desire a repair to be made by other than a Baldor  
Generator repair facility, should contact Baldor Generators’ Customer Service Department at  
920–236–4200. Baldor, in advance of such service, must approve a repair by anyone other than a  
Baldor Generator repair facility in writing. Problems with Baldor products can be due to improper  
maintenance, faulty installation, non–Baldor additions or modifications, or other problems not due to  
defects in Baldor workmanship or materials. If a Baldor Generator repair facility determines that the  
problem with a Baldor product is not due to defects in Baldor workmanship or materials, then the party  
requesting warranty service will be responsible for the cost of any necessary repairs. Parties requir-  
ing warranty service not satisfied with a determination that a problem is outside of warranty coverage  
should contact Baldor Generators’ Customer Service Department at 920–236–4200 for further con-  
sideration. EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE, BALDOR GEN-  
ERATORS DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE  
IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY.  
NO OTHER WARRANTY, EXPRESSED OR IMPLIED, WHETHER OR NOT SIMILAR IN NATURE  
TO ANY OTHER WARRANTY PROVIDED HEREIN, SHALL EXIST WITH RESPECT TO THE  
GOODS SOLD UNDER THE PROVISIONS OF THESE TERMS AND CONDITIONS. ALL OTHER  
SUCH WARRANTIES ARE HEREBY EXPRESSLY WAIVED BY THE BUYER. UNDER NO CIR-  
CUMSTANCES SHALL BALDOR GENERATORS BE LIABLE OR RESPONSIBLE IN ANY MAN-  
NER WHATSOEVER FOR ANY INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, OR  
ANTICIPATED PROFITS RESULTING FROM THE DEFECT, REMOVAL, REINSTALLATION, SHIP-  
MENT OR OTHERWISE. This is the sole warranty of Baldor Generators and no other affirmations or  
promises made by Baldor Generators shall be deemed to create an expressed or implied warranty.  
Baldor Generators has not authorized anyone to make any representations or warranties other than  
the warranty contained herein.  
Warranty Period  
Generator Series  
Labor*  
Parts  
Portable Products  
(Premier, Powerchief, DG Series, K Series)  
1 Year  
3 Years  
Towable Products (TS)  
1 Year or 3,000 Hours  
Whichever comes first  
3 Years or 3,000 Hours  
Whichever comes first  
3600 RPM Standby Systems  
(Some AE Models)  
1 Year or 1,000 Hours  
Whichever comes first  
3 Years or 1,000 Hours  
Whichever comes first  
1800 RPM Standby Systems  
(Some AE Models, DLC, GLC)  
1 Year or 3,000 Hours  
Whichever comes first  
3 Years or 3,000 Hours  
Whichever comes first  
Industrial Standby Systems  
Industrial Prime Power Systems  
International  
1 Year or 1,000 Hours  
Whichever comes first  
1 Year or 1,000 Hours  
Whichever comes first  
1 Year or 1,000 Hours  
Whichever comes first  
2 Years or 1,000 Hours  
Whichever comes first  
1 Year or 1,000 Hours  
Whichever comes first  
1 Year or 1,000 Hours  
Whichever comes first  
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Limited Warranty Continued  
Notes for Warranty Period:  
1. Labor coverage for warrantable repairs is provided for the applicable period  
not to exceed published rates as contained in the Baldor Generators  
Warranty Policy. Mileage is allowed only for permanent installations not to  
exceed published rates as contained in the Baldor Generators Warranty  
Policy.  
2. Proof of purchase date is required for all Portable and Towable products to  
qualify for any warranty consideration. Serial number and model number  
will be required for all warranty work.  
3. For all other products, a Start–up Inspection Form / Warranty Registration  
must be completed in its entirety and submitted to Baldor Generators within  
30 days of start–up to qualify for any warranty consideration.  
Owner’s Responsibilities:  
The owner is obligated to operate and maintain the generator in accordance with the  
recommendations published by Baldor Generators in the Operator’s Manual for the  
generator. The owner is responsible for the costs associated with maintenance and  
any adjustments that may be required.  
The owner is responsible for payment of any of the following expenses that might be  
incurred as a result of a failure under the terms of this warranty:  
1. Rental equipment used to replace the equipment being repaired.  
2. Telephone or other communication expenses.  
3. Living and travel expenses of persons performing service, except as  
specifically included within the terms of specific warranty.  
4. The premium costs for overtime labor requested by the owner.  
5. All parts transportation costs.  
All warranty claims must be submitted to a Baldor Generator repair facility prior to the  
expiration of the warranty period. Baldor Generators shall have no responsibility or  
liability for any defect, latent or otherwise, discovered after the expiration of the  
warranty period provided herein. Extended warranties are available for certain  
Baldor products. These warranties are described in Baldor’s catalog and other sales  
literature. Extended warranties are subject to the terms and conditions of this Limited  
Warranty as modified by the additional terms of the extended warranty.  
Limitations:  
Baldor Generators is not responsible for the repair of generators required because of  
normal wear, accident, misuse, abuse, improper installation, lack of maintenance,  
unauthorized modifications or improper storage.  
Normal Wear: This warranty will not cover repair where normal use has exhausted  
the life of a part or generator. It should be remembered that the service life of any  
generator is dependent on the care it receives and the conditions under which it has  
to operate. Some applications are very often used in dusty or dirty conditions, which  
can cause what appears to be excessive wear. Such wear, when caused by dirt, dust,  
grit or other abrasive material, which has entered the generator because of improper  
maintenance, is not covered by Warranty.  
For all product lines, the engine manufacturer warrants engine systems.  
Contact Baldor Generators for current engine warranties.  
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Owner’s Responsibilities:  
The owner is obligated to operate and maintain the generator in accordance with the recommendations  
published by Baldor Generators in the Operator  
. The owner is responsible for  
the costs associated with maintenance and any adjustments that may be required.  
The owner is responsible for payment of any of the following expenses that might be incurred as a result  
of a failure under the terms of this warranty:  
1. Rental equipment used to replace the equipment being repaired.  
2. Telephone or other communication expenses.  
3. Living and travel expenses of persons performing service, except as specifically included within the  
terms of specific warranty.  
4. The premium costs for overtime labor requested by the owner.  
5. All parts transportation costs.  
Limitations:  
Baldor Generators is not responsible for the repair of generators required because of normal wear,  
accident, misuse, abuse, improper installation, lack of maintenance, unauthorized modifications or  
improper storage.  
Normal Wear: This warranty will not cover repair where normal use has exhausted the life of a part or  
generator. It should be remembered that the service life of any generator is dependent on the care it  
receives and the conditions under which it has to operate. Some applications are very often used in dusty  
or dirty conditions, which can cause what appears to be excessive wear. Such wear, when caused by dirt,  
dust, grit or other abrasive material, which has entered the generator because of improper maintenance,  
is not covered by Warranty.  
No person is authorized to give any other warranties or to assume any other liabilities on Baldor  
Generators’ behalf unless made or assumed in writing by an officer of Baldor Generators and no person is  
authorized to give any warranties or assume any other liability on behalf of the seller unless made or  
assumed in writing by the seller.  
Major components, such as engines, used in Baldor Generators’ generator sets that are not  
manufactured by Baldor Generators are specifically excluded from Baldor Generators coverage and are  
covered separately by their respective manufacturers. Warranty terms and policies of excluded products  
are included with their owners information package supplied with each product.  
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WARNING:  
CALIFORNIA PROPOSITION 65 WARNING:  
Engine exhaust from this product contains chemicals known  
to the state of California to cause cancer, birth defects and  
other reproductive harm.  
WARNING:  
CALIFORNIA PROPOSITION 65 WARNING:  
Diesel engine exhaust and some constituents are known to the  
state of California to cause cancer, birth defects and other  
reproductive harm.  
WARNING:  
CALIFORNIA PROPOSITION 65 WARNING:  
Battery posts, terminals and related accessories are known to  
the state of California to cause cancer, birth defects and other  
reproductive harm.  
30  
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