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PTS-30 PTS-35 PTS-40 PTS-50 Operators Manual

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2. as aa ie dea 6 nun s u DSS dun eu 6 M 7 Color OF c MM 7 Immediately stop the engine 7 REVERSED ENGINE REVOLUTION AND REMEDIES 7 How to tell when the engine starts running 7 iple CX 7 MAINTENANG Eee oct u uuu a Dia ass 8 SERVICE INTERVALS 9 PERIODIC SER VIC 12 etn Lu d 12 Fuel level check and refueling 12 Air bleeding the fuel nennen nennen 13 Checking the fuel DIDOS 5 au u o ete Dade Ae carte 14 Cleaning the fuel filter 14 Fuel filter cartridge replacement 15 ENGINE OIL unit dst aa 15 Checking oil level and adding engine 15 CHANGING engine ee u orm 16 Replacing the oil filter cartridge 17 RADIATOR I T M 17 Checking coolant level adding coolant
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4. 240 120 T 277 P Tg Delta connection with 12 lead generators only aE niin CONNECT T4 Te T12 Ta Ta Ta 10 Ts T41 INSTALLATION 12 LEAD HI WYE Twelve lead generators are dual voltage generators with Six which don t have the connection of the three inner coils There are 12 or 24 cables coming out of the generator SECTION FOLIAGE ta NEUTRAL Tio 2 10 LEAD HI WYE Ten lead generators are dual voltage generators with six coils end of the three inner coils is connected together There are 10 ar 20 cables coming out of the generator INSTALLATION 12 LEAD LOW WYE 10 LEAD LOW WYE Twelve Bad generators dual voltage generators with six coils which don t have the connection ol the three inner coils There are 12 ar 24 cables coming out of the generator VOLTAGE THT Ten lead generators are dual voltage generators with six coils One end of the three inner colls is connected together There 10 or 20 cables coming out of the generator NEUTRAL Bat 2 3 LED 4 Starter 5 On OFF 6 MAT Hurt In Lop In 3 Fuel 10 AC Hot 11 AC Neut 17 PT ECTI 64 FUEL PUMP ray VOLTAGE MAMAS FEE GRAY POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352
5. In the self excited units 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 field 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 Voltage Regulation 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 regula
6. II H E OY Wv n INSTALLATION INSTRUCTIONS The Charger cabinet must be mounted in a vertical position preferably a wall in close proximity to the battery The areas above and below the Charger must be clear for at lest 5 inches to allow free air flaw for cooling The Charger cabinet must not he located in areas subject to falling spraying water The Charger should not be subject to severe shock or vibration If necessary to mount the unit on an engine skid select a point subject to the least amount of shock and vibration and install suitable vibration dampers when needed For wiring use wire having insulation which is unaffected hy the environment af the installation For engine starting bartery installations use flexihle stranded copper wire having insulation which is unaffected by oil engine heat The bushings supplied with the Charger are VE 2 2 cm diameter holes for inch nominal 1 2 em nominal conduit fittings Discard bushing s when conduit s 15 used See Drawings for Mounting Dimensions and External Wiring Information JPERATING PROCEDURES GENERAL The Model MBC 19 Banery Chargers are constant voltage single rate semi float regulated line compensated battery chargers They have Crank Disconnect DK Relay as standard equipment OUTPUT CAPACITY These Chargers are capable of supplying up to 100 of their D C rated output current without al
7. 18 CHANGING GOOLE PTT MM NS 19 Remedies for quick decrease 19 Checking radiator hoses and 19 Precaution at overheating nnn sensa antenna nin 19 Cleaning radiator core outside 2 22 ho norem ette cho Bra doen Gn acte eee xc 19 Antifreeze P D 20 I e 20 AIR CLEANER S maa E D 21 Cleaning Primary Air Filter 21 be d 21 For the air cleaner with a dust cup 21 Dust indieat r Optional u dau rud m im a deca Lan au 22 ELECTRIC WIRING a q reet eret aha q qk a a 22 ntact ea eU IU 22 Adjusting Fan Belt Tension a a TR LUN GaU COR GR 22 CARRIAGE AND STORAGE a 23 Zn CONE a octal decades Da cua ame AOT cet Mrd 23 STORAGE 23 FROUBEESH
8. IM nn qm 1 F 4 i i ch 82 L i u a 4 wk gt _ z rg O pay w n MARATHON SR ECTS asas b Lal E INTRODUCTION The SE350 voltage regulator is an encapsulated electronic voltage regulator which controls the output of a brushless AC generator by regulating the current into the exciter field SPECIFICATION SE350 REGULATOR Sensing amp Power Input 190 240 Vac Burden 500 VA Output Power Continuous 73V dcal3 5 Ade 255w Output Powar Forcing 105 Vde at 5 525w 240 Vac Input Powar Regulation 1 0 Remote Voltage 10 wilh 2000 ohm Adjustment Range rheostat 5 with 1000 ohm Frequency Roll Off Frequency 54 61 Hzlor60 Hz 45 51 Hz for 50 Hz 6 502 40 10 60 C 65 Cto B5 C B watts maximum Size 3 94 LX 2 66 W X 2 20 H Voltage Buildup Internal provisions for automatic voltaga build up from generator residual voltage as low as 10 Vac EMI Suppression Intamal alectromagnatic interference filter EMI Filter CAUTION DO NOT megger or high pat tha generator with the regulator connacted DO MOT high pot the regulator INSTALLATION MOUNTING The SE 350 voltage regulator can be mounted in any plane See Figure 1 for mounting dimensions viue go cr AT mcer uH UNDER FREGUEHEY Lo x
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10. 7 l 1 gt 209 09 gt i EE IS SAN 5 e 1 I T Wee l 1 vet 08991 89011 2 01219 1 2289 jen I Se 01009 82891 00909 6 1 yun 101002 07929 18889 Aejay 3800 ENGINE POWER FACTORS ALTITUDE POWER LOSS FACTORS High altitudes can cause sizeable losses or reductions in available power The exact amount of loss can be difficult to estimate because these losses vary with the type of engine Generally two stroke engines lose more power than four stroke engines and turbocharged or supercharged engines lose less power than naturally aspirated engines Naturally aspirated 4 cycle engines will lose roughly 3 power per 1000 feet m altitude rise Therefore an engine producing 100 HP at sea level will produce approximately 91 HP at 3000 feet elevation POWER DE RATING WITH REDUCED FUEL FOR HIGH ALTITUDES ALTITUDE POWER CORRECTION TERMA 100 FUEL SETTING ERE ERE RE E 1 00 E 95 FUEL SETTING 5 HHHH 90 FUEL SETTING RR 0 3n 85 FUEL SETTING f gt HHE 0 N 2n TURBOCHARGED ENGINE D an D 75 FUEL SETTING A gt RARER 5 NATURALLY ASPIRATED ENGINES d m 5 amp 4 1000 3000 5000 7000 9000 LEVEL ppp 4000 6000 8000 10000 AL
11. SAE10W or SAE10W 30 With the filler plug still in place it would be difficult to below 0 C 32 F SAE15W 40 discharge the oil completely 4 Add new engine oil up to the upper limit of the oil level gauge Be careful not to add oil above the upper limit of the oil level gauge 0 C to 25 C 32 F to 77 F SAE20 or SAE10W 30 SAE15W 40 When using oil of different brands from the previous one be sure to drain all the previous oil before adding the new engine oil NOTE Be sure to inspect the engine locating it on a level place If placed on gradients accurately oil quantity may not be measured 1 Oil drain plug Replacing the oil filter cartridge A CAUTION To avoid personal injury Be sure to stop the engine before changing the oil filter cartridge e Allow engine to down sufficiently oil can be hot and cause burns 1 Replace the oil filter cartridge Oil filter cartridge should be replaced after the initial 50 hours of operation and every 500 hours thereafter Remove the old oil filter cartridge with a filter wrench Apply a film of oil to the gasket for the new cartridge Screw in the cartridge by hand When the gasket contacts the seal surface tighten the cartridge enough by hand Because if you tighten the cartridge with a wrench it will be tightened too much DEG 5 pan pepe IS IS 1 Oil filter cartridge 5 After the new cartridge has been replaced th
12. Also check the fuel system for air or leaks If necessary replace with a new Bad nozzle nozzle Moving parts are overheated due to shortage of lubrication oil or improper lubrication Check amount of engine oil with oil level gauge Check lubricating oil system Atevery 2 times of oil change oil filter cartridge should be replaced MWhen color of exhaust is especially bad Cause Countermeasures Fuel is of extremely poor quality necessary replace with new Nozzle is bad ry Tep nozzle lI When engine must be stopped immediately Cause Countermeasures Color of exhaust suddenly turns dark Bearing parts are Check the lubricating system overheated Check the lubricating system Check the function of the relieve valve in the lubricating system Check pressure switch Check filter base gasket Select good quality fuel Use No 2 D diesel fuel only Check the fuel injection system especially the fuel injection nozzle Oil lamp lights up during operation e the cause of trouble can not be found contact your KUBOTA dealer TROUBLESHOOTING 25 Mi When engine overheats Engine oil Check oil level Replenish oil as insufficient required Fan De BIOKEMI I a Change belt or adjust belt tension elongated Coolant insufficient Replenish coolant Excessive concentration of antifreeze o O 2 TT Add water only or change to cool
13. Remove the battery from the engine adjust the electrolyte level and recharge it Store the battery in a dry and dark place When the engine is not used for a long period of time run it for about 5 minutes under no load every 2 to 3 months to keep it free from rust If the engine is stored without any running moisture in the air may condense into dew over the sliding parts of the engine resulting in rust there If you forget to run the engine for longer than 5 to 6 months apply enough engine oil to the valve guide and valve stem seal and make sure the valve works smoothly before starting the engine Store the engine in a flat place and remove the key from engine Do not store the engine in a place where has flammable materials such as dry grass or straw When covering the engine for storage let engine and muffler cool off completely 10 Operate the engine after checking and repairing damaged wirings or pipes and clearing flammable materials carried by mouse 22 O lt TT o O 2 TT 24 TROUBLESHOOTING TROUBLESHOOTING If the engine does not function properly use the following chart to identify and correct the cause liWhen it is difficult to start the engine Cause Countermeasures Check the fuel tank and fuel filter Remove water dirt and other MiWhen engine suddenly stops Cause Countermeasures Check the fuel tank and refill the fuel Lack
14. At 1 013 x 10 Pa 760 mmHg pressure atmospheric A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system 5 Adding the LLC 1 Add only water if the coolant level reduces in the cooling system by evaporation 2 If there is a coolant leak add the LLC of the same manufacturer and type in the same cool ant percentage Never add any long life coolant of different manu facturer Different brands may have different addi tive components and the engine may fail to perform as specified 6 When the LLC is mixed do not employ any radiator cleaning agent The LLC contains anti corrosive agent If mixed with the cleaning agent sludge may build up adversely affecting the engine parts 7 Kubota s genuine long life coolant has a service life of 2 years Be sure to change the coolant every 2 years NOTE The above data represent industry standards that necessitate a minimum glycol content in the concentrated anti freeze Radiator cement As the radiator is solidly constructed there is little possibility of water leakage Should this happen however radiator cement can easily fix it If leakage is serious contact your local KUBOTA dealer AIR CLEANER Since the air cleaner employed on this engine is a dry type never apply oil to it 1 Open the evacuator valve once a week under ordinary conditions or daily when used in a d
15. 0 to 25 C 32 F to 77 F SAE20 SAE10W 30 or 15W 40 Below 0 C 32 F SAE10W SAE10W 30 or 15W 40 Recommended classification Refer to the following table for the suitable American Petroleum Institute API classification of engine oil according to the engine type with internal EGR external EGR or non EGR and the Fuel Type Used Low Sulfur Ultra Low Sulfur or High Sulfur Fuels Engine oil classification API classification Fuel type gines with non EGR I Engines with internal EGR Pngihes wieder High Fuel If the CF 4 CG 4 CH 4 or CI 4 engine oil is used 0 05 500 ppm with a high sulfur fuel change the engine oil at lt Sulfur Content lt shorter intervals approximately half 0 50 5000 ppm Low Sulfur Fuel Sulfur Content CF or 1 4 0 0 05 500 ppm or cg CF 4 CG 4 CI 4 Class 4 4 4 engine oils unc m cannot be used on EGR type engines 0 0015 9o 15 ppm EGR Exhaust Gas Re circulation 12 PERIODIC SERVICE PERIODIC SERVICE FUEL Distillation Viscosity Fuel is flammable and can be dangerous You should Temperatures Kinematic handle fuel with care cSt Viscosity Saybolt o O lt TT CAUTION To avoid personal injury Do not mix gasoline or alcohol with diesel fuel This mixture can cause an explosion Be careful not to spill fuel during refueling If
16. 1 2 3 O ring 4 5 Cover NOTE The fuel filter cartridge and water separator should be replaced more earlier according to the fuel classification in use ENGINE OIL CAUTION To avoid personal injury Be sure to stop the engine before checking and changing the engine oil and the oil filter cartridge Do not touch muffler or exhaust pipes while they are hot Severe burns could result Always stop the engine and allow it to cool before conducting inspections maintenance or for a cleaning procedure Contact with engine oil can damage your skin Put on gloves when using engine oil If you come in contact with engine wash it off immediately PERIODIC SERVICE 15 IMPORTANT Do not operate a diesel engine when engine oil is overfilled This oil can drain through the air intake system which cause engine disacceleration and oil leaks from breather pipings It could result in a over running or oil hammering of engine in case of the engine with suction blow by gases breathered in ll Checking oil level and adding engine oil 1 Check the engine oil level before starting or more than 5 minutes after stopping the engine 2 Remove the oil level gauge wipe it clean and reinstall it 3 Take the oil level gauge out again and check the oil level B 1550 1 Oil filler plug 2 Oil level gauge Lower end of oil level gauge A Engine oil level within this range is prop
17. DWELL This feature is mostly used when the generator is coupled to turbo charged engines with limited block load acceptance The feature works by introducing a delay between speed recovery and voltage recovery and allows a greater DIP setting without instability With the DWELL control fully counter clockwise the generator voltage will follow the V Hz line Turning the DWELL control clockwise increase the delay time between speed recovery and voltage recovery CURRENT LIMIT I LIMIT ADJUSTMENT This feature is mostly used to limit short circuit current or to provide a current limit on motor starting To use this feature current limit CT s of the correct ratio need to be connected to the AVR S1 52 terminals There is an internal time limit of 10 seconds Consult the factory before using this feature OVER VOLTAGE OVER V ADJUSTMENT This adjustment is set and sealed in the unit and should not be tampered with An over voltage condition is indicated by the illumination of the red LED which also indicates under speed running and over excitation The generator must be stopped to reset an over voltage trip RAMP The AVR includes a soft start or voltage ramp up circuit to control the rate of voltage build up when the generator runs up to speed This is normally pre set and sealed to give a voltage ramp up time of approximately 3 seconds If required this can be adjusted between the limits defined in the specification 56 APPENDIX F ATH
18. u SELECTION e J STABILITY CONTROL FUNCTION ROTATION VOLTS Output Voltage Adjustment Clockwise to Increase Voltage STABILITY Voltage Hunting Prevention Clockwise to Increase Dampening UFRO Setting of UFRO knee point Clockwise Reduces Knee Point 1 Under Frequency Roll Off UFRO 40 ADJUSTMENT AVR CONTROLS AGR460 VOLTAGE ADJUSTMENT The generator output voltage is set at the factory but can be changed by careful adjustment of the VOLTS control on the AVR board or by the external hand trimmer if fitted Terminals 1 and 2 on the AVR will be fitted with a jumper if no hand trimmer is required Terminals 3 and 4 are jumpered only for special low voltage applications CAUTION Do not increase the voltage above the rated generator voltage If in doubt refer to the name plate mounted on the generator case CAUTION Do not ground any of the hand trimmer terminals as these could be above ground potential Failure to do So could cause equipment damage CAUTION Before running generator turn the VOLTS control fully counter clockwise Turn remote volts trimmer if fitted to midway position Turn STABILITY control to midway position Connect a suitable voltmeter 0 300V ac across line to neutral of the generator Start generator set and run at no load at nominal frequency e g 50 53Hz or 60 63Hz If the red Light Emitting Diode LED is lighted refer to the Under Frequency Roll Off UFRO adjustmen
19. x x Figure 1 EXCITER POWER CIRCUIT Connect the regulator wire F to the generator F or F1 field terminal Connect the regulator wire F to the generator F or F2 field terminal See Figure 2 fortypical connection diagram e M MTERCOMAECTION DIAGRAM FOR 416 460 OF 208 240 VOLT ne wre GENERATOR DPT1O0RNAL REMOTE VOR TAGE aD lS Figure 2 SENSING POWER INPUT CIRCUIT Input power and sensing is achieved through terminals 3 and 4 The voltage input requirement of the SE350 is 190 to 240 Vac See Figure 2 for typical connection diagram FUSE A 4 Amp 250 5 X 20 mm fuse is supplied with the regulator Part A 527066 See Figure 3 for location of fuse VOLTAGE ADJUST The screwdriver adjustable potentiometer adjusts the generator outpul voltage Adjustment clockwise increases the generator output voltage When using a remote voltage adjust rheostal remove the jumper wire across terminals 6 and 7 and install a 2000 ohm 1 2 watt minimum rheostat See Figure 2 This will give 10 voltage variation from the nominal For 5 voltage variation use 1000 ohm 1 2 watt rheostat STABILITY ADJUST System stability is the ability of the generator to respond to load transients Decreasing the stability makes the generator less sluggish and faster to respond to load transients the stability of the regulator is decreased too much the generator wil
20. Defective diodes suppressor or windings CHECK AND REMEDY Reduce load The load on each leg should be evenly balanced and rated current should not be exceeded on any leg 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 Check driver If belt driven check bell 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 If voltage is proper at generator terminals but low at load terminals increase external wire size 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 Fluctuating engine speed Regulator stability Regulator external rheostat Defective rectifier assembly Loose terminal or load connections Defective regulator CAUSE Faulty metering Incorrect connections Regulator adjustments Leading power factor Incorrect regulator connection Defective regulator Subsidiary of Corporation
21. Ty y WATER TEMP GAUGE gt SENDER RUT A UN 4 Eu 40 DC L B 8 SPLICE GREEN ES RED O O SL OIL PRESSURE GAUGE GREEN SENDER MAIN SWITCH BRE LL OOOO _ SWITCH LLLA MOMENTARY GROUND PT ECU 63 1 ve ow GLOW 1 E BREL GREEN HOUR METER 7 P lol icf iuf o BLUE STARTERS dE K BROWN WHITE WHITE RED A WHITE BLACK 56 M gsm eee c 2 m F GRAY 12VOLT DC ACHOT 11 MAIN AC BREAKER VOLTAGE SENSING BREAKER E AC NEUTRAL 12 NN WHITE POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 ALL GENSETS WITH RUN SOLENOID EFFECTIVE MAY 09 FOR POWER TECHNOLOGY MATERIAL NA SHEET TYPE SCHEMATIC BEND ALLOW NA 1 f 1 Power lech LEESBURG FLORIDA 34748 8102 352 365 2777 FAX 352 787 5545 PART 12V DC ENGINE CONTROL PT ECU 63 DATE 18MAYO9 DWN BY KM SCALE NOT TO SCALE
22. CHECK AND REMEDY Check engine and governor systems for malfunctions Check load for fluctuation Adjust Regulator stability Refer t Regulator manual 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 CHECK AND REMEDY Check voltage with separate meter at generator terminals Verify generator connections Refer to drawing supplied with the generator or connection diagrams in this manual 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 Verify regulator voltage sensing is connected correctly Consult regulator manual Replace regulator GENERATOR BUILDS VOLTAGE FROM STARTUP THEN GOES TO LOW RESIDUAL VOLTAGE CALISE CHECK AND REMEDY Requlator protective circuit Check indicators on regulator Correct problems adjust regulator as is required operating Refer to regulator manual GENERATOR IS OVERHEATING CAUSE CHECK AND REMEDY Generator is overloaded Reduce load Check with ammeter and compare with nameplate rating Clogged ventilating screens Clean air passages High room temperature or altitude improve ventilation or reduce load
23. PTS 30 PTS 35 PTS 40 PTS 50 Operators Manual amp Supplemental Manual For Stand By Generators Power Technology Southeast Inc 634 State Road 44 Leesburg FL 34748 8103 352 365 2777 Fax 352 787 5545 e 9 2008 MANPT30 40 FORWARD You are now the proud owner of a Power Technology Generator powered by a Kubota engine This engine 1s a product of Kubota s quality engineering and manufacturing The engine 1s made with fine materials and manufactured under the strictest quality control standards and will assure you long satisfactory service To obtain the best use of your engine please read this manual carefully It will help you become familiar with the operation of the engine and contains many helpful hints regarding engine maintenance Continuing improvements and advancements in product design may have caused changes to your engine which are not included in this manual Please contact Power Technology s Customer Service Department for latest information on your Kubota engine or for the number of your local Kubota dealer OUR CUSTOMERS Thank you for your purchase of a Power Technology Generator The information contained in this manual applies to PTS 30 PTS 35 and PTS 40 generators and optional equipment available for Stand By systems Your generator was custom built to your specific requirements and may or may not be equipped with each of these options listed Installation requirements will vary depending on
24. 1 For fuel tanks that are lower than the injection pump The fuel system must be pressurized by the fuel system electric fuel pump 2 If an electric fuel pump is not used you must manually actuate the pump by lever to bleed 3 The primary fuel filter 3 must be on the pressure side of the pump if the fuel tank is lower than the injection pump 4 To bleed follow 2 through 4 above PROCEDURE 3 IMPORTANT Tighten air vent plug of the fuel injection pump except when bleeding or it may stop the engine suddenly TANK BELOW INJECTION PUMP SYSTEM 0070 1 Fuel tank below injection pump 2 Pre filter 3 Electric or Mechanical pump 4 Main Filter 5 Injection pump ENGLISH o O lt TT 14 PERIODIC SERVICE lll Checking the fuel pipes A CAUTION To avoid personal injury Check or replace the fuel pipes after stopping the engine Broken fuel pipes can cause fires Check the fuel pipes every 50 hours of operation When if 1 If the clamp band is loose apply oil to the screw of the band and tighten the band securely 2 If the fuel pipes made of rubber became worn out replace them and clamp bands every 2 years 3 If the fuel pipes and clamp bands are found worn or damaged before 2 years time replace or repair them at once 4 After replacement of the pipes and bands air bleed the fuel system IMPORTANT When the fuel pipes are
25. 365 2777 FAX 352 787 5545 START STOP SWITCH INTERFA CE MODULE BLACK _ GREEN MAGNETIC PICK UP rn BLUE OPTIONAL HIGH AMBIENT WHITE ER E mi WHITE BLACK E GOVERNOR RED 12V DC APECS 3100 BLACK GRAY _ VIOLET NOT USED PACKARD REMOTE PLUG H WHITE RED gt RED J ORANGE H F CRAY 12 Dc D BLACK WHITE BLACK 1000000 EC CAUCE SENDERS OPTIONAL PANEL OPTIONAL 12 VOLT DC ENGINE CONTROL CIRCUIT PT ECU 64 BLUE ENGINE COVERNING SYSTEM START STOP SWITCH OPTIONAL F5D7110 OPTIONAL 123456 Glow 1 Bat 7 Batt 3 LED 4 Starter 5 On OF Hurt In 8 Lop In Fuel 10 AC Hot 11 AC Neut 17 F CRAY I2V DC L D BLACK VOLTACE 274 000000 MAINAC SENSING A WHITE BLACK BREAKER CRAY HOTE I METER C K BROWN WHITE CAUCE SENDERS OPTIONAL POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 OPTIONAL 352 365 2777 FAX 352 787 5545 12 DC ENGINE CONTROL CIRCUIT GAC ESD 2110 KUBOTA KSI SOLENOID WIRINC 12V BATIERY 14 CRAY TO FTA RUN RELAY e WATER TEMPERATURE SWITCH 1 OPTION TO CLOW PLUGS e REMOTE TO DC RECTIFER I a eee TO DC RECTIFER lo G BLUE NORMALLY OPEN PACKARD REMOTE PLUG 16 CREEN WHITE BLACK 16 GA GRAY
26. BLUE SENDERS 16 GA YELLOW _ OPTIONAL 16 BLUE YELLOW GRAY 12V DC When Running 16 WHITE GREEN li BROWN BROWN WHITE REMOTE POWER TECHNOLOGY SOUTHEAST INC SWIICH 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545 12 VOLT DC ENGINE CONTROL CIRCUIT SERIES 200 BOX EXCITER COILS FA e 4 Ft AVC63 4 YOLTAGE REGULATOR e GROUND 120 VOLT SINGLE PHASE 4 WIRE CONNECTION M SERIES EXCITER TYPE m FIELD BREAKER EXCITER COILS L3 STATOR COILS w MAIN BREAEKERS 4 Fd E3 AVC63 4 VOLTAGE REGULATOR MOTE a e LINE El AND E4 WIRES ARE TAPED AND ISOLATED SEPARATELY LOAD GROUND OPTIONAL SERIES BREAKER For Enclosure Fans when Generator 12 Equipped with a Remote Radiator 120 240 VOLT SINGLE PHASE 4 WIRE CONNECTION M SERIES EXCITER 2 e FIELD BREAKER EXCITER COILS T4 GROUND LINE STATOR COILS BREAKERS m AVCO3 4 VOLTAGE REGULATOR K A RNING THIS SCHEMATIC IS FOR T 220 VOLTS 50 Hz T2 I3 APPLICATION DO NOT CHANGE WIRING UNTIL ENGINE SPEED IS SET 3 1500 RPM s 220 VOLT SINGLE PHASE 4 WIRE EUROPEAN CONNECTION M SERIES EXCITER TYPE RESISTANCE CHART SERIES EXCITER TYPE KW Main Stator Less Than 1 0 Ohm Less Than 1 0 Ohm Less Than 1
27. Branch Circuit Protection Required BEER SEE TABLE ABOVE See for Maximum Required Input Current MODEL MBC BATTERY CHARGER STAI RTIN EXTERNAL WIRING LARE BLUFF ELL MOIS SCHEMATIC DIAGRAM MODEL 19 ARNE Pate TO BATTENT BATTER T CHARGER DemECTHMA DF HAL FOWEN DE IRF CER LAT MECERSRBANILY 1 Een EC TION 8 BATTERY CONDITION fully charged battery will be indicated by low Charger output current and for lead acad barreries a full charge specific gravity hydrometer reading cells A battery which has approached end of life will have a reduced ampere hour capacity something less than the battery s rate capacity An adequate check of a battery for capacity in an engine starting application is to monitor the battery voltage while it is cranking the engine during expected worst case starting attempt If the battery was fully charged its cranking voltage should he at least 7595 of nominal voltage 9 volts minimum ona 12 volt lead acid battery which have sufficient capacity but which are not fully charged may pass this test TION Connect per installation instrucrions and apply A C power wwer from the Charger before attempting to service the Charger or before connecting ures or sparks WARNING disconnect turn aff or remove A C or disc
28. Insufficient circulation af cooling air Generator location and enclosure design must provide adequate air flow 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 Tighten realign or replace coupling Belt slap or loose guards Check belt tensioning Check belt quard fasteners EQUIPMENT RUNS NORMALLY ON UTILITY POWER BUT WILL NOT RUN ON GENERATOR SET CAUSE CHECK AND REMEDY Distorted voltaqe waveform Analyze load Excessive SCR thyristor loading will cause distortion Some equipment may be sensitive te distorted waveforms Refer ta Marathon Electric Improper rator voltage Check name plates of devices comprising the load Compare required voltage and frequency frequency with that af 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 SPECIFICATIONS MODEL FRAME SIZE EXCITER RESISTANCE lt _ STATOR ROTOR 2B1 2B2 283 2B4 361 362 363 dedicated sing la phase 431 432 433 three phase L 431 432
29. TIE 7 Numberofcyindes 4 E I Total displacement L cuin e 5 Combustion type Direct injection type E CDIS SAE NET Intermittent KW H P SAEJ1349 HP min r SAE NET Continuous kW min H P SAEJ1349 HP SAE Standby kW min SAEJ1349 HP min Maximum bare speed Maximum bare idling speed rpm 775 to 825 Order of firing 1 3 4 2 5 3 8 3 rpm rpm 62 0 2600 83 1 2600 fo rpm 2800 L 4 71 4 2600 95 7 2600 83 Order of firing Counter clockwise viewed from flywheel side Injection pressure MPa First opening pressure 18 63 190 2275 kgf psi Second opening pressure 23 54 240 3128 Lubricant API classification length x width x height 29 33 x 21 61 x 31 26 Charging generator 12V 1080W KEA 720W EU 12V 136AH 400 CCA or higher Recommended battery capacity 17 8 SAE rating NOTE Specifications are subject to change without notice 28 SPECIFICATIONS Bore and stroke mm n ENGLISH SAE NET Continuous KW mi rpm H P 1349 HP min rpm SAE Standby kW min rpm 33 6 1800 45 0 1800 H P SAEJ1349 min 27 51 1500 36 9 1500 1890 13 42 Counter clockwise viewed from flywheel side length x width x height 30 28 x 2
30. UFRO adjustment Carefully turn VOLTS control clockwise until rated voltage is reached If instability is present at rated voltage refer to stability adjustment then re adjust voltage if necessary O STABILITY ADJUSTMENT The AVR includes a stability or damping circuit to provide good steady state and transient performance of the generator The correct setting can be found by running the generator at no load and slowly turning the stability control counter clockwise until the generator voltage starts to become unstable The optimum or critically damped position is slightly clockwise from this point i e where the machine volts are stable but close to the unstable region OPTIMUM RESPONSE SELECTION The stability selection should be correctly linked A B or A C at the bottom of the board for the frame size of the generator UNDER FREQUENCY ROLL OFF UFRO ADJUSTMENT The AVR incorporates an under speed protection circuit which gives a volts Hz characteristic when the generator speed falls below preset threshold known as the point The red Light Emitting Diode LED gives indication that the UFRO circuit is operating The UFRO adjustment is preset and sealed and only requires the selection of 50 60 Hz 4 pole 6 pole using the jumper Adjustment of the UFRO potentiometer will only be necessary if the AVR is being fitted to a 6 pole generator to replace an AVR of an ea
31. covering and inserting additional heating units A hole shouldbe 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 Forced Air Another method to dry the generator is to run the sel with 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 generator Heat at point of entry should not exceed 80 C 180 F TESTING Visual Inspection 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 which may have been drawn into the generator Verify that the generators air gaps main rotor and exciter are free from obstructions If possible rotate the generator manually to ensure free rotation Never bar aver the engine generator set suing the generator fan WARNING THE FOLLOWING TEST MUST BE CONDUCTED BY QUALIFIED ELECTRICAL PERSONNEL LETHAL 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 RESLLT CONSTANT EXCITATION TEST 12V BATTERY TEST The
32. shall replace ihe electi se product stihacompaiatle new product nr repair the defective product That express warranty shall he inapplicable io any penduct not properly installed aed y ated hy ibre uset Or us any prac damaged q unpaired by exiernal forces THIS 5 THE EXTENT OF WARKAS TIES AVAILABLE ON THIS PRODUCT RACOR SHALL HAVE NO LIABILITY WHATSOEVER FOR CONSEQUENTIAL DAMACES FLU THE USE OF ANY DEFECTIVE PRODUCT OR BY REASON OF THE FAILURE OF PRODUCT RACOR SPECIMCALLY DISAVCO S ALL OTHER WARRANTIES OR IMPLIED WITHOUT LIMITATION ALL WARRANTIES OF FITNESS POR PARTICULAR PURPOSE EXCEPT POR THOSE WHICH APPLY TO PRODUCT OR PART THEREOF THAT iS USED OR BOUGHT FOR USE PRIMARILY FOR PERSONAL FAMILY OR HOUSEHOLD PURPOSES WARRANTIES OF DESCRIPTION WARRANTIES OF MERCHANTABILITY TRADE USAGE OR WARRANTIES TRADE USAGE Hacor s policy is ana of continual improvement in design and manufacturing to insure still liner products therefore specifications equipment and product information while correct at the time of publication is subject to change without notice Copyright PARKER HANNIFIN CORPORATION 2000 Product Brochure Part Number 22360 Rav C ATHLON Athlon Generator User s Manual SAFETY PRECAUTIONS Safety precautions are absolutely necessary during installation and maintenance of your Athlon generator Warning messages are contained throughout this documen
33. 0 4 to 4 Seconds System Response AVR response 10 ms Field Current to 90 80 ms Machine Volts to 97 300 ms External Voltage Adjustment 10 w 1k ohm 1 trimmer Under Frequency Protection Set Point 95 Hz Slope 100 300 down to 30 Hz Max Dwell 20 Volts S Recovery Unit Power Dissipation 18 Watts Max Analog Input Maximum Input 5 VDC Sensitivity 1V per 5 Generator Voltage adjustable Input Resistance 1K Ohms Quadrature Droop Input 10 Ohms burden Max Sensitivity 0 22A for 5 droop Max Input 0 33A 10 Ohms Burden Sensitivity Range 0 5 1 Over Voltage detector Input Set Point 300 V Time delay 1 second fixed CB Trip Coil Voltage 10 30 VDC CB Trip Coil Resistance 20 60 Ohms Over Excitation Protection Set Point 75 VDC Time Delay 8 15 seconds fixed Environment Specifications Operating Temperature 40 C to 70 Relative Humidity 0 70 C 0 95 non condensing Storage Temperature Current Limit Input 55 C to 80 20 100 Hz 50 mm sec 100 2K Hz 3 30 Vibration NOTES 1 with 4 Engine Governing 2 after 10 minutes 3 some de rating may occur at voltage extremes 4 factory set semi sealed select w jumper 5 device connected must be galvanically isolated from ground gt 500 VAC 6 De rating linear from 3 7 A at 50 C to 2 7 A at 70 C 52 WIRING DIAGRAM ROTATING RECTIFIER ROTOR EXCITER ROTOR ROTOR TYPICAL WAIN STATOR P M STATOR EXCITER STA
34. 5000 ppm to 1 0 10000 ppm is used as a diesel fuel change the engine oil and oil filter at shorter intervals approximately half DO NOT USE Fuels that have sulfur content greater than 1 0 10000 ppm Diesel fuels specified to EN 590 or ASTM D975 are recommended No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN87 Since KUBOTA diesel engines of less than 56 kW 75 hp utilize EPA Tier 4 and Interim Tier 4 standards the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines when operated in US EPA regulated areas Therefore please use No 2 D 5500 or 515 diesel fuel as alternative to No 2 D and use No 1 D S500 or 515 diesel fuel as an alternative to No 1 D for ambient temperatures below 10 C 14 F 1 SAE Society of Automotive Engineers 2 EN European Norm 3 ASTM American Society of Testing and Materials 4 US EPA United States Environmental Protection Agency 5 No 1 D or No 2 D S500 Low Sulfur Diesel LSD less than 500 ppm or 0 05 wt No 1 D or No 2 D 515 Ultra Low Sulfur Diesel ULSD 15 ppm or 0 0015 wt IMPORTANT Be sure to use a strainer when filling the fuel tank or dirt or sand in the fuel may cause trouble in the fuel injection pump For fuel always use diesel fuel You are required not to use alternative fuel because its quality is unknown or it may be inferior in quality Kerosene
35. ADDITIVE AS A SHORTENED HEATER LIFE WILL RESULT 1 6 Installation Inspection Run engine up to operating temperature and check installation for leaks Check all pipe fittings and hose connections at the heater as well as at the engine Run the engine until all air is bled from the cooling system Let engine cool down and add additional coolant if necessary 1 7 Operation Check The heater case will warm up quickly and become hot to the touch The outlet hose should be warm and the inlet hose comparatively cool if the coolant is circulating freely If the inlet hose gets very warm before entire system is warm the coolant is not circulating freely due to one or more of the following reasons 1 airlock in hoses due to loops kinks excessive lengths or routing over top of engine 2 heater mounted too high 3 heater not mounted with arrow pointing 4 dirtin cooling system 5 improper coolant mixture or 6 Y itting not directing flow of coolant properly Leave the heater plugged in for a period of up to one hour checking at regular intervals by feeling heater hose at both inlet and outlet If the heater appears to be operating incorrectly or not at all consult your vendor for further instructions 2 0 HEATER MAINTENAN 2 1 Regular Maintenance Periodically check all hoses for damage due to ageing elevated temperatures particularly the portion of hase immediately above the heater outlet over torqued hose clamps abra
36. Alternator Self Excited 60 Hz Insulation Class 0 8 Power Factor 40 C Ambient AG Series Model No and ratings as follows APPLICABLE REQUIREMENTS CAN CSA C22 2 No 0 M9 General Requirements Canadian Electrical Code Part Il CAN CSA C22 2 0 4 04 Bonding of Electrical Equipment CSA C22 2 No 100 04 Motors and Generators ANSI UL 1004 1 1 Edition Rotating Electrical Machines General Requirements ANSUUL 1004 4 1 Edition Electric Generators he C and 1 8 indicators adjacent to the CSA Mark signify thal the produci has been evaluated to the applicable CSA and Standards for use in Canada and the US respectively This US indicator includes products eligible to bear the indicator NR11 National Recognized esting Laboratory is designation granted by the LI S Occupational Safety and Health Administration OSHA to laboratories which have been recognized to perform certification to US Standards M e DOD 507 Rev 2004 06 30 58 ATHLON ATHLON GENERATOR LLC Montross Virginia 1 r1 Il Il 5 LOW OIL PRESSURE SWITCH N C WATER TEMP GLOW PLUGS SWITCH N O GRAY SPLICE LI GRAY es soon 71 GAUGE SENDERS OPTIONAL Cy RED BATTERY CABLE TS
37. CONTROL FUNCTION ROTATION Output Voltage Adjustment Clockwise to Increase Voltage STABILITY Voltage Hunting Prevention Clockwise to Increase Dampening UFRO Setting of UFRO knee point Clockwise Reduces Knee Point To set gen droop to 5 at OPF Clockwise Increases Droop To Optimize Analog Input Sensitivity Clockwise Increases Gain 1 Under Frequency Roll Off UFRO 49 ADJUSTMENT OF AVR CONTROLS AGR341 VOLTAGE ADJUSTMENT The generator output voltage is set at the factory but can be changed by careful adjustment of the VOLTS control on the AVR board or by the external hand trimmer if fitted Terminals 1 and 2 on the AV R will fitted with a if no hand trimmer is required CAUTION D o not incre ase the voltage a bove the rate d gener ator volt age If in dou bt refer to the name plat e mounted on the generator case CAUTION Do not ground any of th e hand trimmer terminals as these could be above ground potential Failure to observe this could cause equipment damage CAUTION Before running generator turn the VOLTS control fully counter clockwise Turn remote volts trimmer if fitted to midway position Turn STABILITY control to midway position Connect a suitable voltmeter 0 300V ac across line to neutral of the generator Start generator set and run on no load at nominal frequency e g 50 53 Hz or 60 63 Hz If the red Light Emitting Diode LED is lit refer to the Under Frequency Roll Off
38. DAMAGE THE FAN AND RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE GENERATOR MOUNTING Single Bearing Units Single bearing units are provided with an SAE flywheel housing adapter flange and flexible drive discs Coupling the generators shaft ta the engine flywheel is accomplished with special steel drive discs bolted ta the shaft In addition to the drive discs there may be a hub spacer spacer discs 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 af the coupling discs which correspond to tapped holes in the prime movers flywheel The outside diameter of the drive discs fit in a rabbet in the flywheel so that concentricity is assured Grade 8 place bolts and hardened washers recommended to mount the drive discs ta the flywheel DO NOT USE FPLIT TYPE LOCK WASHERS Split lock washers whi n biting inta the drive disc cause stress risers which may result in the disc fracturing The SAE flywheel housing adapter ring and the engine flywheel housing are designed to match each ather with no further alignment grzde 5 or greater mounting bolts MagnaPLUS generator frames constructed with two or three bolt hales 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
39. F 790 Heat is supplied just below the replacement element to melt the wax crystals and allow fuel to efficiently pass through the element The heater will automatically turn off at about 75 F 24 C The 200 watt heater is available in 12 or 24 vdc volts direct current The heater is operated by turning on the ignition switch for a minimum of five minutes prior to starting the engine CUSTOMER SUPPLIED ITEMS Manual on off switch optional P ER 1 Because of the heater power demand 20 amps for 12 vdc and 10 amps for 24 vdc an additional relay is recommended for the safest method of installation Racor offers two relay kits available from your dealer RK 11861 for 12 vde systems or AK 11862 for 24 vde systems These kits include an in line fuse holder and fuse and the HK11862 kit also includes a resistor Use the 25 amp fuse with 12 vdc and the 15 amp fuse and resistor with 24 vdc systems 2 An on off toggle switch may be used to control power to the heater relay This allows the operator to cut power to the heater relay during summer use 3 All wires should be 14 AWG American Wire Gauge minimum INSTALLATION Ignition Either heater wire may be used for Hot or Ground Switch 2 Wire terminal connections should be soldered and crimped 3 Run wires in protected locations Avoid hot surfaces and For 24 vdc systems install the resistor places that could pinch or rub on the wires and use the 15 am
40. Heaters may not be used with these models PART NUMBER IDENTIFICATION The example below illustrates how part numbers are constructed 2458 M _ 215R Metal bowl In bowl In bowl Filter 15 GPH Omit if Water Fuel Heater Micron not desired Probe 12 vdc or Rating 30 GPH Specify 24 vdc Not Specify ri lor UL Omi for manne one 245H Manne if nal use 2 10 45 Models desired not desired or 30 INSTALLATION INSTRUCTIONS Determine the LOCATION The Racor 215R 230R and 245R Models may be located on the suction vacuurn side or pressure side up to 30 PSI of the fuel transfer pump For optimum water separation efficiency install unit on the suction side Determine the FILTRATION Primary 30 micron Secondary 10 micron or Final 2 micron filtration The first filter downstream from the fuel tank to the engine is a primary filter Typically this filteris rated for 30 microns however a 10 micron may also be used Between this filter and the engine is a secondary filter optional and it should be rated for 10 micron filtration The final filter prior to the engine injection pump should be equipped with a 2 micran filter BEFORE INSTALLING THE UNIT 1 Ensure fuel port fittings are in hand along with fuel line hardware and ail needed tools and materials 2 Maintain sale working environment The en
41. Ohms and the full load field current does not exceed the maximum continuous current rating of the controller a resistor of ample wattage must be added in series with the field to increase the total resistance to 15 Ohms FREQUENCY COMPENSATION The frequency compensation feature improves system load pickup performance by restraining voltage recovery until the frequency has also started to recover The corner frequency range 15 set for 50 Hz or 60 Hz by connecting the Corner Frequency Jumper to the appropriate terminal The corner frequency setting 1s adjusted by the Underfrequency Control potentiometer Clockwise rotation increases the corner frequency and Counterclockwise rotation decreases the corner frequency Current Version OVEREXCITATION SHUTDOWN The overexcitation shutdown feature removes controller output power after a time delay 1f the exciter field voltage exceeds 100V DC 5 The time delay 15 inversely proportional to the magnitude of the detected overvoltage up to 135V DC Beyond 140V DC the field voltage is removed after approximately two seconds Once the output power 15 removed the controller can be reset by decreasing the input voltage to less than 10V AC for two seconds minimum This can be achieved by stopping the prime mover or by interrupting the controller input power with a reset switch SYSIEM START UP start engine allow a few minutes to warm up to operating temperature and rated speed Generator voltage s
42. Qualified trained technicians MUST do installation and repairs The cautions and warnings point out known conditions and situations that are considered potentially hazardous Each installation WILL also have its own set of hazards that will only be identified by personnel that have been properly trained TABLE OF CONTENTS SECTION 1 PRINCIPLE OF OPERATION SECTION 2 INSTALLATION SECTION 3 OPERATION SECTION 4 SERVICE SECTION5 TROUBLE SHOOTING GUIDE Appendix Generator Warranty Appendix B Generator Data Appendix C Parallel Operation Appendix D SAE Data Appendix E AVR Data Sheets Appendix F Athlon Certifications 1 PRINCIPLE OF OPERATION Athlon generators are brushless self excited or permanent magnet generator PMG excited synchronous AC generators All units utilize sophisticated Automatic Voltage Regulators AVR to control the output voltages and frequencies The self excited 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 AVR The optional PMG adds the PMG excitation to the unit PMG Optional PERMANENT ERE MAGNET STATOR STATOR PERM EXCITOR MAGNET ROTOR AUTOMATIC VOLTAGE REGULATOR OUTPUT POWER GENERATOR STATOR GENERATOR ROTOR ROTATING RECTIFIER SHAFI SHAFT
43. TED CORE INSULATED WREEHED CABLE 19 RESH WEKGED SCREEN TO TERMINAL 2 DHLY CLOCKWISE DW INCREASES VOLTS 51 AGR440 STATOR CY Ne OUTPUT WIN CA HG TERMIN ALS C Tiwhen FOR POSTON SEE 43 OPERATION K2 P2 P3 XX X 3 Trim K1 K2 Power isolation link normally fitted Droop 1 Volts 2 Sensing AGR440 links 6 standard x positions Frequency Stability CD Stabjlity Indicator gt 550kW LE 50H 550kV E C L ligas CONTROL FUNC ROTATION VOLTS Output Voltage Adjustment Clockwise to Increase Voltage STABILITY Voltage Hunting Prevention Clockwise to Increase Dampening UFRO Setting of UFRO knee point Clockwise Reduces Knee Point DROOP To set gen droop to 5 at 0 PF Clockwise Increases Droop VTRIM To Optimize Analog Input Sensitivity Clockwise Increases Gain 1 Under Frequency Roll Off UFRO 44 ADJUSTMENT AVR CONTROLS AGR440 VOLTAGE ADJUSTMENT The generator output voltage is set at the factory but can bechanged by careful adjustment of the VOLTS control on the AVR board or by the external hand trimmer if fitted Terminals 1 and 2 on the AVR will be fitted with a jumper if no hand trimmer is required CAUTION Do not increase the voltage above the rated generator voltage If in doubt refer to the name plate mounted on the generator case CAU
44. The dc signal applied to this input adds to the AVR sensing circuit A1 is connected to the AVR O volts Positive on A2 increases excitation Negative on A2 decreases excitation The TRIM control allows the user to adjust the sensitivity of the input With TRIM fully counter clockwise the externally applied signal has no effect Clockwise it has maximum effect Normal setting is fully clockwise when used with a Power Factor Controller 46 ATHLON AGR341 AUTOMATIC VOLTAGE REGULATOR SPECIFICATIONS sensing Input Voltage 190 264V AC Frequency 50 60 Hz nominal Phase Single Phase Power Input PMG Voltage 140 220 VAC Frequency 100 120 Hz nominal Current 3 Amps per Phase Output Voltage Max 120 VDC Current Continuous 2 7 ADC Intermittent 6A 10 sec Resistance Minimum 15 Ohms Regulation 1 0 Thermal Drift 0 03 per degree C in AVR ambient Soft Start Ramp Time 3 Seconds System Response AVR response 10 ms Field Current to 90 80 ms Machine Volts to 97 300 ms External Voltage Adjustment 10 w 1k ohm 1 waitt trimmer Under Frequency Protection Set Point 95 Hz Slope 170 down to 30 Hz Unit Power Dissipation 12 Watts Max Analog Input Maximum Input 5 VDC Sensitivity 1V per 5 Generator Voltage adjustable Input Resistance 1K Ohms Quadrature Droop Input 10 Ohms burden Max Sensitivity 0 07A for 5 droop OPF Max Input 0 33A Over Excitation Protection Set Point 75 VDC Time Delay 10 seconds fixed Enviro
45. VOLTAGE REGULATOR SPECIFICATIONS Input Voltage 95 132V or 190 264V AC jumper Frequency 50 60 Hz nominal Phase Single Phase Max 90V DC 207V AC input Current Continuous 4A DC Intermittent 6A 10 sec Resistance Minimum 15 Ohms oystem Response AVR response 20 ms Field Current to 90 80 ms Machine Volts to 9796 300 ms External Voltage Adjustment 10 w 1k ohm 1 watt trimmer Under Frequency Protection Set Point 95 Hz Slope 170 down to 30 Hz Unit Power Dissipation 10 Watts Max Build up Voltage 4 Volts at AVR terminals Environment Specifications Operating Temperature 40 C to 70 Relative Humidity 0 70 0 95 non condensing Storage Temperature 55 to 80 Vibration 20 100 Hz 50 mm sec 100 2K Hz 3 3g 1 with 4 Engine Governing 2 after 10 minutes some de rating may occur at voltage extremes 4 factory set semi sealed select w jumper 38 WIRING DIAGRAM ROTATING RECTIFIER EXCITER ROTOR MAIN ROTOR EXCITER STATOR TYPICAL MAIN STATOR sa _ DR rU A l 1 F1 ES F2 WX iX 8 7 HAND TRIMMER whan fitted REMOVE LINK ACADSS 1 4 2 DER 3 THE LEE TER DORE INSULATED ae pn EE AGR460 2 087 3 x ua Z _ 39 OPERATION OL pers JO VOLTS AGR460 UFRO Under Frequency Roll a INDICATOR LED FREQUENCY
46. Warranty shall cover defected materials and workmanship for the above time period Power Technology shall supply replacement parts at no charge The customer shall be responsible for all transportation costs import duties legal documents including but not limited to import licenses customs declaration or inspection services In all cases 1f local warranty services are available through manufacturers representation manufacturers standard warranty shall supersede Power Technology s warranty and any warranty or parts and labor shall be that of the manufacturer The terms and conditions of the manufacturer warranty shall be those offered by the manufacturer for the country or region covered by the manufacturers representative SECTION 1 SAFETY SAFE OPERATION 1 4 Observe Safety Instructions Wear Safety Clothing Check Before Operating the Engine Keep Area Around the Engine Clean Safe Handling of Fuel and Lubricants Exhaust Gases and Fire Prevention Escaping Fluids Cautions Against Burns and Battery Explosion Keep Hands and Body Away From Rotating Parts Anti Freeze and Disposal of Fluids Conducting Safety Checks and Maintenance SAFETY FIRST This symbol the industry s Safety Alert Symbol is used throughout this manual and on labels attached the machine itself It warns of the potential for personal injury It is essential that you carefully read the instructions and safety regulations before you attempt to assemble or u
47. 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 Removethe 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 ahmmeter or a battery light continuity testerplace one test probe on the diode lead terminal past In succession touch the other test probe to the lead screw hole in each heat sin Reverse the probes and repeat the procedure Your have now tested the three diodes connected this terminal post inboth the forward and reverse direction Repeat the procedure using the other diode terminal post Forward Terminal End Reverse 91 Anode Cathode 5 Stud End I Cathode Anode _ FIGURE 3 DIODE POLARITY 2 MLAFLATHUN _ ms A Sahurhary nf Cororatin When the positive test probe 5 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 continu
48. an engine speed governing system that maintains the engine speed RPMs by adjusting the Fuel Control Actuator controlling the fuel injection unit The APECS microprocessor based Controller processes the signal received from a speed sensor in this application a Magnetic Pick up and compares it to the programmed settings These setting are maintained regardless of the load applied to the engine The APECS Controller is software programmable and must utilize the CALT calibration tool for configuring and adjusting the settings CALT 1s a software based calibrating and monitoring tool which permits the user to calibrate the controller as well as make adjustments to the program even while in operation CALT allows adjustments to the PID gain settings for proper tuning of an application The PID gains adjustments will improve response time steady state and stability In the engines performance The APECS Controller retains these settings in memory during shut down periods The settings can also be saved to file for later viewing and printing and may be used to program another controller CALT can be run on an IBM compatible PC a laptop computer 1s desirable for its convenience and portability The APECS Controller is accessed through an Interface Module which provides a connection to the PCs serial port with a 9 pin RS 232 cable Magnetic Pick up E mmm Fuel Actuator 9 Pin RS 232 Cable APECS Model 3100 GAC ESD2100 SERIES SPEED CONTROL
49. and adjust it for proper speed See generator nameplate af Carpani 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 I 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 consull the factory 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 WARNING THE FOLLOWING TEST MUST BE CONDLICTED BY QUALIFIED ELECTRICAL PERSONNEL LETHAL VOLTAGE MAY BE PRESENT AT BOTH THE GENERATOR AND VOLTAGE REGULATOR TERMINALS DURING THIS PROCEDURE CAUTION generator terminals while the generator is al rest Failure to comply could result in personnel injury or equipment damage If the unit is equipped with space heaters verify that the heater circuit is energized MAINTENANCE The following maintenance procedures should befollowed to ensure long equipment life and satisfactory performance Maintenance intervals will depend upon operating conditions T Routinely check intake and exhaust air screens to ensu
50. fan and belt 6 SAFE OPERATION Replace fuel pipes and lubricant pipes with their hose clamps every 2 years or earlier whether they are damaged or not They are made of rubber and age gradually When servicing is performed together by two or more persons take care to perform all work safely Keep a first aid kit and fire extinguisher handy at all times 12 WARNING AND CAUTION LABELS CD Part No 19077 8724 1 or 16667 8724 1 Part No TA040 4957 1 55mm in diameter 37mm in diameter Stay clear of engine fan and fan belt 2 BUH PpP 57 A CAUTION DANGER never open When hot 1ABACAAAPO36K 1AGAMAAAP2620 13 CARE OF WARNING AND CAUTION LABELS 1 Keep warning and caution labels clean and free from obstructing material 2 Clean warning and caution labels with soap and water dry with a soft cloth 3 Replace damaged or missing warning and caution labels with new labels from your local KUBOTA dealer 4 f a component with warning and caution label s affixed is replaced with a new part make sure the new label s is are attached in the same location s as the replaced component 5 Mount new warning and caution labels by applying to a clean dry surface and pressing any bubbles to the outside edge Your dealer is interested in your new engine and has the desire to help you get the most value from it After reading this manual thoroughly you will find that you can do s
51. fuel should spill wipe it off at once or it may cause a fire Do not fail to stop the engine before refueling Keep the engine away from the fire Be sure to stop the engine while refueling or bleeding and when cleaning or changing fuel filter or fuel pipes Do not smoke when working around the battery or when refueling Check the above fuel systems at a well ventilated and wide place When fuel and lubricant are spilled refuel after letting the engine cool off Always keep spilled fuel and lubricant away from engine level check and refueling 1 Check to see that the fuel level is above the lower limit of the fuel level gauge If the fuel is too low add fuel to the upper limit Do not overfill Carbon Flash Point Water and Residue on Sediment 10 percent volume F Residuum SUS at 0 2 90 mms at 37 8 C 100 F Point 40 C Copper Strip Corrosion Cetane Rating The minimum recommended Fuel Cetane Rating is 45 A cetane rating greater than 50 is preferred especially for ambient temperatures below 20 C 4 F or elevations above 1500 m 5000 ft Diesel Fuel Specification Type and Sulfur Content ppm used must be compliant with all applicable emission regulations for the area in which the engine is operated Use of diesel fuel with sulfur content less than 0 10 1000 is strongly recommended If high sulfur fuel sulfur content 0 50
52. housing there is na side thrust or pull an the generator frame thus no real need to secure the feet with than one bolt per foot 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 driver and the generator s shaft Aligning the generator and its driver as accurately as possible will reduce vibration increase bearing life and ensure minimum coupling wear t may be necessary lo shim the generator feet for proper support and alignment Secure the feet of the generator with grage 5 or greater bolts through the holes provided in the 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 bells are used a vibration may be introduced which could lead to premature failure of the bearings END PLAY TESTING Refer to the engine manual for recommended end play specifications and measurement procedures If end play is not to specifi
53. if electric cables and wiring are swollen hardened or cracked Keep dust and water away from all power connections Loose wiring terminal parts make bad connections Be sure to repair them before starting the engine Damaged wiring reduces the capacity of electrical parts Change or repair damaged wiring immediately FAN BELT i Adjusting Fan Belt Tension A CAUTION To avoid personal injury sure to stop the engine and remove the key before checking the belt tension Be sure to reinstall the detached safety shield after maintenance or checking A deflection of between 10 to 12 mm 0 39 to 0 47 in when the belt is pressed in the middle of the span Proper fan belt tension 1 Stop the engine and remove the key 2 Apply moderate thumb pressure to belt between the pulleys 3 If tension is incorrect loosen the alternator mounting bolts and using a lever placed between the alternator and the engine block pull the alternator out until the deflection of the belt falls within acceptable limits 4 Replace fan belt if it is damaged IMPORTANT f belt is loosen or damaged and the fan is damaged it could result in overheats or insufficient charging Correct or replace belt 1 Fan belt 2 Bolt and nut A 10 to 12 mm 0 39 to 0 47 in under load of 6 7 kgf 13 2 15 4 Ibs CARRIAGE AND STORAGE 23 CARRIAGE AND STORAGE CARRIAGE CAUTION To avoid personal inju
54. located inside the saddle box If unsure check the continuity between the neutral terminal inside the saddle box and any inner unpainted panel in the saddle box The gen set builder is responsible for verifying the generator frame generating set bedplate and the main ground output terminal are electrically bonded If unsure about the ground connection or simply to verify remove the saddle box cover and perform a continuity check between the main ground output terminal and any inner unpainted panel in the saddle box Also check for continuity between the main ground output terminal and the generator set bedplate 3 2 4 PROTECTION The installer and or end user is responsible for making sure that all local electrical and safety codes and regulations pertaining to the installation site are followed 13 4 SERVICE Performing routine service will help keep your generator running smoothly The condition of the winding and bearings should be examined periodically especially if the generator has been idle for a long time Also regular inspection and maintenance is required for generators fitted with air filters 4 1 AIR FILTERS AN Removal of filters exposes live parts Unit must be OFF Air filters for the removal of airborne particulate matter dust are offered as an additional option Filters need to be ordered concurrently with the generator Air filters need to be charged with oil before the engine generator is used Filter maintenance
55. not installed plug them at both ends with clean cloth or paper to prevent dirt from entering Dirt in the pipes can cause fuel injection pump malfunction B Du C4 b S Sus E yer a SS w 0 x S k k 1 Clamp band 2 Fuel pipe llCleaning the fuel filter pot Every 100 hours of operation clean the fuel filter in a clean place to prevent dust intrusion 1 Close the fuel filter lever 1ABACAAAPO110 1 Fuel filter lever A OFF 2 Fuel filter pot B ON 2 Remove the top cap and rinse the inside with diesel fuel 3 Take out the element and rinse it with diesel fuel 4 After cleaning reinstall the fuel filter keeping out of dust and dirt 5 Air bleed the injection pump IMPORTANT Entrance of dust and dirt can cause a malfunction of the fuel injection pump and the injection nozzle Wash the fuel filter cup periodically O ring Filter element Filter bowl 1 2 3 Spring 4 5 Screw ring Mi Fuel filter cartridge replacement 1 Replace the fuel filter cartridge with a new one every 500 operating hours 2 Apply fuel oil thinly over the gasket and tighten the cartridge into position by hand tightening only 3 Finally vent the air IMPORTANT Replace the fuel filter cartridge periodically to prevent wear of the fuel injection pump plunger or the injection nozzle due to dirt in the fuel Fuel filter cartridge Air vent plug Pipe joint
56. of fuel if necessary Fuel is thick and doesn t flow Air or water mixed in fuel system Engine oil becomes thick in cold weather and engine cranks slow Battery is discharged and the engine will not crank impurities As all fuel will be filtered by the filter if there should be water or other foreign matters on the filter clean the filter with kerosene If air is in the fuel filter or injection lines the fuel pump will not work properly To attain proper fuel injection pressure check carefully for loosened fuel line coupling loose cap nut etc Loosen joint bolt stop fuel filter and air vent screws of fuel injection pump to eliminate all the air in the fuel system Change grade of oil according to the weather temperature Charge battery In winter always remove battery from machine charge fully and keep indoors Install in machine at time of use HM When output is insufficient Fuel is insufficient Check fuel system Check lubricating oil system Check to see if lubricating oil filter is working properly Filter element deposited with impurities would cause poor lubrication Change element Air cleaner is Clean the element every 100 hours of dirty operation Do not use poor quality fuel as it will cause wear of the pump Only use No Overheating of moving parts Injection pump wear 2 D diesel fuel See FUEL in PERIODIC SERVICE section NOTE
57. one day s work 1ABACAAAPO 170 1 Recovery tank A FULL B LOW 3 When the coolant level drops due to evaporation add water only up to the full level 4 Check to see that two drain cocks one is at the crankcase side and the other is at the lower part of the radiator as figures below 1 Coolant drain cock IMPORTANT If the radiator cap has to be removed follow the caution and securely retighten the cap If coolant should be leak consult your local KUBOTA dealer Make sure that muddy or sea water does not enter the radiator Use clean fresh water and 50 anti freeze to fill the recovery tank Do not refill recovery tank with coolant over the FULL level mark Be sure to close the radiator cap securely If the cap is loose or improperly closed coolant may leak out and decrease quickly Changing coolant 1 To drain coolant always open both drain cocks and simultaneously open the radiator cap as well With the radiator cap kept closed a complete drain of water is impossible 2 Remove the overflow pipe of the radiator pressure cap to drain the recovery tank 3 Prescribed coolant volume U S gallons V3600 E3 V3600 T E3 V3800 DI T E3 V3300 E3BG V3600 T E3BG V3800 DI T E3BG 9 0 L 2 38 U S gal NOTE Coolant quantities shown are for standard radiators 4 An improperly tightened radiator cap or a gap between the cap and the seat quickens lo
58. operation See ENGINE OIL in PERIODIC SERVICE section 2 When ambient temperature is low operate the machine after the engine has been completely warmed up DAILY CHECK To prevent trouble from occurring it is important to know the conditions of the engine well Check it before starting CAUTION To avoid personal injury Be sure to install shields and safeguards attached to the engine when operating Stop the engine at a flat and wide space when checking Keep dust or fuel away from the battery wiring muffler and engine to prevent a fire Check and clear them before operating everyday Pay attention to the heat of the exhaust pipe or exhaust gas so that it can not ignite trash 1 Parts which had trouble in previous operation 2 By walking around the machine 15 to 20 4 Amount of coolant 8 5 Dust in air cleaner dust cup 21 22 O lt TT 3 By inserting the key into the starter 1 Proper functions of meters and pilot lamps no stains on switch these parts 2 Proper function of glow lamp timer 4 By starting the engine 1 Color of exhaust fumes 2 Unusual engine noise 3 Engine start up condition 4 Slow down and acceleration behavior 6 Damaged parts and loosened bolts and nuts o O lt TT 4 OPERATING THE ENGINE OPERATING THE ENGINE STARTING THE ENGINE NORMAL A CAUTION To avoid personal injury Do not allow children to approa
59. out the rotor will drop on the main stator core Having the rotor in this position will limit tha 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 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 brackel is removed Remove the bearing bracket retaining bolts Using a pair of screw drivers wedge Ihe 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 an the main stator core Continue to pull the bracket free from the bearing inspect the bearing bore and o ring if equipped far damage wear if worn or damaged repair or replace prior to reassembly Drive End Bearing Bracket Removal Two Bearing Units 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 bdfore 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 Afler ap
60. parts controls or projections may cause personal injury e Use additional safety items e g hardhat eye protection gloves etc as appropriate or required e DO NOT operate machinery or equipment while under the influence of alcohol medication or other drugs or while fatigued e DO NOT wear radio or music headphones while operating engine CHECK BEFORE OPERATING THE ENGINE e Ifthe engine is malfunctioning DO NOT operate until repairs are made e sure all guards and shields are in place before operating the engine Replace any that are damaged or missing e Check to see that the area around the engine 15 clear of foreigr objects before starting e Always keep the engine at least 3 feet 1 meter away from buildings or other facilities DO NOT allow children or livestock to approach the machine while In operation e DO NOT start the engine by shorting across starter terminals 1 AREA AROUND THE ENGINE CLEAN SAFE HANDLING OF FUEL AND LUBRICANTS EXHAUST GASES AND FIRE PREVENTION Be sure to stop the engine before cleaning Keep the engine clean and free of accumulated dirt grease and trash DO NOT stop the engine without idling Temperatures around the engine rises suddenly Keep the engine idling for about 5 minutes before stopping Always stop the engine before refueling or lubricating DO NOT smoke or allow flames or sparks in your working area Fuel is extremely flammable and explosive
61. proper use appears in the Generator s during the warranty period given that upon examination by Athlon the defect is solely due to defective material or workmanship The defective part is to be promptly returned FOB Athlon plant or other destination specified by Athlon All identification marks and numbers must be intact to aid identification Any part repaired or replaced under warranty will be returned to the customer by Athlon free of charge Athlon shall not be liable for any expenses that may be incurred in removing or replacing any part sent to us for inspection or in fitting any replacement part supplied by us Athlon shall have no liability for defects in any items which have not been properly installed in accordance with recommended installation practices This warranty shall be conditioned upon Athlon receiving written notice of any defect within 45 days after the defect is discovered In no event shall Athlon s liability for such defective or nonconforming products exceed the purchase price paid by Buyer for the item s In all cases of claims the Athlon decision shall be final on all questions as to defects and the exchange of a part or parts EXCLUSIONS This warranty does not 1 cover any tax duty custom inspection or testing fee or any other charge of any nature related thereto nor does it cover the costs of disassembling or removing defective equipment or reassembling reinstalling or testing rep
62. starter to cool 2 minutes between subsequent starting attempts IMPORTANT Damage to the Starter Motor Starter Solenoid Run Solenoid or any generator component due to excessive or prolonged starting attempts attributed to an external Low Battery Control Monitoring or Auto Start System will not be covered by the Power Technology Southeast Inc Limited Warranty OPERATOR S MANUAL 2 O Lu KUBOTA DIESEL ENGINE MODELS V3600 E3 V3600 T E3 V3800 DI T E3 V3300 E3BG V3600 T E3BG V3800 DI T E3BG 1J411 8911 4 READ AND SAVE THIS MANUAL 4 CONTENTS 22 E O lt LLI ASAFE OPERA TION cA 1 SERVICING OF THE ENGINE tene d kd intct 1 NAME SOF PART SQ 2 PRE OPERATION CHECK 3 BREAK IN tli oe MANNI OR RNC TURPE PROCU 3 DAILY CHECK dc 3 OPERATING THE ENGINE uyu uuu ndo teste e eden 4 STARTING THE 4 COLD WEATHER STARTING 5 STOPPING THE ENGINE SL lass 6 CHECKS DURING OPERATION u kuu u End cd teca td cvi oie 6 Radiator Cooling water Coolant 6 Oll pressure lamps su eee
63. the engine under normal operations toggle the Start Stop Switch to the Stop position 10 If a fault occurs turn Generator Main Switch OFF and then ON to reset PT ECU 64 CHECKING ENGINE AFTER STARTING 1 2 3 4 Allow the engine to warm up 3 to 5 minutes before applying a load In colder climates allow few extra minutes longer Perform a visual inspection of all areas of the engine and generator Listen for any abnormal noises Check for any abnormal exhaust gases SIOPPING THE ENGINE It is recommended to disconnect or reduce the power load from the generator before shutting down the engine Then follow the steps outlined above for normal shut down IMPORTANT Damage to the Starter Motor Starter Solenoid Run Solenoid or any generator component due to excessive or prolonged starting attempts attributed to an external Low Battery Control Monitoring or Auto Start System will not be covered by the Power Technology Southeast Inc Limited Warranty OPERATING THE ENGINE NON ECU CONTROLLED ENGINE STARTING CONTROLS 1 Main Switch Turns power On or Off to the engine start circuit 2 ON Position Must be in this position for the engine to start and run 3 OFF Position Used to cut the power to the start circuit of the engine Always turn the switch to the OFF position when servicing the generator set or engine 4 Start Position to use for starting the engine The switch will return to the original position when
64. voltmeter ammeter wattmeter measuring total power per generator and frequency meter is required in order to adjust the engine and generator controls to share kW in relation to engine ratings and kVAr in relation to generator ratings Reactive Load Control When two identical generators are operating together in parallel and an unbalance occurs in field excitation circulating currents begin to flow between the generators This current will appear as a lagging power factor or inductive load to the highly excited generator and as a leading power factor or capacitive load to the generator with the lower field current This is known as the reactive circulating current and there are two methods of controlling it in parallel operation Reactive droop compensation The bus voltage droops or decreases as the reactive lagging power factor load is increased Reactive differential compensation The reactive differential compensation circuit allows parallel generators to share reactive loads with no decrease or droop in generator voltage 31 Athlon Generators use the droop method The method of kVAr sharing is to create a generator voltage characteristic which falls with decreasing power factor increasing kVAr This is achieved with a current transformer C T which provides a signal dependent on current phase angle i e power factor to the AVR If parallel operation is envisioned for your generator please contact the f
65. your application therefore Power Technology can only suggest general installation requirements See Installation Requirements in Section 3 Follow all Safety Instructions as outlined In Sections 1 and 3 of this manual Other important Safety Precautions are posted through out the manual as well In the event you experience a problem with your generator please contact the sales dealer one of our authorized service centers or Power Technology s Customer Service Department directly at 1 800 760 0027 from 8 00 a m to 5 00 p m EST Please have the generator model and serial numbers available when you call This will help expedite service and parts to you Parts may be obtained directly through Power Technology and shipped the same day if ordered by 3 00 p m EST Generator Model Number Generator Serial Number POWER TECHNOLOGY SOUTHEAST INC 634 STATE RD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545 www PowerTech Gen com Limited Warranty Power Tech Generators Power Technology Southeast Inc warrants to you the original purchaser that each product of our manufacture 15 free from defects In materials and workmanship That each generator will deliver its rated output as indicated on The Power Technology Nameplate if properly installed serviced and operated under normal conditions in accordance with Power Technology s instructions THE WARRANTY COVERAGE TERMS 2 years from date of purchase or 3000 hours whicheve
66. 0 2 4 2 DIRECTION OF ROTATION Viewing from the drive end the direction of rotation is clockwise which follows the same direction of rotation used most often by diesel engine manufacturers The generator can be driven counter clockwise with small efficiency reduction and a higher noise level This will also change the phase rotation To correct this the output cables will need to be rewired Contact the factory for details 2 4 3 VOLTAGE AND FREQUENCY Verify that the voltage and frequency outputs listed on the generator nameplate match those required for the generator set application 2 4 4 AVR SETTINGS The automatic voltage regulator AVR settings are pre adjusted by the factory to give acceptable performance for initial testing However if adjustments need to be made the AVR can be accessed by removing the saddle box cover In some generators the AVR will have a cover over it which will need to be removed to gain access The generator will have one of four AVR models AGR460 AGR440 AGR341 or AGR321 A basic overview of adjustments is given below The complete datasheet for each model is provided below in Appendix E Please refer to the nameplate on the generator frame to determine which AVR model is installed in the generator 2 441 AGR460 Dutput jus tment Refer Dotosheet Renove this junper to ottech renote wol ocross These two termals AVR Input Valtage Place o jun
67. 0 10 x 30 31 NOTE Specifications are subject to change without notice NOTE FOR E3BG T E3BG type Flywheel type is SAE clutch No 11 1 2 SAE clutch No 10 or its equivalent Flywheel housing type is SAE No 3 or its equivalent Governor drop is within 596 Continuous will operate at the stated rating continuously and have a 10 overload capability for one hour in 12 hours Standby will operate at the stated full rating for one hour in 12 hours No overload capacity is specified for this rating SPECIFICATIONS 29 Bore and stroke 2 ENGLISH Combustion type Spherical type E TVCS SAE NET Continuous kW min rpm 39 2 1800 52 5 1800 H P SAEJ1349 rpm 32 1 1500 43 0 1500 SAE Standby kW min rpm 43 1 1800 57 8 1800 H P SAEJ1349 HP min rpm 35 3 1500 47 3 1500 1890 13 42 Counter clockwise viewed from flywheel side Injection pressure MPa kof psi 13 93 142 2020 Lubricant API classification above CF grade length x width x height 30 28 x 21 22 x 31 61 12 3 0KW Charging generator 12V 540W Recommended battery capacity 12V 88AH NOTE Specifications are subject to change without notice NOTE FOR E3BG T E3BG type Flywheel type is SAE clutch No 11 1 2 SAE clutch No 10 or its equivalent Flywheel housing type is SAE No 3 or its equivalent Governor drop is within 596 Continuous will operate at the stated rating continu
68. 0 Ohm Phase Phase Phase 0879 23 0 28 0 23 0 28 0 23 0 28 0 SECTION D GENERATOR END TROUBLESHOOTING GUIDE ZERO oR VOLTAGE Check Breaker 15 Check Gen Fuse BAD OFF Coll Replace eae to Turn ON Fuse Breaker Wiring To Defective Panel Breaker Check Ohm s on Exciter Leads OK BAD 12 V Battery Test Replace Exciter OK Replace Voltage VOLTAGE TEST Zero High Voltage OK Or Voltage Low Voltage Check AMP Check Replace Draw Main Breaker AVR From equipment On GenSet Check Load Distribution One Voltage Line Check may be Gen End Higher than the other 12 VOLT BATTERY TEST One Coil Both Coils Low Voltage Low Voltage sensing Voltage Replace Low or None AVR Replace Check Replace Stator Connections Stator Check Engine RPM 1800 Replace Stator See Engine Troubleshooting Engine Problem OVERLOAD CONDITION Check AMP Draw Check Load Distribution Disconnect AVR Conduct 12 Volt Battery Test OK Replace Stator Check Stator Resistance Replace AVR And Test Ee opm T PHILLIPS amp TEMRO INDUSTRIES AUTOMOTIVE ENGINE PRE HEATER OPERATING PRINCIPLE The heater operates on the principle of Ihermosyphoning by which cold coolant is drawn from the
69. 3000 Service Hours or One Year NOTE Do not use a commercial coolant antifreeze that only meets the ASTM D3306 or D4656 specification This type of coolant antifreeze 1s made for light duty automotive applications CHECKING RESERVOIR TANK COOLANT LEVEL At a Minimum of 25 Hours of Operation Ensure that the coolant level of the radiator reservoir tank 1s between the upper limit FULL and the lower limit LOW on the side of the reservoir tank CLEANING RADIATOR CORE Visually inspect the core for any obstructions such as dirt or debris Use running water to clean particles from between fins IMPORTANT Never use hard objects to clean radiator core damage to core could result OPERATING HOURS and SERVICE LOG THIS SERVICE LOG IS PROVIDED TO HELP YOU KEEP ANACCUMULATIVE RECORD OF OPERATION HOURS ON YOUR GENERATOR SET AND THE DATES REQUIRED SERVICES WERE PERFORMED ENTER TIME TO THE NEAREST HOUR OPERATING HOURS SERVICE RECORD DATE HRs RUN CUMLATIVE DATE SERVICES ENGINE STARTS BUT WON T RUN Engine Runs OK Unplug Remote Start Stop from Control Box Problem with Remote Connection Contact Jump OS Equipment Manufacturer Oil Pressure Switch with Jumper Wire 2 pole Oil Pressure Switch Check Power single Pole to Hold Circuit of Run Solenoid Disconnect Wire to Test Check Oil Pressure With Gauge Has Power NO Power Replace Defecti
70. 4 pur Leya jing e FOOTE apgedes 100 si y 21481 s2dENOA aoa J Apseunroidde pue Addins pen AWE y apqe ui o enbo st ago J amp mawy Lior SULYWEIS AE poe ut ua sr nding put 21471 Samra 21 urg aua mod parnseaus j sao t UN pur UE mino adya stp pug neod Aramgg o uzsmreq uon 3 I arcus Ag aip Hurpea anpor sod Gene zi tag aedu speuiuiis mino freya mq ye sup inseam adod 01 pt FUSS to ST ma Lina mina 228 012 ut V mous santa aul Ut aol s parnseaui oU j Sumser 241522213 225 wards pue 132183 pareurpiogs Apmxdoadum ur peo Aq p sng2 aq gorgpuos FT UI rap jou SHOP mno afya pug ase213u 10U afeita J Arane i jo sXieQgosrp d32D 352221 arp punou mBonrpuca ap at uo si diho freya pue y os sanea atn Ue 22 40 St wod Aranea painseaur J Fuse jo ajqedes ins are
71. 9 5 4 AGR341 AVR SYMPTOMS Generator produces no voltage Generator produces low voltage with load applied Generator produces high voltage Generator produces unstable voltage SOLUTIONS 20 Check link K1 K2 on auxiliary terminals of AVR Verify generator connections Check diodes Test and adjust or replace AVR Check speed with tachometer Check diodes Test and adjust or replace AVR Check speed with tachometer Verify generator connections Check load PF Leading PF can cause voltage to climb Test and adjust or replace AVR Check speed with tachometer Verify generator connections Replace defective or worn rheostat Test and adjust or replace AVR 5 5 AGR321 SYMPTOMS Generator produces no voltage Generator produces low voltage with load applied Generator produces high voltage Generator produces unstable voltage SOLUTIONS 21 Check link K1 K2 on auxiliary terminals of AVR Verify generator connections Check diodes Test and adjust or replace AVR Check speed with tachometer Check diodes Test and adjust or replace AVR Check speed with tachometer Verify generator connections Check load PF Leading PF can cause voltage to climb Test and adjust or replace AVR Check speed with tachometer Verify generator connections Replace defective or worn rheostat Test and adjust or replace AVR 5 6 EXCITATION TESTS 5 6 1 CHECKING PMG on units fitted wIPMG With the unit operati
72. AC input Current Continuous 4A DC Intermittent 6A 10 sec Resistance Minimum 15 Ohms Regulation 1 0 Thermal Drift 0 0496 per degree C in AVR ambient oystem Response AVR response 20 ms Field Current to 9096 80 ms Machine Volts to 97 300 ms External Voltage Adjustment 10 w 1k ohm 1 watt trimmer Under Frequency Protection Set Point 95 Hz Slope 170 down to 30 Hz Unit Power Dissipation 12 Watts Max Build up Voltage 4 Volts at AVR terminals Analog Input Maximum Input 5 VDC Sensitivity 1V per 5 Generator Voltage adjustable Input Resistance 1K Ohms Quadrature Droop Input 10 Ohms burden Max Sensitivity 0 07A for 5 droop 0 PF Max Input 0 33A Environment Specifications Operating Temperature 40 C to 70 C Relative Humidity 0 70 C 0 95 non condensing Storage Temperature 55 to 80 Vibration 20 100 Hz 50 mm sec 100 2K Hz 3 3g 1 with 4 Engine Governing 2 after 10 minutes some de rating may occur at voltage extremes 4 factory set semi sealed select w jumper 5 device connected must be galvanically isolated from ground gt 500 VAC 42 WIRING DIAGRAM ROTATING RELTIFIETS EXCITER ROTOR MAIN ROTOR DETAILS OF THE MAIN STATOR AND WAIN TERMIN AL ARE SHOWA SEPARATE MRING DIAGRAM Be GONMECTORS l l FITTED FRAME 4 HAND TRIMMER whan fitta REMOVE ACROSS 1 amp 2 THE LSE OF
73. AG164D 056 19 026 AG184E 064 20 021 AG184F 074 22 023 AG184G 083 22 023 AG184H 0 89 24 024 AG184J 096 24 024 AG224C 059 21 0 142 AG224D 064 21 0142 AG224E 069 20 0156 AG224F 083 20 0 156 AG224G 0 994 20 0156 AG274C 112 20 0 156 AG274D 126 20 0156 AG274E 134 20 0 182 AG274F 152 20 0 182 AG274G 069 20 0182 AG274H 082 20 0 182 AG274J 208 20 0182 AG274K 208 20 0 182 24 5 6 2 2 UNBALANCED MAIN TERMINAL VOLTAGES Unbalanced voltages indicate a fault on the main stator winding or main cables to the circuit breaker These faults may also cause noticeable load increase on the engine Disconnect the main cables and separate the winding leads U1 U2 U5 U6 V1 V2 V5 V6 W1 W2 W5 W6 to isolate each winding section 5 6 2 2 AVR PERFORMANCE TESTING AVR CONTROLLED GENERATORS Resistance Resistance AG164A 0 008 AG164B 0 006 AG164C 0 004 AG164D 0 003 AG224C 0 09 AG6H 0 0013 AG224F 0033 C AG224G6 0028 C 2740 003 o All models of automatic voltage regulators can be tested as follows 1 Remove exciter field leads X amp XX F1 amp F2 from the AVR terminals X amp XX F1 amp F2 2 Connect a 60W 240V incandescent bulb to AVR terminals X amp XX F1 amp F2 3 Turn the AVR VOLTS c
74. AGES 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 Check voltage with a separate meter at the generator terminals Incorrect defective connections 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 Test the generator using the 12 volt battery test as specified In the testing section If the windings results indicate generator problems perform insulatian continuity and diode tests as specified in the testing section Regulator protection operating Adju
75. Be sure to check with the appropriate authorities prior to installation and obtain the required permits which apply NOTE Damage to the generator and optional equipment due to improper installation may not be covered by Power Technology Southeast Inc Limited Warranty LOCATING THE GENERATOR A permanent location for the generator 15 a major factor to consider when planning installation These units are large and extremely heavy and will require a substantial foundation like a concrete slab to support its weight Placing the generator directly on the earth 1s not recommended dirt and debris can be drawn into the generator causing untimely component failure Another consideration Is water drainage low lying areas prone to flooding should be avoided Therefore planning for a permanent location 15 an important first step in the installation Local and or State Building Codes may mandate dimensions and materials used in a foundation or slab SERVICABILITY As with any machine the generator will require periodic maintenance Be sure the generator is accessible on all sides Recommended clearance between the generator and other objects is at least 2 feet This clearance is also required for proper ventilation and cooling Avoid locating the generator next to an object which may cause an air flow restriction EXHAUST ROUTING The exhaust from the generator must be safely routed away from all building openings Avoid exhausting near windows do
76. ES oman SSSR ESE Z T SQELESE TITEL 5 237 Ya pir 31915 PES 034560 5 40423135 440 40 ASIN jen t ka SE B TSE LLET SAET WOO rangs331 kk TH 31915 RES SE PDT8 Bb VODIOT TYRES 3115 ero DNI LSY3H1n05 ASOTONH231 H3MOd h ad hd i SNOLLV2O1 7 335 s GPG TSE XJ 2 T ESECTSE ZDTE Bb WOO 57 kk OH ALLS 69 ONT LSWSHLAOS ASCOY0NH231 H3MOd e ww M ES lt D SMS SUNN UU INSTALLATION connection with 12 lead machine only NNE M L L T3 Tg T 11 Tg T7 T12 710 T5 111 120 240 TYPICAL SYSTEM DIAGRAM Main Rotor Exciter Rotor L1 00000 c Exciter PMG L2 stator Stator 200 999 L3 KO 235 i Power Output voltage E Sensing Regulator Inputs 11 SECTION INSTALLATION 12 LEAD HI DELTA 12 LEAD LOW DELTA Li JMABATHUN Della connection with 12 lead generators only
77. GHIA C s wing 01 imga 2503 WED atop uw speupulra TAQ MC saja aroda npn G 20 mona Dy Indu q39u mdm y w TE sj ainoa pagepdaurgu parexipur st ou s qe 225 ao s paydde si saun palega 0j papaman utm wadde 24 su pue E O pS tow Il 288252 ON jo Jo Furfregarspun p 01 pes s um s 12doidur qo ot qnoupp at s rsunsnipr pia semo tias paund agi uo yodin peleas tow Apradazd Suneisdo gi feya ou iar pur w 21981 ur oy enba sr aro wod daneg EWU JE Area t uonzauuos 004 synod samp pre sajo 9 1 impaunpoa STEIN UE qu seam ra rego pow sod Aime sut m susti pinoys sSurpeai Fl que Burpsssoid asnaq maun mino pur poss 51140 Aga 4 ALONE 1 KOLINAS View Qutlet Flow check Valve Front View Reusable 5ee thru Spin on Bowl Selt venting Contamnani Drain Optional Heater Feedthiru 5 SPECIFICATIO
78. Hz generator this would be about 47 Hz while for a 60 Hz generator it would be about 57 Hz The figure below shows the relationship between voltage and frequency within the UFRO Note when the UFRO potentiometer is turned counterclockwise CCW the knee point is shifted to the right If it is turned clockwise CW the knee point is shifted to the left CW CCW lt Knee Point 100 95 90 Voltage Percentage 85 80 75 80 85 90 95 100 Frequency Speed Percentage Typical Setting Shown 3 1 3 1 2 EXCITATION TRIP EXC TRIP Only for AGR341 amp AGR321 AVRs In the event of a short circuit from line to line or line to neutral or a large overload PMG excited AVRs such as the AGR341 and AGR321 provide maximum excitation power Therefore these AVRs utilize an over excitation circuit to protect the generator windings This circuit detects high excitation and after a set amount of time typically 8 10 seconds it removes the excitation If the excitation trip is not set properly the output of the generator will fail when loaded or slightly overloaded and the LED will stay lit The 11 voltage across terminals X and XX should be within 5 of 70 volts This is the correct setting of the excitation trip Stop the generator to reset See wiring diagrams Appendix E 3 1 3 1 3 OVER VOLTAGE OVERIV Only for the AGR321 AVR The over voltage function removes generator excitation AVR output if the AVR sen
79. LON GENERATOR CERTIFICATIONS Athlon Generators are designed and manufactured for safe and reliable operation in factories certified to ISO 9001 2000 Athlon Generators are rated for standby or continuous duty Athlon AC synchronous generators are brushless 4 pole self ventilated alternators which create 60 Hz power at 1800 RPM or 50 Hz power at 1500 RPM The generators can be provided in one or two bearing configurations They are designed and built in accordance with IEC 6003 1 1 amp 2 requirements BS4990 amp 5000 NEMA MG1 2006 CSA amp C UL and CE Athlon Generators carry the following quality marks from internationally recognized agencies 1909000 57 a CSA INTERNATIONAL _ __ Certificate of Compliance Certificate 2240891 Master Contract 248614 Project 2240891 Date Issued November 13 2009 Issued to Athlon Generator LLC 15885B Kings Highway Montross VA 22520 USA The products listed below are eligible to bear the CSA Mark shown With adjacent indicators C and US for Canada and US or with adjacent indicator US for US only or without either indictor for Canada only Issued by K Atkins EU C i US gt t Authorized by Len Cafideloro Product Group Manager PRODUCTS CLASS 4211 01 MOTORS AND GENERATORS CLASS 4211 81 MOTORS AND GENERATORS CERTIFIED TO U S STANDARDS Three phase Brushless
80. NS MODEL Maximum Flow Hate LPH Replacement Element Series Fuel Ports SAEJ476 Clean Pressure PSI 0 12 Drop kPa 0 82 Height In B 3 211 Width 4 102 Depth In 4 102 Weight Dry Ibs 1 8 kgs 80 Operating 409 2559 2008 Spin on Series Fuel Filter Water Separators for Diesel Engines Vent Plug Qutlet Hand Operated Fuel Priming Pump Replaceable 2 10 or 30 micron spin on elements Optional Water Probe 245R R25 1 47 1 47 0 31 0 61 2 14 4 21 9 0 10 5 229 267 4 102 102 4 4 102 102 2 2 2 80 1 0 F 409 121 C Filtration Parker Hannilin Corporation Racor Division P O Box 3208 3400 Finch Road Modesto GA 95353 USA 209 521 7860 B00 344 3286 www parker com racar Racor s 2158 230R and 245R Fuel Filter Water Separators are specifically designed to handle todays tough diesel filtration problems ese units feature a standard in head fuel priming pump and are different from one another only in flow capacity and element size These units may be used an the suction vacuum side pressure side up to 30 PSI of the fuel transfer pump The die cast aluminum mounting head features two outlets and one inlet for installation to most fuel systems The fuel ports are standard SAEJ476 1 4 NPTF tapered dryseal pipe thread Many varieties of fittings are available from R
81. Never store flammable liquids in the engine compartment Refuel at a well ventilated and open place If fuel or lubricants spill clean up immediately and properly dispose of DO NOT mix gasoline or alcohol with diesel fuel The mixture can cause a fire Engine exhaust fumes can be very harmful if allowed to accumulate Be sure to run the engine in a well ventilated area where there are no people or livestock near by The exhaust gas from the muffler is very hot To prevent a fire do not expose dry grass oil or any other combustible materials to exhaust gas Keep the engine and mufflers clean all the time To avoid a fire be alert for leaks of flammables from hoses and lines Be sure to check for leaks from hoses and pipes such as fuel and hydraulic by following the maintenance check list To avoid a fire do not short across power cables and wires Check to see that all power cables and wires are in good condition Keep all power connections clean Bare wire or frayed insulation can cause a dangerous electrical shock and personal injury CALIFORNIA Proposition 65 Warning Diesel Engine Exhaust and some of it s constituents are known by the State of California to cause Cancer Birth Defects and Other Reproductive harm ESCAPING FLUIDS e Relieve all pressure in the air oil and cooling systems before any lines fittings or related items are removed or disconnected e alert for possible pressure release when disco
82. OO TIN uu umu abe hapa ab 24 SPECIFICATIONS uu aku ec tedio toto e 26 WIRING DIAGRAMS o O 2 TT o l O IT FOREWORD You are now the proud owner of a KUBOTA Engine This engine is a product of KUBOTA quality engineering and manufacturing It is made of fine materials and under a rigid quality control system It will give you long satisfactory service To obtain the best use of your engine please read this manual carefully It will help you become familiar with the operation of the engine and contains many helpful hints about engine maintenance It is KUBOTA s policy to utilize as quickly as possible every advance in our research The immediate use of new techniques in the manufacture of products may cause some small parts of this manual to be outdated KUBOTA distributors and dealers will have the most up to date information Please do not hesitate to consult with them SAFETY FIRST This symbol the industry s Safety Alert Symbol is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and safety regulations before you attempt to assemble or use this unit DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING Indicates a po
83. P O Box 490133 Leesburg FL 34749 USA Power Tech must be notified in writing within five 5 business days of any product failure General Conditions This Warranty is the sole property of the original owner user A transfer of ownership shall terminate this Warranty This Warranty is only valid within the contiguous United States and Canada Warranty coverage is available outside the U S and Canada please speak to a factory representative for those details This Warranty does not cover any products or parts not purchased from Power Technology Power Technology reserves the right to make design improvements and model changes without any obligation to change units or parts previously manufactured Warranty registration card must be completed and mailed to Power Tech at the above address to validate the Warranty This is the only express warranty on Power Tech products No person agent or dealer is authorized to give any Warranties on behalf of Power Technology Southeast Inc and not to assume for Power Technology Southeast Inc any other liability in connection with any of its products unless made in writing and signed by an officer of Power Technology Southeast Inc LIMITATIONS ON OUR RESPONSIBILITY WITH RESPECT TO PRODUCTS PURCHASED AND USED FOR PERSONAL FAMILY OR HOUSEHOLD USE Our responsibility is to repair or replace defective parts as stated above We will not be responsible for any other expenses losses or inconvenience which you ma
84. Preheating will cease during engine cranking cycle LED continues flashing Engine begins an 8 seconds crank cycle After 4 seconds of cranking the PT ECU 64 will check for an AC signal from the generator If an AC signal is verified the engine will start and the LED will remain ON during the normal run operation If the AC signal 1s not verified the PT ECU 64 will terminate the cranking cycle and LED will flash a fault code Starter disengages immediately after engine run 15 verified PT ECU 64 deactivates the Low Oil Pressure and High Water Temperature Switches for 6 seconds this will assure oil pressure build up time If oil pressure does not build up the engine will immediately shut down and go into a fault mode Likewise for a high temperature situation If engine will not start on the first attempt the PT ECU 64 will initiate the start cycle 2 more times before going into a fault mode Glow Plugs will preheat for 8 seconds per attempt Engine will crank for 8 seconds per attempt To shut down the engine under normal operations toggle the Start Stop Switch to the stop position 10 If a fault occurs turn Generator Main Switch OFF and then ON to reset PT ECU 64 Fault Codes LED Flashes Failure to start 1 Engine High Water Temperature Low Oil Pressure No AC Signal Low Coolant Level Option WN 120 APECS 3100 ELECTRONIC ENGINE SPEED GOVERNING SYSTEM APECS Advanced Proportional Engine Control System is
85. REACH OF THIS WARRANTY abiain performance of this limited warranty the alleged defective product must ba returned together with reasonable proof of purchase postage or freight prepaid directhy l Warranty Department Warranty Departmani Phillips amp Temro Industries Inc Phillips Termro Industries Ltd 9700 Wast 74th Sirasi 100 Paquin Road Eden Pralno MM 55344 Winnipeg Manitoba RJ 3V4 The Company will return the repaired or replaced product pastage freight prepaid Final determination of defects shall ba made in accordance with procedures established by the Company This limited warranty gives the original consumer purchaser specific rights You may have other rights which vary Irom state to state or province to province depending upon the location of your residence Some states do not allow the exclusion or limitation of incidental or consequential darnages Manufacturer s rights retained The Company reserves the right to make changes design additions or improvements to any of its products al any Time without incurring any obligation whalsoaver to install f replace ihe same or improve upon products previously manufactured 703405 11 16 98 Made in USA Fabriqud aux EU Printed in USA Impriml aux EU Page 3 MASTER CONTROL SYSTEMS INC BOX 276 910 NORTH SHORE DRIVE LAKE BLUFF ILLINOIS 60044 USA 847 295 1010 FAX 847 295 0704 INSTALLATION AND OPERATING MODEL MBC 19 BATTERY CHARGER A E
86. Residual Volta Residual voltage atregulator power Check wiring diagram for proper No Output input wires 3 amp 4 below 10Vac connections Flash generator field Refer to Field flashing section in generator manual Acceleration time to rated speed too long Reduce acceleration tima Interrupt power input to regulator after acheiving rated speed Connect field leads F1 F2 Connect power input leads 3 4 Field leads F1 F2 not connected Power input leads not connected Blown or missing fuse Replace fuse Defective regulator Replace regulator Defective generator Consultgenerator manual _ uu Output Voltage Low Incorrect connections Check wiring diagram for proper connections Voltage adjustturned down Rotate voltage adjust CW until desired vollage is reached Remote voltage adjustis turned down Rotate remote voltage adjust CW until desired voltage is reached a _______________ Output Voltage High Voltage adjust turned too high Rotate voltage adju sl CCW until desired voltage is reached Remote voltage adjust is turned too Rotate remote voltage adjust COW high until desired voltage is reached Output Voltage High Defective regulator Replace regulator NoAdjustment Remote Voltage Adju st Voltage adjust wire backwards Reverse the wiring ofthe remote Operates Backwards voltage adjust 0000 04 Generator Output stability ad
87. START UP terminations are tight and properly insulated The following procedure should be followed when starting the generator set for the first time WARNING MAGNAPLUS GENERATORS MAY HAVE VOLTAGE 1 PRESENT AT THE LEAD TERMINALS WHEN THE SHAFT IS ROTATING DO NOT PERMIT OPERATION OF THE GENERATOR UNTIL ALL LEADS HAVE BEEN CONNECTED AND INSULATED The generator output must be disconnected from the Be sure that the main circuit breaker or fused disconnect is in the open position 2 Open the input power to the automatic vollage regulator Remove the fuse or disconnect and insulate one of the regulator input power leads See separate regulator manual FAILURE TO DO THIS MAY RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE Verify that all prime mover start up procedures have 4 Verify that all equipment is properly grounded earthed 3 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 mair 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 accesss plates covers screens and guards If they have been removed for assembly or inspection reinstall and check for security 5 Start the prime mover
88. TER LIFE WILL RESULT FROM EXCESSIVE VIBRATION PROPERTY DAMAGE MAINTAIN A MINIMUM CLEARANCE OF 3 BETWEEN HEATER AND OTHER ENGINE COMPONENTS FAILURE TO MAINTAIN MINIMUM CLEARANCE MAY RESULT IN HEAT DAMAGE It is best to mount the heater below the lowest point of the cooling system to ensure that adequate pressure head is provided to the heater inlet and to ensure that thermosyphon coolant flow is maximized See Figure 1 Coolant flow may be restricted if the heater is mounted too high See Figure 2 Heater must be mounted with the heater outlet pointing upward as indicated by the arrow on the tank body Otherwise coolant flow will be impeded and the heater will be prevented from maintaining the desired engine temperature Also excessive cycling of the heater may occur causing shortened heater life The heater has a unique multi point mounting system that accommodates different applications Figures 6 through 8 illustrate three possible mounting configurations Select a mounting surface that is smooth and free of fasteners Secure Ihe heater in the selected location using the bolls nuts and lock washers provided 1 3 1 3 1 1 3 2 1 3 3 1 3 4 703405 Figure 5 Typical Installation Figure 6 Bottom Figure 7 Side Figure 8 Top Mount Mount Mount Plumbing General Recommended hose size for both inlet and outlet connections is 5 B for heaters up to 1500 watts and 3 4 for 2250 watt heaters Use standard heater hose and ho
89. TION Do not ground any of the hand trimmer terminals as these could be above ground potential Failure to do So could cause equipment damage CAUTION Before running generator turn the VOLTS control fully counter clockwise Turn remote volts trimmer if fitted to midway position Turn STABILITY control to midway position Connect a suitable voltmeter 0 300V ac across line to neutral of the generator Start generator set and run on no load at nominal frequency e g 50 53 Hz or 60 63 Hz If the red Light Emitting Diode LED is lit refer to the Under Frequency Roll Off UFRO adjustment Carefully turn VOLTS control clockwise until rated voltage is reached If instability is present at rated voltage refer to stability adjustment then re adjust voltage if necessary O gt G N STABILITY ADJUSTMENT The AVR includes a stability or damping circuit to provide good steady state and transient performance of the generator The correct setting can be found by running the generator at no load and slowly turning the stability control counter clockwise until the generator voltage starts to become unstable The optimum or critically damped position is slightly clockwise from this point i e where the machine volts are stable but close to the unstable region OPTIMUM RESPONSE SELECTION The stability selection jumper should be correctly linked A B B C or A C at the bottom of the board for the frame size o
90. TITUDE FT ATMOSPHERIC PRESSURE vs ALTITUDE 0 3280 6500 9840 13120 ALTITUDE FT 750 29 6 E 700 27 6 A b0 A OE 650 25 6 D z z 600 23 7 gt z e 550 21 7 5 500 19 7 gt 450 17 8 0 1000 2000 3000 4000 ALTITUDE M ATMOSPHERIC TEMPERATURE amp HUMIDITY POWER LOSSES These losses are generally considered to be nominal with values seldom exceeding 5 Natural atmospheric variations however can combine causing nearly 20 de rating For example air of 120 F 50 at 100 humidity Even 100 40 C temperature at 90 to 100 humidity will cause 10 de rating The local and or field operating conditions must be evaluated and the power de rated from SAE J 1349 per these factors ATMOSPHERIC FACTORS CHART POWER AVAILABLE DUE TO TEMPERATURE AND HUMIDITY VARIATIONS 25 77 1 000 97 992 990 984 980 977 973 E 86 1 9851 980 973 969 364 957 954 949 _ 8 4 ois 89 ACCESSORY POWER REQUIREMENTS Additional power deductions should be made for any accessories that are installed These deductions are necessary to accurately identify the expected net power available for the prime power requirement The accessory items are variable for each installation application and can t be determined or deducted by the engine manufacturer The following accessories are typical in a Stand By Generator application Auxiliary Alternator Generat
91. TOR Nh Y NW Y Y Y m ITT B7 B B7 OUTPUT INPUT INUKE CDRHMECTURS ARE Ta AW DALY 25 FITTEO DM FRAME 4 ARD ABE ISOLATION TRANSFORMERS EXCITATION SWITCH whan fitted iB REMOVE LINK ACROSS amp TRIMMER when fitted REMOYE LINK 5 1 amp Z THE USE OF TWO GORE EC n GFF GABLE 15 SCREEN TEFMIMAL 2 OHLY DRODP E TI when fitted r STATOR is 2 DUTPLIT ET B Bl 51 3251 52 ST 32 Al AS WHOING 1 TERMINALS FOR GT PESTON GOMMEZTIDN AGRA 53 OPERATION eee wx JO No link 6P50Hz 6P60H Volts 4P50H Limit 24 60H Frequency 32 1 Selection L Indicator LED ri l Rms Stability Dwell Stability Selection gt ssokw N F so ssokw Droop lt 9o w Trim Over V EXC U VW FO E1 BO B1 5152 5152 BELLS CONTROL FUNCTIO N DP To set Frequency Related Voltage Dip Clockwise Increases Voltage Dip 1 Under Frequency Roll Off UFRO 54 ADJUSTMENT AVR CONTROLS AGR321 VOLTAGE ADJUSTMENT The generator output voltage is set at the factory but can be changed by careful adjustment of the VOLTS control on the AVR board or by the external hand trimmer if fitted Terminals 1 and 2 on the AVR will be fitted with a jumper if no hand trimmer is requir
92. UNIT The ESD2100 Speed Control Unit 1s part of an engine governing system designed to control engine speed and stability throughout the load range Operating in combination with a magnetic pick up and electric actuator the ESD2100 will maintain the proper engine speed by adjusting the fueling system according to the applied load By maintaining a set engine speed the generator voltage output and frequency will remain constant and stable FSD2110 STABILITY 2 D 1 Es E4 PICKUP TRIM ACTUATOR BATTERY aoe cmn o9 5I 154 FUSE im OPTIONAL 51 SPEED TEIM j CONTROL 5E ACTUATOR MAGHETIC BATTERY PICK UP 10 SECTION C WIRING SCHEMATICS SHS LBA TSE XN LLLTSSELTSE 25 337 br OE AIS FEY NI LSWSHLNOS ASOTONH231 E 440 IVNOILdO Lavis NINN 3NIDN3 O JuniwviBdWal O 1531 0 m0 SLHOT1 HNVd WNOLLdO 440 JOA 15Y3H Lfh05 3MDd L Nee TEE zt S9e ESE COLB BR bE VOTHOTHS SHES ve 31v15 PES LSWSHLNOS HOLIMS O24135 BEE UARALR ouau S ES EN SE KWA LLLCSSELTSE rengs331 be OE 31715 F PE SSES SS
93. Y PLEASE REMEMBER SAFETY FIRST If you are sure of the instructions or procedures contained herein seek qualified help before continuing When in doubt ask Questions are much easier to handle than mistakes caused by a misunderstanding of the information presented in this manual RECEIVING AND STORAGE RECEIVING AND STORAGE Upon receipt of the generator it is recommended that 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 acception the shipment Any claims for damage must be promptly filed with the delivering carrier UNPACKING AND HANDLING Carelully read all instruction shipped with the unit This service manual emphasizes the safety precautions When Jifting attach an overhead crane to the lifting lug s 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 wamings are not readily understood seek clarification from qualified personnel before proceeding Before any service work is done disconnect all power sources and lock out all controls to prevent an unexpected start up of the gener
94. acor or hardware dealers Fittings may not be supplied with this unit A vent plug is fitted to easily evacuate trapped air making fuel priming an easy no mess experience Engines will benefit from near 100 water separation and fuel filtration with Racar s proprietary Aquabloc water repelling media The replaceable spin on filler elements are available in 2 10 and 30 micron ratings The reusable see thraugh contaminant collection bowl allows the operator to check contamination build up at a glance The contaminant drain is opened by ioi the knob counterclockwise if facing the bowls bottom side OPTIONAL FEATURES available option is water probe which alerts the operator when it s time to drain the bowl The probe must be used with a 12 or 24 vdc powered Water Detection Kit See Accessories for available models For use with diesel fuel systems only A powerful 12 or 24 vdc 200 watt In bowl heater option is available to quickly warm the element fuel thus providin easier starting and optimum operating efficiency in cold weather or climates Danger Accessories are not intended for use with gasoline or flammable liquid applications Additionally a metal bawl is available for severe service heavy duty or marine applications This bowl features a 3 8 drain plug which may be replaced by a UL listed drain valve refer to parts list For marine applications specify Models 215RMAM 230HMAM or 245RMAM Note
95. actory at time of ordering so that the proper accessories can be provided 32 APPENDIX D SAE DATA SAE ADAPTOR COUPLING COMBINATIONS x 6 AG18 AG22 Adaptor ALPHA 17 750 17 750 17 750 A Available Most Common e AG184H amp J 33 X Special Order Only Coupling amp Adaptor Combinations Available ww 5 e F e _ n o sam wem em m oma sam _ ume ma mm sam 3 mw sm n _ mm was sm n x 4 mm w wm n x s mm u nw zum x pe om mw mw zo o we MT M ff y 34 Standard Industrial Flywheels em was Tsan was wm was ca o mam mas r vn mas mam zoe m m zm wwe _ Delco Industrial Flywheels m em me wm mum wa win mm wem _ 35 Bolt Size SAE PLATE BOLT TORQUE VALUES Model Number AG16 AG18 AG22 Bolt Size M10 X 30 mm M10 X 50 mm M16 X 35 mm M16 X 55 mm M20 X 55 mm M16 X 65 mm M 24 X 65 mm 36 Torque Nm N N N NO NO oO N N O 1072 Torque Ft Ib N 4 D O O APPENDIX E AVR DATA SHEETS 37 ATHLON AGR460 AUTOMATIC
96. aired or replaced equipment or finishing the reinstallation thereof 2 apply and shall be void with respect to equipment operated in excess of rated capacity or otherwise not in accordance with installation maintenance or operating instructions or to equipment which has been subjected to abuse negligence misuse misapplication accident damages by circumstances beyond Athlon s control due to improper installation operation maintenance or storage or to other than normal use or service and 3 apply to equipment or components not manufactured by or for Athlon THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES EXCEPT TITLE INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE NO EMPLOYEE REPRESENTATIVE OR AGENT OF ATHLON OTHER THAN AN OFFICER OF THE CORPORATION IS AUTHORIZED TO ALTER OR MODIFY ANY PROVISION OF THIS WARRANTY OR TO MAKE ANY GUARANTEE WARRANTY OR REPRESENTATION EXPRESS OR IMPLIED ORALLY OR IN WRITING WHICH IS CONTRARY TO THE FOREGOING 26 APPENDIX B GENERATOR DATA MODEL NUMBER Athlon Generators use a model number system conforming to that used by many manufacturers of similar types and models of generators For example Athlon Generator Model AG224D can be interpreted as shown below Number of Poles Core Designation Frame Number refers to the frame size of the generator and follows industry standa
97. ally dangerous if not properly maintained and operated The best Safe Guard against a dangerous situation is education good judgment and common sense For safe trouble free operation of your generator set some general precautions are listed below Be sure to read understand and follow these precautions Please call Power Technology Southeast Inc with any concerns you may have with your generator set 1 HOT PIPING An engine and exhaust system may get extremely hot while running Do not work on a generator set until it has sufficiently cooled 2 DANGEROUS FUELS Use extreme caution when handling storing and using fuels All fuels are highly explosive In a vaporous state Store fuel In a well ventilated area away from spark producing equipment Keep fuels and all chemicals out of the reach of children Never add fuel to the tank while the engine is running Spilled fuel may ignite on contact with hot parts or from ignition spark Always keep fuel lines and connections tight and in good condition Don t replace flexible fuel lines with rigid lines If you notice any fuel leakage fuel accumulation or electrical sparks DO NOT OPERATE THE GENERATOR SET 3 EXPLOSIVE BATTERY GASES The gases generated by a battery being charged are highly explosive Do not smoke or permit any flames or sparks to occur near a battery at any time especially when it is being charged Avoid contact between terminals with tools to prevent sparks and possible burns Alwa
98. and insert Y fiting as per Figure 9 Connect the heater outlet tube to the remaining opening on the Y fitting then tighten hose clamp Figure 9 Y Fitting 11 16 98 Made in USA Fabriqu aux EU Printed in USA Impriml aux EU Page 2 1 4 Cord Installation Procedure Using industry accepted methods secure cord to prevent contact with heated surfaces or moving parts WARNING ELECTRIC SHOCK ENSURE POWER CORD IS FASTENED TO EXISTING WIRING IN ENGINE COMPARTMENT PREVENT DAMAGE FROM CONTACT WITH HOT OR MOVING PARTS ELECTRIC SHOCK NOT ENERGIZE HEATER WHILE STANDING IN WATER OR IF POWER PLUG IS WET USE GFCI 3 WIRE GROUNDED OUTDOOR EXTENSION CORD USE 14 GAGE WIRE EXTENSION CORD FOR HEATERS HIGHER THAN 1500 WATTS 1 5 Refilling Antifreeze Always pre mix water antifreeze and coolant additives before installing engine Refill the engine with the heater outlet hose disconnected at the engine until the outlet hose is full of coolant Connect the outlet hose and continue refilling the engine It may be necessary to bleed cooling system at highest point to eliminate airiocks Tighten all hose clamps Re tighten all hose clamps after 2 weeks as the hoses may set CAUTION Use A 50 50 SOLUTION OF ETHYLENE GLYCOL ANTI FREEZE AND WATER FOR OPTIMUM HEATER PERFORMANCE Do NOT USE MORE THAN 60 CONCENTRATION OF ANTI FREEZE AS A SHORTENED HEATER LIFE WILL RESULT DO NOT USE HEATER IN COOLING SYSTEM CONTAINING ANY FORM OF ANTI LEAK
99. and the environment High levels of vibration from the drive engine or misalignment of the set will stress the bearing and reduce its service life If the vibration limits set out in BS5000 3 and ISO 8528 9 are exceeded bearing life will be reduced Long stationary periods in an environment where the generator is subject to vibration can also cause false brinelling surface failure which puts flats on the balls and grooves on the races leading to premature failure Very humid atmospheric or wet conditions can emulsify the grease causing corrosion and deterioration of the grease leading to premature failure of the bearings For normal situations users may expect to be able to obtain 30 000 hours service life from Lifetime Lubricated bearings and 40 000 hours from greasable bearings 16 5 IROUBLE SHOOTING GUIDE Athlon generators are provided with excitation control systems Four automatic voltage regulator AVR systems are available across the range of generator models and sizes The following will assist the user in determining any faults Follow the guide for the proper AVR in question 5 1 AGR460 AVR SYMPTOMS Generator produces no voltage Generator produces unstable voltage Generator produces high voltage Generator produces low voltage at no load Generator produces low voltage with load applied SOLUTIONS 17 Check speed with tachometer Check residual voltage and flash the field as necessary see se
100. ant with the specified mixing ratio Radiator net or radiatorfin clogged Clean net or fin carefully with dust Inside of radiator or coolant flow Clean or replace radiator and parts route corroded Fan or radiator or radiator cap Replace defective parts defective Thermostat Check thermostat and replace if defective necessary Temperature gauge or sensor defective Overload running Reduce load Head gasket defective or water Replace parts leakage Unsuitable Tuel Use the specified fuel used Check temperature with thermometer and replace if necessary 26 SPECIFICATIONS SPECIFICATIONS V3600 E3 V3600 T E3 Vertical water cooled 4 cycle diesel ENGLISH Number of cylinders Bore and stroke mm in 98 x 120 3 86 x 4 72 in SAE NET Intermittent kW min rpm 45 8 2600 58 8 2600 SAE NET Continuous kW min rpm 39 8 2600 51 1 2600 SAE Standby kW min rpm Paci mem Total displacement L cu in 3 620 220 9 2800 1 15 42 Counter clockwise viewed from flywheel side Lubricant classification Dimension mm in 745 x 536 x 741 5 length x width x height 29 33 x 21 10 x 29 19 29 33 x 21 20 x 31 26 Charging generator 12V 1080W KEA 720W EU Recommended battery capacity 12V 136AH 400 or higher 17 8 C SAE rating NOTE Specifications are subject to change without notice SPECIFICATIONS 27 edl
101. at the vent plug Close the vent plug start the engine and check for leaks Follow manufacturer s priming procedures if SAE 1839 0 50 100 applicable Correct as necessary with the engine off Water Separation Time Minutes 215R 2308 2458 Percent EHiciency TROUBLESHOOTING PROCEDURES A major cause of pawer loss or hard starting is the result of an air leak If your unit will not prime or fails ta hold prime first check that vent plug and drain valve are properly closed and that the element and bowl are tightened Check fitting connections and ensure the fuel lines are not pinched or clogged with contaminants If problems persist and the element is new call your Hacor Distributor or Racor Customer Service for assistance SAE 905 Fuel Flow Restriction Flow GPH INSTALLING OPTIONAL FEATURES NOTE ELECTRICAL OPTIONS ARE FOR USE WITH DIESEL FUEL APPLICATIONS ONLY WATEH PROBE Racor 200R Series units can be specified with a water probe The probe senses continuity values and must be used with a special electronic detector to function properly Due to the various models available these electronic detectors are sold separately Installation instructions are supplied with each kit See Accessories for part numbers IN BOWL HEATER NOT FOR MARINE MODELS The in bowl heater is a cold weather starting aid with an internal automatic thermostat that turns the heater on if the fuel tem perature drops below 45
102. ator set driver Proper grounding earthing of the generator frame and distribution system in compliance with local and national electncal codes and specific site requirements must be provided These safety precautions are necessary to prevent potential serious personal injury or even death The hazards associated with lifting or moving your MagnaPLUS generator are pointed out in the installation and maintenance sections Incorrect lifting or moving 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 thal there will be voltage present the generator terminals whenever the generators 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 This manual is not intended to be a substitute for property 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 on the generator frame Apply lifting forces in a vertical direction When transporting single bearing generators the generators rotor m
103. ature The stationary field exciter stator 15 designed to be the primary source of the generators 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 ind ces volage into the generators main stator armature At rated speed the main stators 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 af 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 Voltage Regulation In the standard configuration shunt excited the automatic voltage regulator receives both its input power and voltage sensing from the generators output terminals See Figure 1 With the optional PMG configuration the regulator receives input power fram the PMG The regulator automatically monitors the generators output voltage against an internal reference set point and provides the nec
104. base plate Once the generator is mounted be sure there is a solid electrical connection for ground by checking for continuity between the generator frame and the base plate A properly rated ground conductor must be attached to the generator frame and base plate if anti vibration mounts are used between the two Normally this conductor can be half the cross sectional area of one of the main power wires Refer to all local electrical codes regarding grounding of the unit 2 4 PREOPERATIVE CHECKOUT 2 4 1 INSULATION RESISTANCE The resistance of the insulation windings must be measured after both final assembly and installation of the generator set but before the unit is started for the first time To measure the resistance of the windings follow the steps below 1 Disconnect the AVR 2 Disconnect any conductors between ground and neutral 3 Using a 500V insulation tester or a similar device test the resistance between one of the output lead terminals and ground Resistance should be greater than 5 4 lf resistance is less than SMO follow the dry out procedure in this manual 5 Repeat step 3 for the remaining two output leads 6 NOTE During manufacture the windings are tested at high voltage Further high voltage testing may degrade insulation and reduce operating life If high voltage testing is required for customer acceptance tests must be performed at lower voltages i e Test Voltage 0 8 2 X Rated Voltage 100
105. bottom of the engine block heated in the tank and returned to the top of the engine block Ideal engine warm up time is 2 3 hours Mounting Kit Verify the contents of the package with the following parts list before proceeding with installation n Ant M om TAPER SES L 220 2131 Mounting Bracket Bolt 1 4 20 x 3 4 Nut 1 4 20 Split Lock Washer 1 4 1 4 220 2093 Hose Clamp 6 N A DANGER ELECTRIC SHOCK DO NOT OPERATE HEATER WITHOUT PROTECTIVE COVER DEATH OR SERIOUS INJURY MAY RESULT WARNING FiRE HAZARD USE COOLANT ONLY EXPLOSION COULD RESULT IN DEATH OR INJURY ELECTRIC SHOCK DO NOT OPERATE THE HEATER WITH ANY FOREIGN MATERIALS ADJACENT TO IT THIS COULD RESULT IN DEATH OR INJURY ELECTRIC SHOCK OPERATOR SERVICEABLE PARTS INSIDE REFER SERVICING TO QLIALIFIED PERSONNEL DISCONNECT HEATER FROM POWER BEFORE SERVICING TO PREVENT DEATH OR INJURY CAUTION NEVER PLUG IN HEATER IF ELEMENT IS NOT IMMERSED IN COOLANT AS SHORTENED HEATER LIFE WILL RESULT NEVER RUN ENGINE WHILE HEATER IS PLUGGED IN AS ELEMENT BURNOUT WILL RESULT Preparation Drain and flush cooling system to remove contaminants Recycle or dispose of engine coolant properly to prevent environmental contaminatian Determine Heater Inlet Connection Preferred heater inlet connection is to the engine block drain hole When block drain is inaccessib
106. bridge 1s an internal part of the static regulator The static regulator senses a change in the generator output and automatically regulates current flow 1n the exciter field coil circuit to increase or decrease the exciter field strength An adjustable rheostat sized to be compatible with the regulator 1s used to provide adjustment of the regulator sensing circuit 4 ROTATING FIELD ASSEMBLY The rotating field assembly consists basically of four members 1 the shaft assembly 2 the core assembly 3 the field coil damper windings and 4 balance lugs to provide a high degree of static and dynamic balance CORE ASSEMBLY The core assembly consists of a quantity of thin steel plates compressed and fastened together to form a single laminated assembly The field windings are wound around this assembly FIELD COIL Field coils of heavily insulated wire are wet wound directly onto the poles Field coil leads are brought out to the rectifier assembly for connection to the source of DC excitation voltage BALANCE The rotor assembly 15 precision balanced to a high degree of static and dynamic balance Although the balance will remain dynamically stable at speeds in excess of the design frequencies the prime mover should be adequately governed to prevent excessive over speed High centrifugal forces created by excessive over speed may damage the rotor windings and field coils BEARING The generator rotor assembly 15 suspen
107. cation it is an indication that the generator shaft is not moving freely inthe assembly and normal life of the thrust bearing could be impaired Probable causes of this problem are 1 Improper seating of drive discs in the flywheel resulting in misalignment 2 Improper mating of generator frame to engine flywheel hausing resulting in misalignment 3 Improper G dimension per SAE J620c on either the engine or generator TORSIONAL VIBRATION Torsional vibrations are generated in all rotating shaft systems In some cases the amplitude of these vibrations at critical speeds may cause damage to either the generator its driver or both It is therefore necessary to examine the torsional vibration effect onthe entire rotating system IT IS THE RESPONSIBILITY OF THE GENERATOR SET 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 A of Comporation MeBATUON ENVIRONMENTAL CONSIDERATIONS The MagnaPLUS generator is designed for heavy duty industrial applications however diri moisture heal and vibration are enemies of rotating electrical machinery Excessive exposure to the elements may shorien generator life The temperature of the cooling air entering the intake openings of the generator should not exceed the ambient temperature shown on the g
108. ch the machine while the engine is running Be sure to install the machine on which the engine is installed on a flat place Do not run the engine on gradients Do not run the engine in an enclosed area Exhaust gas can cause air pollution and exhaust gas poisoning Keep your hands away from rotating parts such as fan pulley belt flywheel etc during operation Do not operate the machine while under the influence of alcohol or drugs Do not wear loose torn or bulky clothing around the machine It may catch on moving parts or controls leading to the risk of accident Use additional safety items e g hard hat safety boots or shoes eye and hearing protection gloves etc as appropriate or required Do not wear radio or music headphones while operating engine Check to see if it is safe around the engine before starting Reinstall safeguards and shields securely and clear all maintenance tools when starting the engine after maintenance IMPORTANT Do not use ether or any starting fluid for starting the engine or a severe damage will occur When starting the engine after a long storage of more than 3 months first set the stop lever to the STOP position and then activate the starter for about 10 seconds to allow oil to reach every engine part 1 Set the fuel lever to the ON position 40 1 Fuel lever A ON 2 Place the engine st
109. cified torque Do not put any tools on the battery or battery terminals may short out Severe burns or fire could result Detach the battery from the engine before maintenance Do not touch muffler or exhaust pipes while they are hot Severe burns could result o O lt TT 1ABAAAAAP 1280 MAINTENANCE 9 SERVICE INTERVALS Observe the following for service and maintenance Er Check offue pipes and damp bands Every 50 hours RE Cleaning of air cleaner element Cleaning of fuel filter 14 Every 250 hours Check of fan belt tightness 22 Check of radiator hoses and clamp bands Check of intake air line Ta i Replacement of oil filter cartridge Replacement of fuel filter cartridge 15 Removal of sediment in fuel tank Every 500 hours Cleaning of water jacket radiator interior 181020 Replacement of fan belt E 22 T 3 Cleaning of water separator Check of turbo charger BENE Every 3000 hours Check of injection pump L ow 173 Check of fuel injection timer Change of radiator coolant L L C 191020 Replacement of radiator hoses and clamp bands 19 Replacement of intake air line Replacement of fan belt or every 500 hours gt T J I e O 2 TT o O lt TT 10 MAINTENANCE IMPORTANT The jobs indicated by must be done after the first 50 hours of operation 1 Air cleaner should be cleaned m
110. clutch No 11 1 2 SAE clutch No 10 or its equivalent Flywheel housing type is SAE No 3 or its equivalent Governor drop is within 596 Continuous will operate at the stated rating continuously and have a 10 overload capability for one hour in 12 hours e Standby will operate at the stated full rating for one hour in 12 hours No overload capacity is specified for this rating 31 WIRING DIAGRAMS INDE 06929 8729 a See yams 01999 91791 MOI 5 C gn O 440 09991 os er ov MOIS 1 uoeo T un 8 L sdue O xog esnJj _ 172M EEE e OL9LE LOOLS EX KN Josueg TER due 10 89 _ IH Jae U9IIMS 3 c 9 OLOVE OLODL JojeuJejv as Tlfld 0705271 01009 01021
111. considered to be within acceptable limits if all voltages are balanced within 1 at the main terminals Faults in the AVR or transformer control are then assumed and described below If voltages are balanced but low the probability is that there is a fault in the main excitation windings or rotating diode Rectifier Diodes Diodes on the main rectifier assembly can be checked with a multimeter The diode function must be checked not simply the resistance measurement The leads connected to each diode should be disconnected at the terminal end thus isolating the AVR from the generator Forward and reverse resistance should then be checked A properly functioning diode will have a much greater resistance in one direction than the other Typical reverse biased resistance will be 30K ohms or greater while forward biased resistance will be less than 10 ohms A open bad diode will give a infinite reading in both directions while a shorted bad diode will have a very low resistance in both directions Replacement of Faulty Diodes The following procedure can be used to replace faulty diodes as shown below However diode failures after a break in period are usually traceable to an external fault such as lightening strike To avoid continuing problems it is recommended that the entire rectifier assembly be replaced The rectifier assembly is split into positive and negative plates The main rotor is connected across these plates Each plate carrie
112. ction 5 3 Verify generator connections Check diodes Test and adjust or replace AVR Check speed with tachometer Verify generator connections Replace defective or worn rheostat Test and adjust or replace AVR Check speed with tachometer Verify generator connections Check load PF Leading PF can cause voltage to climb Test and adjust or replace AVR Check speed with tachometer Verify generator connections Check diodes Test and adjust or replace AVR Check speed with tachometer Check diodes Test and adjust or replace AVR 5 2 AGR440 AVR SYMPTOMS Generator produces no voltage Generator produces unstable voltage Generator produces high voltage Generator produces low voltage at no load Generator produces low voltage with load applied SOLUTIONS 18 Check speed with tachometer Check residual voltage and flash the field as necessary see Section 5 3 Verify generator connections Check diodes Test and adjust or replace AVR Check speed with tachometer Verify generator connections Replace defective or worn rheostat Test and adjust or replace AVR Check speed with tachometer Verify generator connections Check load PF Leading PF can cause voltage to climb Test and adjust or replace AVR Check speed with tachometer Verify generator connections Check diodes Test and adjust or replace AVR Check speed with tachometer Check diodes Test and adjust or replace AVR 5 3 RESIDUAL VOLTAGE CHECK Thi
113. d minimize unsupported cable weight apply no axial strain along the cables and support the cables outside the saddle box Be sure the supports allow for vibration without introducing excessive force on the cables and allow a sufficient bending radius for all bends An insulated or non magnetic pass through plate should be installed if single core cables are used Verify the winding resistance by following the steps in section 5 6 2 before final connections are made When making electrical connections to the terminal block be sure the output cable connectors are placed on top of the existing generator winding connectors 3 2 2 TERMINAL TORQUE SETTINGS Before making any electrical terminal connections for the first time clean plated surfaces with a degreasing agent then lightly abrade them to remove any tarnish Do not score the surface All generator connections including links CT s accessories cables etc should be torqued to 45 Nm or 33 ft Ibs Generator output cables should be connected to terminals using 8 8 grade steel bolts in addition to anti vibration hardware The torque value on all electrical connections should be checked periodically 3 2 3 GROUNDING The generator neutral output does not come connected to the frame ground If the neutral is supposed to be earthed connected to the ground use a conductor no smaller than half the diameter of a main power 12 wire to connect the neutral terminal to the earth terminal both
114. d disiribun Jiruvhde duct and or system oplions for farther investigation hy users having technical expertis H is imponan iat you anaiy te aspects wf yar application and ihe information erescermang the product ihe curent product coulog Poeta the variery nfoperatian cutidiiona and appliealions oe these rsy therta 155 own analysts anil ising is okey responsible Far mak ing che Final selection of the products and systema and assuring harail pectormance and warning requinernesits at Ee applacatons ane met The described herem including wich product Ieatures designs availability and pricing ans subject io change by Pirker Hannilin Corporation aral ies subsidiaries al any Um LIMITED WARRANTIES STATEMENT Ali products manutachated or distributed by Racor ant subjecr the following and onty the following LIMITED EXPRESS WARRANTIES and no Fur a pere ol one 12 year Iram and aber the date ef purchase id s ree Racor Racor warranis and uarsniers only ihe orig haad purchaser user that sach a product shall be free Crom detects of materials ard workmanship sn the manudacsuring process The wnrmnry pumpa iail manae specifically mired io CX days nien tat of A producr aimed be de fectiee must be ruta ip rhe place of purchase Racan at iss sale pilan
115. d fuel can plug a filter Drain aff some fuel by loosening the vent plug and opening the drain valve Marine models remove the drain plug Disconnect the water sensor and heater connectors if equipped Spin the element and bowl off together Remove the bowl and clean the O ring gland Apply a coating of clean fuel or motor oil to the new O ring and element seal Spin the bowl onto the new element and then spin them both onto the filter head snugly by hand only DO NOT USE TOOLS Close the bowl drain Marine models replace the drain plug Apply thread sealant to threads needed Connect the water sensor and heater connectors if equipped With the vent plug still loosened operate the primer pump until fuel purges at the vent plug Close the vent plug start the engine and check for leaks Correct as necessary with the engine off Follow manufacturer s priming procedures if applicable CD CD n nM un REPLACEMENT PARTS LIST Item Part No Description 1 RK20045 Head 1 4 18 NP TF Ports HK20025 Primer Pump Assembly RK20179 Plastic Vent Plug 3 B 16 UNF HK12041 Metal Plug 1 4 18 NPTF R155 215R 2 mic Replacement Element R15T 215 10 mic Replacement Element R15P 215H 30 mic Replacement Element R208 230R 2 mic Replacement Element H20T 230R 10 Replacement Element R20P 2308 30 mic Replacement Element H255 245R 2 mic Replacement Element R25T 245R 10 mic Replacement E
116. ded on a shielded factory lubricated ball bearing A visual inspection of the bearing 1s recommended at typical service intervals If signs of abnormal wear or leakage are observed the bearing should be replaced Never use liquids of any kind to clean the generator end and bearing SIATOR ASSEMBLY The stator assembly consists of laminations of steel mounted in a rolled steel frame Random wound stator coils are fitted into the insulated slots 77 n eee pn LT A _ 4222 um u F i j i 3 I T a T ENENN am A a ate oe x SN Ys am ZF Ir 3300 amp V 3300T ENGINE with MARATHON GENERATOR END SECTION GENERATOR MAGNAPLUS GENERATOR 280 430 Frame Installation Operation and Maintenance Manual Marathan A Subsidiary of Regal Beloit Corp 100 East Randolph Street PO Bex 8003 E W 402 8003 Phone 715 675 3311 JMARATHO aww Fax 715 675 6361 P A Subsidiary of Hegal Beleit Corporation CONTENTS Safety 2 Receiving and Storage 2 Principles of Operation 3 4 Installation 4 6 Wiring Connections 6 9 Operation 8 10 Maintenance 10 11 Testing 11 12 Service 12 14 Troubleshooting 14 17 Specifications 18 Parts List amp Recommended Spare Parts 19 20 SAFET
117. dedicated single phe EXCITER FIELD NO LOAD TERMINAL VOLTAGE NO LOAD VOLTS WITH 12 VDC FIXED EXCITATION 480 V 60HZ HIGH WYE 60 HZ HIGH WYE 50 HZ 363611607 0692 on __ 5 DEDICATED GENERATOR RESISTANCE EXCITER FIELD SINGLE PHASE STATOR ROTOR LOAD VOLTS 60 HZ ll _281PSL1512 1106 84 62 45 _ 28211514 2 51 1516 361 G IPSL1612 2043 a aa 432PSL1814 009 m 18 PARTS LIST SINGLE BEARING Typical Generator Cross Section mS 2 mr Referenca Reference Part Name Number D d Bearing O ring 280 frame onh Rectifier Assembl Air Intake Screen 280 frame only NES er Sotor lt Stator q Conduit Box ___10 Exhaust Screen drip cover not shown 0 Generator Frame 20 Mounting Base 2 3 4 5 T Note Illustration above is a 280 frame MagnaPlus Other Frame sizes are typical Optional PMG not shown The generator madel and serial numbers are required when ordering parts MARATHON a EMT Corporate SECTION B VOLTAGE REGULATORS and ENGINE CONTROLLERS VOLTA INSTRUCTION MANUAL i 4 5 Seo gt 722 lt 5 2 gt 1542 225 and ALI c 2
118. devices e O 2 TT 4 KEEP THE ENGINE AND SURROUNDINGS CLEAN Be sure to stop the engine before cleaning Keep the engine clean and free of accumulated dirt grease and trash to avoid a fire Store flammable fluids in proper containers and cabinets away from sparks and heat Check for and repair leaks immediately DO NOT stop the engine without idling Allow the engine to cool down first Keep the engine idling for about 5 minutes before stopping unless there is a safety JAFAAAAAD0120 problem that requires immediate shut down 5 SAFE HANDLING OF FUEL AND LUBRICANTS KEEP AWAY FROM FIRE Always stop the engine before refueling and or lubricating DO NOT smoke or allow flames or sparks in your work area Fuel is extremely flammable and explosive under certain conditions Refuel at a well ventilated and open place When fuel and or lubricants are spilled refuel after letting the P engine cool down DO NOT mix gasoline or alcohol with diesel fuel The mixture can cause a fire or severe engine damage Do not use unapproved containers e g buckets bottles jars Use approved fuel storage containers and dispensers SAFE OPERATION 3 6 EXHAUST GASES amp FIRE PREVENTION Engine exhaust fumes can be very harmful if allowed to accumulate Be sure to run the engine in a well ventilated location and where there are no people or livestock
119. e Reversed engine revolution must be stopped immediately since engine oil circulation is cut quickly leading to serious trouble i How to tell when the engine starts running backwards 1 Lubricating oil pressure drops sharply Oil pressure warning light if used will light 2 Since the intake and exhaust sides are reversed the sound of the engine changes and exhaust gas will come out of the air cleaner 3 A louder knocking sound will be heard when the engine starts running backwards Remedies 1 Immediately turn the starter switch to the OFF position and set the engine stop lever to the STOP position to stop the engine 2 After stopping the engine check the air cleaner intake rubber tube and other parts and replace parts as needed 22 O lt TT 8 MAINTENANCE MAINTENANCE CAUTION To avoid personal injury Be sure to conduct daily checks periodic maintenance refueling or cleaning on a level surface with the engine shut off and remove the key Before allowing other people to use your engine explain how to operate and have them read this manual before operation When cleaning any parts do not use gasoline but use regular cleanser Always use proper tools that are in good condition Make sure you understand how to use them before performing any service work When installing be sure to tighten all bolts lest they should be loose Tighten the bolts by the spe
120. e Compare this voltage with the value recorded during initial startup If this value of no load excitation voltage is markedly higher than the bench mark reading it is an indication of problems in either the exciter main field or the rotating rectifier assembly Ensure that RPM is the same as initial test 5 Monitor and record insulation resistance with 500 volt mega ahm 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 DRYING WINDINGS Generators in service may inadvertently have theirwindings 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 before operating the unit If this precaution is not taken serious damage ta the generator can result The fallowing procedures may be utilized in drying the generators windings The method selected will be influenced by winding wetness and situation limitations 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 Thisprocess can be accelerated by enclosing the unit with
121. e engine oil level normally decreases a little Thus run the engine for a while and check for oil leaks through the seal before checking the engine oil level Add oil if necessary NOTE Wipe off any oil sticking to the machine completely PERIODIC SERVICE 17 RADIATOR Coolant will last for one day s work if filled all the way up before operation start Make it a rule to check the coolant level before every operation WARNING To avoid personal injury Do not stop the engine suddenly stop it after about 5 minutes of unloaded idling Work only after letting the engine and radiator cool off completely more than 30 minutes after it has been stopped Do not remove the radiator cap while coolant is hot When cool to the touch rotate cap to the first stop to allow excess pressure to escape Then remove cap completely If overheats should occur steam may gush out from the radiator or recovery tank Severe burns could result 22 O lt TT o O 2 TT 18 PERIODIC SERVICE Checking coolant level adding coolant 1 Remove the radiator cap after the engine has completely cooled and check to see that coolant reaches the supply port Z8 874 UN 1 Radiator pressure cap 2 If the radiator is provided with a recovery tank check the coolant level of the recovery tank When it is between the FULL and LOW marks the coolant will last for
122. e DO NOT check a batteries charge by placing a metal object across the terminals Use a voltmeter or hydrometer e DO NOT charge a battery if frozen it may possibly explode Frozen batteries must be warm up to at least 61 F 16 C before charging KEEP HANDS AND BODY AWAY FROM ROTATING PARTS e Keep your hands and body away from all rotating parts such as cooling fan v belts pulleys and flywheel Contact with these rotating parts can cause serious personal injury e Be sure to stop the engine before adjusting belt tension or checking the cooling fan e DO NOT run the engine without safety guards installed Be sure the safety guards are properly aligned and securely fastened before operating the engine 3 ANTI FREEZE AND DISPOSAL OF FLUIDS e Anti freeze contains toxic chemicals Wear rubber gloves when handling anti freeze In case of contact with skin wash immediately to avoid personal injury e DO NOT mix different types of Anti freeze The mixture can produce a chemical reaction resulting in the formation of harmful substances Only use anti freeze that is recommended and approved by Caterpillar e Bemindful of the environment Before draining any fluids be prepared to dispose of them in a manner consistent with environmental protection regulations in your location e When draining fluids from the engine use appropriate containers to hold the different fluids do not mix fuel oil or coolant togethe
123. e Ifthe glow lamp should redden too quickly or too slowly immediately ask your KUBOTA dealer to check and repair it If the engine does not catch or start at 10 seconds after the starter switch is set at STARTING position wait for another 30 seconds and then begin the engine starting sequence again Do not allow the starter motor to run continuously for more than 20 seconds COLD WEATHER STARTING If the ambient temperature is below 5 C 23 F and the engine is very cold start it in the following manner Take steps 1 through 4 above 5 Turn the key to the PREHEATING position and keep it there for a certain period mentioned below IMPORTANT Shown below are the standard preheating times for various temperatures This operation however is not required when the engine is warmed up Preheating time V3600 E3 V3600 T E3 V3300 E3BG V3600 T E3BG NO NEED Approx 15 seconds Approx 30 seconds 6 Turn the key to the STARTING position and the engine should start If the engine fails to start after 10 seconds turn off the key for 5 to 30 seconds Then repeat steps 5 and 6 IMPORTANT Do not allow the starter motor to run continuously for more than 20 seconds Be sure to warm up the engine not only in winter but also in warmer seasons An insufficiently warmed up engine can shorten its service life When there is fear of temperature dropping below 15 C 5 F detach the battery f
124. e center TROUBLESHOOTING 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 sleps have been arranged in an attempt to do the easy checks first and prevent further damage when troubleshooting a disabled machine A Subextary of agai Bed Corporation 14 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 generators prime mover is vital Has the prime mover been maintaining constant speed If nol have there been extended periods of under speed operation Has the prime mover experienced an over speed condition lf yes what was the maximum speed and how long did the unit operate at the televated speed The generator speed should be maintained at rated nameplate value during all operating tests The frequency of the generator depends upon rotational speed Most 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 WARNING HIGH VOLT
125. e consult the factory when faced with a significant non linear load 2 INSTALLATION Different generating set configurations will require different levels of site installation For example most enclosed sets that include switchboards and circuit breakers will require little or no connectors pass throughs or wiring for grounding whereas open configurations will likely require both Please read and follow each section as it applies to the specific generating set being installed 2 1 LIFTING AN The Lifting Lugs on the generator are meant to support the generator only Once assembled as a set the lifting lugs on the generator cannot be used to lift the assembly Severe personal injury or equipment damage may result Each generator is provided with two lifting lugs and should be used with a shackle and pin type safety lifting aid fitted to chains rated well above the minimum lifting force The chains should then be attached to a beam acting as a spreader to provide even distribution of weight on the chains and help ensure the generator remains as level as possible when lifted The use of rope is highly discouraged The lugs are positioned to allow the generator to be lifted as close to its center of gravity as possible thereby allowing the generator to remain level with ground when lifted However design constraints limit the location of the lugs so there is no guarantee that the generator will stay perfectly horizontal to the ground as it is li
126. echnology recommends a 1 1 mixture of water glycol NOTE Use a mixture that will provide protection against the lowest ambient temperature NOTE 100 percent pure glycol will freeze at a temperature of 23 C 9 F Most conventional heavy duty coolant antifreezes use Ethylene Glycol Propylene Glycol may also be used in a 1 1 mixture with water Ethylene and Propylene Glycol provide similar protection against freezing and boiling See the tables below ETHYLENE GLYCOL Freeze Boil Concentration Protection Protection 50 Percent 36 C 33 F 106 C 223 F 60 Percent 51 C 60 F 111 C 232 F PROPYLENE GLYCOL Freeze Boil Concentration Protection Protection 50 Percent 29 C 20 F 106 C 223 F NOTE Do not use Propylene Glycol in concentrations that exceed 50 percent glycol because of Propylene Glycol s reduced heat transfer capability Use Ethylene Glycol in conditions that require additional protection against boiling or freezing CHECKING RADIATOR COOLANT LEVEL Remove the radiator cap after the engine has completely cooled and check to see that coolant reaches the supply port 1 to the bottom of the fill neck and check after every 25 hours of operation 11 COOLANT SERVICE LIFE Coolant Type Service Life Commercial Heavy Duty Coolant Antifreeze that Meets ASTM D5345 3000 Service Hours Years Commercial Heavy Duty Coolant Antifreeze that Meets ASTM D4985
127. eck the battery charge by placing a metal object across the terminals Use voltmeter hydrometer DO NOT charge a frozen battery There is a risk of explosion When frozen warm the battery up to at least 16 C 61 F illi Gy 1AEABAAAPOO80 1ARAEAAAPO520 KEEP HANDS AND BODY AWAY FROM ROTATING PARTS Be sure to stop the engine before checking or adjusting the belt tension and cooling fan Keep your hands and body away from rotating parts such as the cooling fan V belt fan drive pulley or flywheel Contact with rotating parts can cause severe personal injury DO NOT run the engine without safety guards Install safety guards securely before operation Me To 1ABAAAAAP1470 SAFE OPERATION 5 10 ANTI FREEZE amp DISPOSAL OF FLUIDS Anti freeze contains poison Wear rubber gloves to avoid personal injury In case of contact with skin wash it off immediately DO NOT mix different types of Anti freeze The mixture can produce a chemical reaction causing harmful substances Use approved or genuine KUBOTA Anti freeze Be mindful of the environment and the ecology Before draining any fluids determine the correct way to dispose of them Observe the relevant environmental protection regulations when disposing of oil fuel coolant brake fluid filters and batteries L o O 2 TT 1BJABAAAPO 190 e When draining fluids from the engine place a suitable container unde
128. ed WARNING Do not increase the voltage above the rated generator voltage If in doubt refer to the name plate mounted on the generator case WARNING Do not ground any of the hand trimmer terminals as these could be above ground potential Failure to do so could cause equipment damage Before running generator turn the VOLTS control fully counter clockwise Turn remote volts trimmer if fitted to midway position Turn STABILITY control to midway position Connect a suitable voltmeter 0 300V ac across line to neutral of the generator Start generator set and run on no load at nominal frequency e g 50 53 Hz or 60 63 Hz If the red Light Emitting Diode LED is lit refer to the Under Frequency Roll Off UFRO adjustment Carefully turn VOLTS control clockwise until rated voltage is reached If instability is present at rated voltage refer to stability adjustment then re adjust voltage if necessary O gt 5 N STABILITY ADJUSTMENT The AVR includes a stability or damping circuit to provide good steady state and transient performance of the generator A jumper link selector is provided to optimize the response of the stability circuit to various size generators The jumper should be positioned as shown in the diagram according to the kW rating of the generator The correct setting of the stability adjustment can be found by running the generator at no load and slowly turning the stability control coun
129. ed Fits standard 2 1 16 diameter panel openings Measures 2 1 4 major diameter by 3 1 8 deep to end of threaded connector studs Water Detection and Element Restriction Kit RK 11 1570 not shown Similar to HK 20726 above except the unit features two LEDs Illuminates and sounds a momentary buzzer at every nawer up and then when water or filter restriction is detected vacuum switch set at factory for 7 inHg Automatically resets Hardware and instructions are included Wire and terminals are customer supplied Gauge Type Element Restriction Monitor Kit 16068 This 2 diameter gauge is also ideal for in dash applications Fuel flow to the engine becomes restricted as the element slowly plugs with contaminants The gauge monitors the filter restriction and informs the operator of filter condition anytime the engine is running Hardware and instructions included however plated steel Tee and vacuum tubing not supplied These items may be ordered from your Hacor dealer WARNING The following statemernd required pursaant sa Proposition 65 applicabbe sn de Ssane of California This product may a chemical kagen to the State CalsTomta lu casse Cancer WARNING ur improper selection or improper use of the produces andor systems described herman oz mand imas can couse death personal injury and propery damage his document anil ucher inienn tram Parker Hannifin Corpeeanen its subsidies and anhonze
130. ely equal ta 50 of the generator s three phase ratings Note Single phase KW KVA ratings are approximately equal to 50 of the generator s three phase ratings k Lb OPERATION 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 bad connections or foreign materials diagrams and ensure that all connections and Review all prirme mover prestart up instructions and ensure that all recommended steps and procedures have been followed Remove any masking materials affixed during painting Inspect the moverand any accessory equipment to ensure that nameplates and all safety warming caution signs and decals provided with the equipment are in place and clearly visible Mote t is strongly recommended that the authority having jurisdiction over the installation site be consulted to determine if any additional warning 2 Bar the set over by hand for at least 2 revolutions to be sure that there is interference and that the set turns caution notices or additional safety devices are freely the set does not turn freely check for required by local codes standards Any such clearance in the generator and exciter air gap required notices or devices should be installed prior to initial startup 3 Check all wiring agalnst the proper connection
131. enerators 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 exireme condilions If the generator is t be installed in an area where blowing sand and dust are present the enclosure should be fitted with fillers Filters reduce erosion on the generators 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 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 condull entrance Protect the Interior of the generator from shavings when drilling sawing An approved connector must be used in conjunction with the conduit To minimize the transmission of vibration lt is essential that flexible conduit be used for all electrical entrance to the generator conduit box 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 qualit
132. er 22 O lt TT 16 PERIODIC SERVICE 4 If the oil level is too low remove the oil filler plug and Changing engine oil add new oil to the prescribed level 5 After adding oil wait more than 5 minutes and check the oil level again It takes some time for the oil to A CAUTION drain down to the oil pan To avoid personal injury e Be sure to stop the engine before Engine oil quantity draining engine oil When draining engine oil place o O lt TT V3600 E3 V3600 T E3 V3800 DI T E3 some container underneath the V3300 E3BG 13 2 L 3 49 U S gal engine and dispose it according to V3600 T E3BG V3800 DI T E3BG local regulations Do not drain oil after running the API service classification above CF grade engine Allow engine to cool down sufficiently IMPORTANT Engine oil should be MIL L 2104C or have properties of API classification CF or higher 1 Change oil after the initial 50 hours of operation and Change the type of engine oil according to the every 500 for DI spec 250 for IDI spec hours ambient temperature thereafter When the annual operating hours are below 500 DI above 25 C 77 F orSAE10W 30 spec or 250 IDI spec replace the oil every year SAE15W 40 2 Remove the drain plug at the bottom of the engine and drain all the old oil Drain oil will drain easier when the oil is warm 3 When letting out the oil remove the filler plug too
133. esistance IR value of around 25 assuming it has been stored in a clean dry area If the value is below 10 then the generator should undergo drying out procedure and tested again Generators in service should have an IR value above 1 MQ If not the generator should undergo a drying out procedure and tested again If the IR rating for all phase to phase and neutral to phase measurements are above 1 MO then the windings are in working order If the IR value is still below 1 MO for any of the measurements then the windings may need to be replaced 14 4 2 1 WINDING CONDITION ASSESSMENT Be sure to disconnect the AVR and ground the leads of the Resistance Temperature Detector RTD before conducting this test To determine the condition of the windings the insulation resistance is measured from each phase to phase and from each phase to neutral This measurement should be conducted as part of regular maintenance after extended shutdown periods or if the insulation resistance value is suspected to be low e g wet or dirty windings Caution is necessary when it is possible that alternator windings may be excessively damp or dirty low voltage typically 500V Mugger mega ohm meter or similar instrument should be used to obtain the initial measurement of the insulation resistance Test voltages should be applied gradually and only for a short period only long enough to make a determination about the status In no event sh
134. essary DC output voltage to the exciter field required t maintain constant generator terminal voltage The generators terminal voltage is changed by adjusting Ihe regulators reference sel point Consul regulator manual for specific adjustment and operating instructions MOTOR STARTING When a motor is started a large surge of current is drawn by the motor This staring 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 ush of starting current the generator voltage dips temporarily If the motor is too large for the generator the generators voltage dips greater than 30 percent This may result in the motor starter de energizing or the motor horsepower per generator KW in motor starting capability For specific data contact Marathon Electric PARALLEL OPERATION MagnaPlus generators are buill 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 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 swi
135. f the generator UNDER FREQUENCY ROLL OFF UFRO ADJUSTMENT The AVR incorporates an under speed protection circuit which gives a volts Hz characteristic when the generator speed falls below a preset threshold known as the knee point The red Light Emitting Diode LED gives indication that the UFRO circuit is operating The UFRO adjustment is preset and sealed and only requires the selection of 50 60 Hz using the jumper link For optimum setting the LED should illuminate as the frequency falls just below nominal i e 47 Hz on a 50 Hz system or 57 Hz on a 60 Hz system DROOP ADJUSTMENT Generators intended for parallel operation are fitted with a quadrature droop C T which provides a power factor dependent signal for the AVR The C T is connected to S1 S2 on the AVR The DROOP adjustment is normally preset in the works to give 5 voltage droop at full load zero power factor 45 Clockwise increases the amount of signal injected into the AVR and increases droop with lagging power factor cos With the control fully counter clockwise there is no droop TRIM ADJUSTMENT An analog input A1 A2 is provided to connect to the Power Factor Controller or other devices It is designed to accept dc signals up to 5 volts CAUTION Any devices connected to this input must be fully floating and galvanically isolated from ground with an insulation capability of 500 VAC Failure to do this could result in equipment damage
136. fted Care must be exercised to prevent personal injury or equipment damage Each generator has been carefully inspected and tested before shipment from the factory However it is highly recommended that the generator be thoroughly inspected Check all bolts to insure they are tight and examine the insulation on lead wires for chafing 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 2 2 ENGINE GENERATOR ASSEMBLY During assembly the generator and engine shafts must be properly aligned and allowed to rotate so that the engine flywheel holes and the generator coupling holes can be lined up and coupling bolts installed and tightened In order to help with alignment it may be necessary to add shims to the generator s feet This holds true for both single and dual bearing generators AN Disable and lockout any engine starting devices before installing or servicing the generator Also note that improper alignment can result in equipment damage and or personnel injury 2 2 1 SINGLE BEARING GENERATORS The generator frame housing and SAE coupling plates have been coated with a rust preventative to prevent corrosion during shipping and storage This coating MUST BE REMOVED prior to assembly with the engine Use a petroleum based degreaser and clean all mating surfaces To make the alignment of the shafts and bolt holes of single bear
137. g provisions Note AVR Model AG460 is not suitable for parallel operation e Paralleling current transformer s e Paralleling provisions on governor controls Before operating generator sets in parallel each set should be checked by starting operating and adjusting the sets as individual units before attempting paralleling The driving engines should have the same speed regulation characteristics and the governors should be adjusted to give the same speed regulation The generators must have the same phase rotation The voltage and frequency must be the same for all sets with voltages in phase Voltage Regulator The voltage regulator controls the generator output voltage and the reactive power supplied by the generator When two or more AC generators operate in parallel the voltage regulator must have paralleling provisions either internally or external to the regulator to allow the voltage regulator to control the reactive or VAR load while it is in parallel operation Additional paralleling circuitry is absolutely necessary to control the reactive current flowing between the generator sets A droop kit accessory is required for parallel operation When operating in parallel with other generators itis important that e Frequency must match within close limits e Voltages must match within close limits e Phase angle of voltages must match within close limits Once connected in parallel a minimum instrumentation level per generator of
138. generator load voltage is dependent on 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 1 Shutdown the generator set and connect a voltmeter on the generator terminals 2 Disconnect the regulators 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 3 With na load on the generator main breaker open run the generator at rated speed Measure the generators terminal voltage and compare this value with values recorded during installation If voltage readings are normal the main generator and excitation are operating properly Troubleshooting should continue with the regulator If readings are not narmal the problem is in the generator Continue testing diodes surge suppressar and windings Continuity Resistance Test The generator has four components which can be checked using an ohm meter exciter stator exciter rotor main stator and main rotor Each of these components are comprised of various windings which 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 precis
139. gine must be off and obtain good ventilation and lighting Do not smoke or allow open flames near the installation Eye protection is recommended and have fluid drip pans and absorbant shop cloths available ta anticipate spills 3 The chosen mounting location should allow 2 inches below the unit for draining water and replacing elements 4 Pipe thread paste is recommended on port fitting connections Do not use pipe tape a loose piece could clog the system s Engine r amus 1 Fuel Tank 2624 f a T aes t 15 r supplied is Fuel Transfer A shut off valve customer suppmed Fuel I njection 4 recommended when the fuel rank is mounted Purnp Pump higher than the filter zii UL Typical T if fuel Fuel Tank system rrr 3 3 diagram NO OMNE LIE coa SECONDARY FINAL FILTEH LOCATION PRIMARY FILTER LOCATION AND Shown on the pressure side of the pump MARINE MODEL LOCATION Could also be on the suction side of the Shown on the suction side ol the pump Use a 2 or 10 micron filter pump Use a 30 10 micron filter PERFORMANCE INFORMATION BRASS 1 4 NPT FITTINGS CHART 951 N4 H4 951 N4 H5 951 N4 H6 853 N4 H5 953 N4 H6 SAE Jada Clogging m a 5D 100 150 200 250 300 350 Cc ou OPERATING INSTRUCTIONS PRIMING Loosen the vent plug Operate the primer pump until fuel purges
140. he AVC63 4 is typically set with this jumper connected to the 60 Hz terminal This gives a corner frequency of 55 Hz For 50 Hz operation and a corner frequency of 45 Hz the Corner Frequency Jumper must be moved to the 50 Hz terminal Voltage Adjust Rheostat Jumper The Avc63 4 1s typically set with the Voltage Adjust Rheostat Jumper connected across terminals 6 and 7 This enables adjustment of the generator output voltage through the controller s internal voltage control potentiometer Clockwise rotation of the voltage control increases generator voltage POTENTIOMETER CONTROLS Amp 230 Fast Blow Fuses The AVC63 4 potentiometer controls are located on the components and terminals side of the controller Voltage control Stability control and Underfrequency control allow for fine tuning the controller to a specific application INPUT POWER SENSING INPUT Power for the exciter field and AVC63 4 1s derived from the generator output The acceptable power input range 1s 171 to 264 V AC and is connected to terminals 3 and 4 EXCITER FIELD POWER CIRCUIT Controller terminal F is connected to the brushless exciter field positive terminal and controller terminal F 15 connected to the brushless exciter field negative terminal 6 BASLER MODEL AVC63 4 VOLTAGE REGULATOR IMPORTANT The exciter field DC resistance must be 15 Ohms or higher and less than 100 Ohms If the exciter field DC resistance 15 less than 15
141. he nozzle and the filter PERIODIC SERVICE 21 llEvacuator valve Open the evacuator valve once a week under ordinary conditions or daily when used in a dusty place to get rid of large particles of dust and dirt the air cleaner with a dust cup optional Remove and clean out the dust cup before it becomes half full with dust usually once a week or even every day if the working surroundings are dusty Install the air cleaner dust cup with TOP indicated on the rear of the cup in the up position However it may be installed in either direction when the cover is placed at the lower part IMPORTANT If the dust cup is mounted incorrectly dust or dirt does not collect in the cup and direct attachments of the dust to the element will cause its lifetime to shorten to a great extent Air cleaner body Secondary element Dust cup 1 2 3 Primary element 4 5 Top mark 22 O lt TT o O 2 TT 22 PERIODIC SERVICE ll Dust indicator optional If the red signal on the dust indicator attached to the air cleaner is visible the air cleaner has reached the service level Clean the element immediately and reset the signal with the RESET button 1 RESET button 2 Dust indicator 3 Service level 4 Signal ELECTRIC WIRING CAUTION To avoid personal injury Shorting of electric cable or wiring may cause a fire Check to see
142. he regulator will turn the SCR later in each half cycle causing reduced charge currents The battery voltage sensing network is high in impedance approximately JK ohm and will not cause battery discharge on power outage CRANK DISCONNECT The crank disconnect relay is supplied by the terminals This reed relay shunts the SCR pulse transformer input when operated which prevents SCR turn on SHUTDOWN Shutdown sense signal comes from the B terminal Amy time the voltage on that terminal drops below 5 0 volts the shutdown sense circuit begins to steal the SCR drive signal which reduces charge current H the terminal voltage falls below 2 5 volts sufficient SCR drive signal is stolen to prevent SCR turn on causing all charge current to stop Output current will return when the B voltage rises above 2 5 volts paite aE eg Burque13 Tump mo g 2574 nguna pus 2570 JH SKS pudra UE 5182 3 uraqosd jp t XU PEP HIE je spea 38 832 Rajo pamjdaumu uo suns yae Juag Ajuga uan AparErporuur gp sana mada ng Arse w opu Fea wei 12021 91 Fees AT HEq jon st HAF aE y HAF sdeqaa Gl enBa sr sajoi raueg zum uy LON pasepdai aq pinogs daneg J3a 53212 25 xp 22 120010 j papasu si peunou 12
143. hould build up If the voltage does not build up it may be necessary to Field Flash the generator See section on Field Flashing Slowly adjust the controller s voltage control potentiometer until the generator voltage reaches the nominal level Apply and remove the generator load to verify stability If the generator responds too slowly or hunts oscillates adjust the controller s stability control with no load applied Also check the stability of the governor system mechanical or electronic 1f applicable Next check the regulation under normal operating conditions If not acceptable check the engine speed Be sure to use an average sensing voltmeter not an RMS sensing voltmeter and should be connected at the same point as the controller sensing Verify the corner frequency setting by slowly reducing the generator frequency until the generator output voltage just starts to decrease If adjustment of the corner frequency 15 required Current Version rotate the underfrequency control fully counterclockwise Reduce the generator frequency from nominal either 50Hz or 60 Hz to the desired corner frequency Slowly adjust the underfrequency control clockwise until the generator output voltage Just starts to decrease 1 3 4 5 6 7 9 PT ECU 64 ENGINE CONTROL MODULE Generator Main Switch must be In the ON position Toggle the Start Stop Switch to the Start position Glow Plugs will preheat for 8 seconds LED flashes slowly
144. inants carried into the generator by required airflow High Humidity amp tropical Climates Although the normal generator windings are humidity and moisture resistant in service areas that are particularly moist or humid such as tropical environments and all marine applications additional protection is recommended Special winding insulations are available as well as space heaters to compensate for these harsh environments Altitude amp High Ambient Temperature Operations For applications over 1000 meters 3300 feet elevation or where the temperature of the ventilating air to the generator exceeds 40 C 104 F de rating of the generator is necessary GC RN 55 _________ 0 gt _ M TP 2 5 de rate CC T TI _ l lt1 de rate T _ TL 5 54 7 a C LC eo de rate 2 _ nh L l s 20 0 4 _ _ 4 012111 5 1000 2000 3000 ALTITUDE METERS Non Linear Loading When subjected to non linear loads generator output is affected causing additional heat in the generator rotor and stator Solid state electronic devices such as SCR devices can introduce high frequency harmonics which adversely affect the normal waveform of the generator To account for these phenomena generators must be oversized Pleas
145. ing generators easier place two dowels at diametrically opposite holes on the engine flywheel The generator coupling plate can then be aligned with the engine flywheel as the generator is placed onto the base Once the bolt patterns of the two plates are lined up the dowels must be removed and coupling bolts and nuts installed in every bolt hole Bolt sizes and required torque values are shown in Appendix D SAE Data The combined engine generator shaft will need to be rotated as the coupling hardware is installed and should be done with care so as to ensure the safety of the installer s and protection of the assembly s components Be sure to follow approved working practices particularly when reaching inside the assembly to install and fastened coupling hardware 2 2 2 TWO BEARING GENERATORS Following the coupling manufacturer s guidelines for proper fit and alignment a flexible coupling should be used to join the engine to the generator For belt driven generators avoid axial load on the bearings by verifying the alignment of the pulleys and belts Using a screw type tensioning mechanism is recommended to maintain pulley alignment while providing accurate belt tension adjustment Adapter guards must be installed after the coupling assembly is finished The motor generator set builder is responsible for providing a suitable guard for open coupled sets 2 3 GROUNDING The generator frame must be firmly mounted to the generator set
146. ion equipment to make accurate measurements however a standard ohm meter will provide a good indication of winding continuity OJMARATHON T Gua a A Sutekary af Corporation Insulation Test Insulation resistance is a measure of the integrity of the insulating materials that separate the electrical windings from the generators steel core This resistance can degrade over lime or be degraded by contaminants dust dirt oil grease and especially moisture Mast winding failures are due to a breakdown in the insulation system In many cases low insulation resistanceis caused by moisture collected when the generator is shutdown Insulation resistance is measured with a megger mega ohm meter megger measures insulation resistance by placing 500 volts between the winding and the frame of the generator Caution must be taken to remove all electranic devices requiators 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 rator Minimum resistance is 2 mega ohms If the winding resistance is low it must be dried see maintenance section repaired DIODE TESTING If the generator is close coupled to an engine it may be necessary to bar over the enginein order to qain access ta a given area of the rectifier assembly NEVER use the generators fan as a fulcrum to
147. is different between the two types of connections is known Refer to sections 2 4 4 to find the diagram of the specific AVR in the generator Find the potentiometer label volts Using a small flathead screwdriver turn the volt potentiometer counterclockwise until it stops Run the generating set with no load Verify the frequency output is correct Slowly turn the volt potentiometer clockwise until the desired voltage is reached Soh ely Again please note the type of connection line to line or line to neutral the voltmeter is hooked up to when setting the voltage The stability control of the AVR is preset at the factory and will not normally require further adjustment However if the voltage output oscillates changes constantly the stability can be adjusted following the instructions below Connect a voltmeter to the output of the generator either line to line or line to neutral Run the generating set with no load and verify that the generator shaft speed is stable and spinning at the proper rpm Refer to sections 2 4 4 to find the diagram of the specific AVR in the generator Find the potentiometer label stability Using a small flathead screwdriver turn the stability potentiometer clockwise until it stops Slowly turn the stability potentiometer counterclockwise until the generator voltage begins to oscillate Turn the stability potentiometer clockwise slightly just until the voltage stabilizes The stabi
148. ischarged gases may not be drawn into the vehicle interior through windows doors air conditioners etc The engine powering your generator set discharges deadly carbon monoxide as part of the exhaust gas when running It is essential that the exhaust system be leak proof and routinely inspected 10 EXCESSIVE NOISE Never operate the generator set without an adequate muffler or with a faulty exhaust system Exposure to excessive noise can lead to a hearing impairment 11 ELECTRICAL SHOCK A battery can cause electrical burns and shocks Use reasonable care when working near the battery to avoid electrical connections by contacting the battery terminals with tools Remove wristwatch rings and all jewelry when working on the generator set 12 BACKFIRE A sudden backfire can cause serious burns Do not operate your generator set without its air cleaner flame arrestor place 13 FLASH FIRE A sudden flash fire can cause serious burns To avoid the possibility of a flash fire do not smoke or permit a flame or spark to occur near the carburetor fuel lines fuel filter fuel pump or other potential source of spilled fuel or vapors 14 FIRE HAZARD Be careful when parking your vehicle to prevent grass fires from being started by hot exhaust gases or exhaust system Keep away from hot engine and generator parts to avoid burning yourself Keep the generator set and compartment clean and free of debris especially combustible materials Never sto
149. ity tester Reversing the test leads reverse biased will result in the diode switching off and no electricity will be conducted The resultsof these tests should indicate one of three conditions 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 wil be less than 10 ohms The battery light tester will have the light on in one direction and off in the other 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 amp diodes are essentially in the same circuit When a diode is stressed to failure there is 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 SERVICE 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 All service procedures sho
150. just not set properly Rotate the stability adjust in a GW Voltage Hunting _ Sas direction Unt hunting Stops Foor Regulation Defective regulator Replace regulator m L A Subsidiary r Corporation Marathon Electric Mfg Corp RUNS 100 East Randolph Street AN 84 P O Box 8003 D RU Wausau WI 54402 8003 AND RUNS Fax 715 675 8026 gt Litho in US A GPN011 6 99 BASLER AVC63 4 ANALOG VOLTAGE CONTROLLER The AVC63 4 voltage regulator 15 designed for use on 50 60 Hz brushless generators Features Include frequency compensation over excitation shutdown a solid state build up circuit and EMI filtering The AVC63 4 attaches to the generator with spade type wire terminals for a secure connection The AVC63 4 has three adjustable potentiometers for fine tuning the output voltage stability and under frequency The regulator is encapsulated in a protective plastic shell and back filled with an electronic compound which provides protection from environmental hazards AVC63 4 Specifications DC Output Power 4 Amps at 63V DC 7 Amps at 100V DC 9 Amps at 134V DC Exciter Field DC resistance 15 Ohms Min 100 Ohms Max AC Power Input 190 240V AC Single Phase 50 60 Hz 10 Burden 500VA sensing Input 190 240V AC Single Phase 50 60 Hz 1096 Common with AC Power Input Voltage Adjust Range 171 264V AC Regulation Accuracy Better than 1 0 N
151. kcase above FULL mark 2 Remove the oil filler cap and add oil 1f necessary Clean the oil filler cap Install the oil filler cap The refill capacities for the engine crankcase Reflect the approximate capacity of the crankcase or sump plus a standard oil filter Auxiliary oil filter systems will require additional oil LUBRICATING OIL SPECIFICATION Use only good quality lubricating oil which meets the following Specification API Class CF Engine Oil Above 25 77 25 32 to 77 F Below 0 C 32 F V 3300 amp V 3300 T ENGINE REFILL CAPACITIES Crankcase Oil Sump 14 13 2L and Filter LUBRICATING OIL VISCOSITY RECOMMENDATIONS The minimum ambient temperature during cold engine start up and the maximum ambient temperature during engine operation determine the proper SAE viscosity grade of oil Refer to the Engine Oil Viscosity Table below Minimum Temperature in order to determine the required oil viscosity for starting an engine in cold conditions Refer to the Engine Oil Viscosity Table below Maximum Temperature in order to select the oil viscosity for engine operation at the highest ambient temperature that 1s anticipated Oil Viscosity SAE 10W 30 SAE 30 or SAE 10W 40 SAE 10W 30 SAE 20 or Ambient Temperature SAEIOW 40 SAE 10W 30 SAE 10W or SAE 10W 40 10 ENGINE COOLANT MAINTENANCE COOLANT RECOMMENDATIONS For optimum performance Power T
152. l tend to hunt under steady state conditions The screwdriver adjustable potentiometer adjusts the system stability Adjustment clockwise increases the stability Increasing the stability increases the response time of the generator Conversely decreasing the sta bility decreases the response time of the generator V HZ ROLL OFF FREQUENCY SELECTION The roll off point is the frequency where the generator voltage starts to decrease This reduces the Kilowatt load to the engine which allows the engine to recover in speed under any load transient condition Use jumper to select 50 HZ or 60 Hz The screwdriver adjustable potentiometer sets the roll off frequency from 54 61 Hz in the 60 Hz setting or from 45 51 Hz in 50 Hz setting The SE350 has the roll off point preset to 58 Hz in the 60 Hz mode and 48 Hz in the 50 Hz mode To change the roll off point adjust engine speed to the desired rated speed 50 or 60 Hz Set the voltage to the desired setting at rated speed Adjust engine speed to the desired roll off point Turn the potentiometer coun terclockwise until the voltage starts to drop off Then adjust the potentiometer clockwise until the voltage returns torated Re adjustengine speed to rated speed START UP PROCEDURE PRELIMINARY SET UP Ensure the voltage regulator is correctly connected to the generator Refer to the specific connection diagram supplied with the generator Sel the regulator voltage adjust to full co
153. le this connection can be made lo the lowest accessible point in the engine block on the suction side of the system pump or by installing the proper size hose fitting in the lower radiator hose Plan to keep the inlet hose length from the engine as short as possible Determine the Heater Outlet Connection Plan to splice the heater outlet hose into the hose line coming from the passenger compartment heater to the engine block Keep the outlet hose length as short as possible but maintain a minimum rise of 12 inches to ensure proper circulation Avoid selecting a heater location that requires the hose to be routed In manner that will restrict coolant flow such as routing over the top of the engine block Avoid sharp bends or loops to ensure against airlocks Coolanl may not circulate if airlocks are present See Figures 1 to 4 below 103405 Figura 1 Correct Figure 2 Incorrect Heater Figure 3 Incorrect Outlet Figure 4 Incorrect Sharp Installation Mounted Too High Hose Looped Over Top o Loop or Bend in Hose Engine 11 16 98 Made in USA Fabriqu aux EU Printed in USA Imprimi aux EU Page 1 1 2 1 21 1 2 1 2 1 2 1 3 1 2 1 4 Mounting Onca heater inlet and outlet connections have been determined select a location to mount the heater that meets the following conditions Mount the heater to the firewall or inside the fender See Figure 5 CAUTION Do MOUNT THE HEATER TO THE ENGINE BLOCK AS A SHORTENED HEA
154. lement R25F 2458 30 mic Replacement Element 22244 Bowl O ring 4 HK22350 02 See thru Bowl Assembly Head top view Kz 2 TRK22354 01 12vdc Heater See thru Bowl Fuel ports are 1 RK22354 02 24vde Heater and See thru Bowl MEAN F LE RK20022 Metal Plug 1 27 20 UNF LE 9 RK30964 Water Probe and Connector Kil 22368 Marine Metal Bowl drain amp 1 2 port 1 HK30476 Self Venting Drain Knob 20011 Check and Plastic HK20742 Marine Metal Check Ball Cap HK20075 Complete Gasket O ring Kit Must be used with a Water Detection See Accessories below 5 16 B mm diameter clearance for fasteners Water Detection Kit 20725 This 12 vdc under dash module illuminates an LED when power is on and then when water is detected The DRAIN LED will remain illuminated until the water is drained below the probe tips The unit automatically resets Hardware and instructions Included Wire terminals are customer supplied Measures 2 3 4 by 1 by 1 1 2 deep Water Detection Kit 4 RK 20726 This 2 diameter gauge type module is ideal for in dash applications The corrosion resistant body is waterproof from the face side and may be used with12 or 24 vdc electrical systems The unitilluminates an LED and sounds a momentary buzzer at every power up and then when water is detected The unit automatically resets Hardware and instructions are included however wire and terminals are customer suppli
155. lity should be set so that the voltage output is stable but close to the unstable range N poids 9 10 3 1 3 LOAD TESTING 3 1 3 1 AVR ADJUSTMENTS After adjusting the voltage and stability the AVR will not typically require further adjustment However if voltage collapse or poor voltage regulation result when a load is applied additional adjustments may need to be made Please see the subsections below on the other possible adjustments to determine if one or more of these will fix the problem being experienced Be sure to read through each carefully to be sure the correct adjustment is being made and to be sure it is done correctly 3 1 3 1 1 UNDER FREQUENCY ROLL OFF UFRO The UFRO is an under speed protection circuit that produces a volts frequency speed characteristic whenever the speed of the generator shaft goes below a set threshold called the knee point The UFRO needs adjustment if the generator is under load and a the LED remains constantly lit or b if voltage regulation is poor The knee point can be adjusted by using a small flathead screwdriver to turn the UFRO potentiometer Please refer to the proper AVR diagram in section 2 4 4 to locate the UFRO potentiometer Turning the UFRO potentiometer clockwise will lower the knee point frequency speed setting and turn off the LED Ideally the knee point should be set so that the LED lights whenever the frequency becomes less than the nominal frequency For a 50
156. llation Operation Maintenance SECTION B VOLTAGE REGULATORS and ENGINE CONTROLLERS MARATHON SE350 VOLTAGE REGULATOR INSTRUCTION MANUAL 1 4 BASLER AVC64 4 ANALOG VOLTAGE CONTROLLER 5 7 PT ECU 64 ENGINE CONTROL MODULE 8 APEC 3100 ELECTRONIC ENGINE SPEED GOVERNING SYSTEM 9 GAC ESD2110 SERIES SPEED CONTROL MODULE 10 SECTION C WIRING SCHEMATICS REDCO PANEL ASSEMBLY of 9 SMIP BOX WIRING 3 PHASE 1 of 1 12 LEAD ZIG ZAG 1 of 1 3 PHASE 12 LEAD HI DELTA 1 of 1 3 PHASE 12 LEAD HI WYE 1 of 1 3 PHASE 12 LEAD LOW WYE 1 of 1 12 VOLT DC ENGINE CONTROL CIRCUIT PT ECU 64 1 of 1 12 VOLT DC ENGINE CONTROL CIRCUIT GAC ESD 2110 1 of 1 12 VOLT DC ENGINE CONTROL CIRCUIT SERIES 200 BOX 1 of 1 120 VOLT SINGLE PHASE 4 WIRE CONNECTION M SERIES EXCITER TYPE 120 240 VOLT SINGLE PHASE 4 WIRE CONNECTION M SERIES EXCITER TYPE 2 220 VOLT SINGLE PHASE 4 WIRE EUROPEAN CONNECTION SERIES EXCITER TYPE 3 RESISTANCE CHART 30 35 40KW SERIES EXCITER TYPE 4 SECTION D GENERATOR END TROUBLESHOOTING GUIDES ZERO OR LOW VOLTAGE VOLTAGE TEST 12 VOLT BATTERY TEST 2 OVERLOAD CONDITION 3 OPTIONS DYNA GEN OPTIMAL SERIES AUTOMATIC TRANSFER SWITCH Manual Supplied with Switch DYNA GEN TSC3 TIMER MODULE Manual Supplied with Timer PHILLIPS amp TEMRO INDUSTRIES ENGINE PRE HEATER 1 3 MASTER CONTROL SYSTEMS MBC 19 BATTERY CHARGER 1 4 RACOR 200R SPIN ON SERIES FUEL FILTER WATER SEPERATOR 1 4 SAFTEY PRECAUTIONS A generator set can be potenti
157. lowing the battery to be depleted Loads across the battery which are less than the Charger s rated current will be supplied by rhe Charger with the remaining Charger output being available to charge the battery if required For loads greater than the rated output the Charger will supply at least its rated output if the crank disconnect terminals and DK2 are not energized with the battery supplying the remainder BATTER CITY is limited to 115 ampere hours except where A C line voltage is not abnormally high the maximum battery may twice the 115 ampere hour limit LINE REGULATION The Charger is regulated line compensated and requires no tap semings The line voltage regulation output change is 1 maximum fora 10 line voltage change The Charger will operate with line changes of up to 15 of nominal with reduced current rating on low line voltages WATER CONSUMPTION The unit is a Charger which has an output voltage somewhat higher than float level voltages This allows the Charger to charge a battery in reasonable time and maintain the charge with minimal gassing With semi float Chargers the battery water level should be checked at least once month until a water consumption pattern is established Longest battery life will be obtained when distilled water is used to fill batteries EQUALIZING The MBC 19 Models are single rate semi float Chargers They do not have means for equalizing the battery In engi
158. m pinholes may be invisible Do not use hands to search for suspected leaks Use a piece of cardboard or wood instead If injured by escaping fluid see a medical doctor at once This fluid can produce gangrene or a severe allergic reaction Check any leaks from fuel pipes or fuel injection pipes Use eye protection when checking for leaks Be careful not to empty the fuel tank Otherwise air may enter the fuel system requiring fuel system bleeding See FUEL in PERIODIC SERVICE section of exhaust While the engine is run within the rated output range The color of exhaust remains colorless the output slightly exceeds the rated level exhaust may become a little colored with the output level kept constant If the engine is run continuously with dark exhaust emission it may lead to trouble with the engine Wimmediately stop the engine if The engine suddenly slows down or accelerates Unusual noises are suddenly heard Exhaust fumes suddenly become very dark The oil pressure lamp or the water temperature alarm lamp lights up OPERATING THE ENGINE 7 REVERSED ENGINE REVOLUTION AND REMEDIES CAUTION To avoid personal injury Reversed engine operation can make the machine reverse and run it backwards It may lead to serious trouble Reversed engine operation may make exhaust gas gush out into the intake side and ignite the air cleaner It could catch fir
159. m the generator to allow the moisture to escape Be sure air can flow freely into one side of the generator and out another At a minimum there should be two openings Using two electric fan heaters rated 1 to 3 kW direct hot air into one of the openings Make sure the heat source is at least 300 mm 12 inches away from the windings to prevent overheating and insulation damage Heat at the entry point should not exceed 80 180 F A period of 3 hours is typical to restore the IR of a generator If the generator will not be run immediately insure that anti condensation heaters if installed are in operation and retest windings before running 15 Short Circuit Method The short circuit method is a process that should only be performed by a technician qualified in the safe operating practices required around generator sets Contact the factory for detailed instructions should this method be chosen 4 3 BEARINGS All bearings are supplied from the factory pre packed with Athlon Generator grease conforming to the specifications of Kluber Asonic GHY 72 grease Do not mix with any grease of different specifications Mixing grease of differing specifications will reduce bearing life The specification for Athlon grease is available on request from the factory Lifetime Lubricated bearings are fitted with integral seals and are not greasable The life expectancy of bearings in service is a direct function of the working conditions
160. mp starting F Damage caused by water ingestion or electrolysis G Damage caused by ingestion of substances other than clean filtered air fuel or intake water H Damage caused by faulty repairs performed by a repair facility not authorized in writing by Power Tech I Damage caused by operation with improper fuel or at speeds loads conditions modifications or installation contrary to published specifications or recommendations J Original installation charges and startup costs K Removal and re installation charges of more than 1 hour labor for outside units 2 hours for compartment mounted units and 3 hours for below deck marine units Customer is responsible for additional labor charges due to difficult access removal or installation L Starting batteries and labor or charges related to battery service M Loss of revenue or the rental of equipment due to down time N Generator repairs made within the warranty period other than by an authorized Power Tech service dealer without prior written approval from Power Tech warranty department O Damage caused by negligent maintenance such as but not limited to Failure to provide the specified type and quantity of lubricating oil cooling air flow and proper coolant mixture and level Failure to provide adequate air intake or maintenance of the air intake system Failure to provide scheduled maintenance as prescribed in supplied manuals P Engine fluids such as fuel oil or coolant antifreeze Q Shop sup
161. ne staring applications running the engine periodically will allow a battery charging generator or alternator to equalize the battery after the cranking energy has been returned to the battery A battery equalized in this manner will be indicated by a zero charge curcent reading of the batery charger ammeter after the engine is stopped After a time interval the battery voltage will drop and the Charger will show a small output current which 1 dependent upon leakage and load current CRANK DISCONNECT In applications requiring battery output currents which exceed the Charger output ratings such engine cranking a crank disconnect signal must be supplied the Charger This signal should be a DC voltage of the same nominal value as the Charger DC rated voltage The signal may be either polarity and is supplied to terminals DKI and DK2 The current required by the disconnect relay 18 less 20mA on 12 volt units and LOmA on 24 volts units Wiring these terminals to the starter contactor or starter motor terminals would provide the required signal on engine starting application Battery Lend Wire Size Max Run Min Wire Loop Length AWG Ohms Drop OFT 16 04 25F 120mn 07 Model MARIA SOFt I2 QBv 8 32 Terminal Screws 10 150 Crank Disconnect Signal 54 AWG Min STARTING Ground CONTACTOR 16 AWG Min To A C Power Source At Nameplate Voltage Frequency
162. near the engine The exhaust gas from the muffler is very hot To prevent a fire do not expose dry grass mowed grass oil or any other combustible materials to exhaust gas Keep the engine and muffler clean at all times avoid a fire be alert for leaks of flammable substances from hoses and lines Be sure to check for leaks from hoses or pipes such as fuel and hydraulic fluid by following the maintenance check list To avoid a fire do not short across power cables and wires Check to see that all power cables and wirings are in good condition Keep all electrical connections clean Bare wire or frayed insulation can cause a 1 11 dangerous electrical shock and personal injury L o O 2 TT 7 ESCAPING FLUID Relieve all pressure in the air the oil and the cooling systems before disconnecting any lines fittings or related items e Be cautious of possible pressure relief when disconnecting any device from a pressurized system that utilizes pressure DO NOT check for pressure leaks with your hand High pressure oil or fuel can cause personal injury Escaping fluid under pressure has sufficient force to penetrate skin causing serious personal injury e Fluid escaping from pinholes may be invisible Use a piece of cardboard or wood to search for suspected leaks do not use hands and body Use safety goggles or other eye protection when checking for leaks e f injured by escaping fl
163. ned to accept dc signals up to 5 volts WARNING Any devices connected to this input must be fully floating and galvanically isolated from ground with an insulation capability of 500V ac Failure to observe this could result in equipment damage The dc signal applied to this input adds to the AVR sensing circuit A1 is connected to the AVR 0 volts Positive on A2 increases excitation Negative on A2 decreases excitation The TRIM control allows the user to adjust the sensitivity of the input With TRIM fully counter clockwise the externally applied signal has no effect Clockwise it has maximum effect Normal setting is fully clockwise when used with a Power Factor Controller 55 OVER EXCITATION EXC ADJUSTMENT This adjustment is set and sealed in the unit and should not be tampered with An over excitation condition is indicated by the illumination of the red LED which also indicates under speed running and over voltage The generator must be stopped to reset an over excitation trip DIP ADJUSTMENT This feature is mostly used when the generator is coupled to turbo charged engines with limited block load acceptance The feature works by increasing the V Hz slope to give greater voltage roll off in proportion to speed With the DIP control fully counter clockwise the generator voltage will follow the normal V Hz line as the speed falls below nominal Turning the DIP control clockwise provides greater voltage roll off aiding engine recovery
164. ng measure voltages at the regulator terminals P2 P3 and P4 These should be balanced and within the following ranges 50 Hz generators 170 180 volts 60 Hz generators 200 216 volts Should the voltages be unbalanced stop the set remove the PMG sheet metal cover from the non drive end bracket and disconnect the multi pin plug in the PMG output leads Check leads P2 P3 and P4 for continuity Check the PMG stator resistances between output leads These should be balanced and within 10 of 2 3 ohms If resistances are unbalanced and or incorrect PMG stator must be replaced If the voltages are balanced but low and the PMG stator winding resistances are correct then the PMG rotor must be replaced 5 6 2 CHECKING GENERATOR WINDINGS AND ROTATING DIODES This procedure is carried out with leads X and XX disconnected at the AVR Connect a 12 volt DC power supply to leads X and XX Start the set and run at rated speed Measure the voltages at the main output terminals U V and W If voltages are balanced and within 10 of the generator nominal voltage refer to 5 6 2 1 Check voltages at AVR terminals 6 7 and 8 These should be balanced and between 170 250 volts If voltages at the main terminals are balanced but voltage at 6 7 and 8 are unbalanced check continuity of leads 6 7 and 8 If voltages are unbalanced refer to 5 6 2 2 5 6 2 1 BALANCED MAIN TERMINAL VOLTAGES Exciter windings main windings and main rotating diodes are
165. ngine to be covered under their warranty Engines used in the manufacture of Power Tech products are warranted solely by the engine manufacturer PRIOR APPROVAL IS REQUIRED FOR ANY WARRANTY SERVICE Failure to obtain authorization prior to the repair being performed will result in the claim being denied claims must be submitted within 30 days of the repair Along with the following a copy of the original repair order Power Tech authorization number Power Tech serial number and operation hours shown on the genset mounted hour meter THIS WARRANTY DOES NOT COVER THE FOLLOWING A Normal wear items including but not limited to turbo chargers fuel injector s starter alternator and electronic components as well as normal engine and or generator wear A1 Travel time and fuel charges to and from the repair facility or travel time and fuel charges for mobile service Except stationary units with a maximum of 2 hours travel time B Defects malfunctions or failure resulting from accidents abuse misuse improper servicing improper installation improper storage and lack of performance of required maintenance service C Products which have been subjected to alteration modification neglect or unauthorized repairs D Troubleshooting routine service tune ups replacement of filters belts coolant lubricants hoses clamps exhaust system components fuel system components gaskets and or seals E Electrical items damaged by welding or ju
166. nment Specifications Operating Temperature 40 C to 70 C Relative Humidity 0 70 C 0 95 non condensing Storage Temperature 55 C to 80 C Vibration 20 100 Hz 50 mm sec 100 2K Hz 3 30 1 with 4 Engine Governing 2 after 10 minutes some de rating may occur at voltage extremes 4 factory set semi sealed select w jumper 5 device connected must be galvanically isolated from ground gt 500 VAC 47 WIRING DIAGRAM ROTATING RECTIFIER ROTOR EXCITER ROTOR 8 STATOR EXCITER STATOR MAIN TYPICAL MAN STATOR W W OY Y GOAMECTORS ARE FITTED OM FRAME 4 AND ABOVE a 11 IO DO ON 1 HU LEAD when fitted 1 7 5 PARKING PLACE ONLY HAND TRIMMER when fitted AGR341 REMOWE LINK ACROSS 1 amp 2 THE SE EAE BASULATID CAHE RECOMMENDED CONECT SCREEN AYR TERWIMAL 2 ONLY 2 F1 5 TOR SS WHE MG g1 TERMIN ALS DEGOP L T whem fitted FOR G T SEE 48 OPERATION 227 O L I a ee Trim Power isolation link normally fitted Droop AGR341 Sensing links standard Ms jore positions DIP Selection Stability Selection No link 6P50Hz Indicator Py gt 550kw otabilit LED PsoH n 90 550kW 1 lt 90kW aJ HO
167. nnecting any dev from a system that Is pressurized DO NOT check for pressure leaks with your hands High pressure oil or fuel can cause personal injury e Escaping hydraulic fluid under pressure has sufficient force to penetrate skin causing serious personal injury e Fluid escaping from pinholes may be invisible Use a piece of Hydraulic Line SN Glass cardboard or wood to search for suspected leaks do not use hands and body Use safety goggles or other eye protection when checking for leaks e If injured by escaping fluid see a medical doctor immediately This fluid can produce gangrene or severe allergic reaction CAUTIONS AGAINST BURNS AND BATTERY EXPLOSION To avoid burns be alert for hot components during operation and just after the engine has been shut off Such as the muffler muffler cover radiator piping engine body coolants engine oil etc e DO NOT remove the radiator cap while the engine is running or immediately after stopping Wait approximately ten minutes for the radiator to cool before removing the cap sure the radiator drain valve petcock and hose clamps tighten Check radiator pressure cap and oil fill cap before operating the engine e The battery presents an explosive hazard When the battery 15 being activated hydrogen and oxygen gases are extremely explosive e Keep sparks and open flames away from the battery especially during charging DO NOT strike a match near the battery
168. not one that can be accomplished effectively on site bul rather one that should be conducted by an authorized service centerequipped with the appropriate apparatus and solvents necessary to property clean and dry the generator 8 Monitor the generator output current to verify that itis at WARNING or below nameplate value THE FOLLOWING TEST MUST BE CONDUCTED BY 10 Check generator speed frequency under load Adjust QUALIFIED ELECTRICAL PERSONNEL LETHAL as necessary Refer to prime mover or governor VOLTAGE MAY BE PRESENT AT BOTH THE manuals 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 SHUTDOWN PROCEDURE There are no specific instructions for shutting down the generator however several good practices should be observed to prolong equipment 4 Every 2 000 operating hours or in conjunction with 1 Iltis advisable to disconnect all loads open main circuit scheduled engine maintenance check the DC no load breaker or disconnect prior to shutdown This is especially important if loads can be damaged by low vollage or low frequency conditions during generator coast down 2 isolate all conditions that could apply voltage to the Z JMARATHON A Subsiciany of Balai Coralie 10 excitation voltage per item 7 in the startup procedur
169. o Load to Full Load Response Time Less Than 1 5 Change in Sensing Voltage EMI Suppression Internal Electromagnetic Interference Filter Over Excitation Shutdown Field Voltage shuts down after time delay if exciter field voltage exceeds 100V DC 5 Voltage Build Up Internal provisions for automatic voltage build up from generator residual voltage as low as 6V AC Power Dissipation 8 Watts Max Operating Temperature 40 F 40 C to 140 F 60 1 Voltage Control 2 Stability Control 3 Underfrequency Control Previous Version Current Version Previous versions of the AVC63 4 controller sold prior to mid 2003 are slightly different in appearance and control adjustment The controller version can be determined by the location of the heat sinks The above illustrations show the heat sink locations of both versions Adjustment of the Under frequency 5 BASLER MODEL AVC63 4 VOLTAGE REGULATOR Control is different on previous versions of the AVC63 4 When adjusting the Underfrequency Control on previous versions clockwise rotation decreased the corner frequency while counterclockwise increased the corner frequency NOTE Further reference to corner frequency adjustments of the AVC63 4 are for the Current Version and should be reversed for the Previous Version JUMPER CONTROLS Two jumpers connect to the controller terminals the Corner Frequency Jumper and the Voltage Adjust Rheostat Jumper Corner Frequency Jumper T
170. o the inner race only RECTIFIER ASSEMBLY REMOVAL 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 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 resaldered on the replacement A Subswfouy of Rega Betal Corporation m 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 RETURNED GOODS Contact Marathon Electric Manufacturing Corporation for authorization belore 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 servic
171. oint is called OVERHEATING While running make the following checks to see that all parts are working correctly If anything is unusual inspect it referring to the relevant description in MAINTENANCE and PERIODIC SERVICE section Coolant If the coolant temperature warning lamp lights up or if steam or coolant does not stop squirting from the radiator overflow pipe turn off the load and keep the engine idling COOLING DOWN for at least 5 minutes to let it cool down gradually Then stop the engine and take the following inspection and servicing 1 Check to see if the coolant runs short or if there is any coolant leak 2 Check to see if there is any obstacle around the cooling air inlet or outlet 3 Check to see if there is any dirt or dust between radiator fins and tube 4 Check to see if the fan belt is too loose and 5 Check to see if radiator water pipe is clogged i Cleaning radiator core outside If dust is between the fin and tube wash it away with running water IMPORTANT Do not clean radiator with firm tools such as spatulas or screwdrivers They may damage specified fin or tube It can cause coolant leaks or decrease cooling performance 22 O lt TT o O lt TT 20 PERIODIC SERVICE BIAnti freeze CAUTION To avoid personal injury When using anti freeze put on some protection such as rubber gloves Anti freeze contains poison e f sh
172. ome of the regular maintenance yourself However when in need of parts or major service be sure to see your KUBOTA dealer For service contact the KUBOTA Dealership from which you purchased your engine or your local KUBOTA dealer When in need of parts be prepared to give your dealer the engine serial number Locate the serial number now and record them in the space provided 9 Ew To be filled in by purchaser SERVICING OF THE ENGINE SERVICING OF THE ENGINE 1 Engine serial number 1 ENGLISH e O 2 TT 2 NAMES OF PARTS NAMES OF PARTS sc 158389 3 d EUG tx JA KE 9 gt L Ej RR 2 h b 4 0 5 N D m A hp 1 40 2 Q Y 7 I x D SN b 5 o Adu 3 8 1 0 s SIDO O T zd E S In 4 1 Intake manifold 2 Speed control lever 3 Engine stop lever Shut off solenoid 5 Fuel feed pump 6 Cooling fan 7 Engine hook 8 Oil filter cartridge 9 Fuel filter 10 Oil filler plug NSS 11 Exhaust manifold 12 Alternator Fan belt 15 Oil pressure switch 16 Flywheel 17 Oil drain plug 18 Oil pan PRE OPERATION CHECK 3 PRE OPERATION CHECK BREAK IN During the engine break in period observe the following by all means 1 Change engine oil and oil filter cartridge after the first 50 hours of
173. onnecting Charger or battery leads Similarly not not connect nr disconnect battery leads with any loads connected to prevent at the barrery CAUTION IF the battery leads B and B are to be disconnected from the Charger they must either be insulated or disconnected at the battery first to prevent short circuiting the battery IAL OPERATION When power is first applied the Charger will normally supply at least rated current as indicated on the Charger ammeter As the battery charge builds up the charge current will reduce finally to a level required to maintain the battery charge and supply any additional loads The charge current should reduce to lower values within 30 hours or less for properly sized Chargers The following voltages apply to 12 volt systems and are proportional to other systems When connected to a fully discharged battery the charge current will be higher than rated current for part of the charge cycle A very deep discharged battery can cause Charger shutdown if itv terminal voltage is less than 5 volts for up to several hours before high charge currents Haw Note that for deep discharged battery to eventually allow Charger to turn on there must be no other loads on the Charger or battery CHARGER MAINTENANCE There Field adjustments to be made these Chargers The only adjustable device is the float voltage adjustment on the regulator P C board which is factory set using precision equi
174. ontrol potentiometer fully clockwise 4 Connect a 12V 1 0A DC supply to the exciter field leads X amp XX F1 amp F2 with X F1 to the positive 5 Start the generating set and run at rated speed 6 Check that the generator output voltage is within 10 of rated voltage The bulb should light for approximately 8 seconds and then turn off Failure to turn off indicates a faulty protection circuit and the AVR should be replaced Turning the VOLTS control potentiometer fully counter clockwise should turn off the lamp with all AVR types Should the bulb fail to light the AVR has failed and should be replaced IMPORTANT After testing turn potentiometer fully counter clockwise 25 APPENDIX A ATHLON GENERATOR WARRANTY NOTE This warranty is extended only to Athlon industrial or commercial clients It does not extend to customers of Athlon clients WARRANTY PERIOD Athlon warrants Standby Duty Generators to be free from defects in materials and workmanship for a period of 24 months from date of commissioning 30 months from date of shipment or 1200 hours of run time whichever occurs first Athlon warrants Continuous Duty Generators to be free from defects in materials and workmanship for a period of 12 months from date of commissioning 18 months from date of shipment or 5000 hours of run time whichever occurs first CORRECTION OF DEFECTS Athlon will repair or at its option replace any defect that under
175. ontroller DIP ADJUSTMENT The DIP adjustment allows some control over the generator voltage dip upon the application of load This feature is mostly used when the generator is coupled to turbo charged engines with limited block load acceptance and operates only when the speed is below the UFRO knee point LED lit With the DIP potentiometer fully counterclockwise the generator voltage characteristics will follow the normal V Hz line as the speed falls below nominal Turning the DIP potentiometer more clockwise increases the V Hz slope providing a greater voltage dip and aiding engine recovery The DIP potentiometer can be set at any desired position to suit a particular engine type OVER EXCITATION EXC TRIP ADJUSTMENT The adjustment is set and sealed in the unit and should not be altered An over excitation condition is indicated on the common LED which also indicates under speed operation The generator must be stopped to reset an over excitation condition 51 ATHLON 21 AUTOMATIC VOLTAGE REGULATOR SPECIFICATIONS Sensing Input Voltage 190 264V AC Frequency 50 60 Hz nominal Phase Single or Three Phase Power Input PMG Voltage 140 220 VAC max 3 Phase 3 Wire Frequency 100 120 Hz nominal Current 3 Amps per Phase Output Voltage Max 120 VDC Current Continuous 3 7 ADC Intermittent 10 sec Resistance Minimum 15 Ohms Regulation 0 5 Thermal Drift 0 02 per degree C in AVR ambient Soft Start Ramp Time
176. op lever to the START position 3 Place the speed control lever at more than half OPERATION ran ch cet f NOS Ra k 1 Speed control lever A IDLING 2 Engine stop lever B OPERATION C START D STOP 4 Insert the key into the key switch and turn it ON KTC Switch A SWITCHED OFF A PREHEATING B OPERATION B SWITCHED OFF C PREHEATING C OPERATION D STARTING D STARTING 5 Turn the starter switch to the PREHEATING position to allow the glow lamp to redden NOTE with lamp timer in use The glow lamp goes out in about 5 seconds when the lamp timer is up Refer to this for pre heating Even with the glow lamp off the glow plug can be pre heated by turning the starter switch to the PRE HEATING position 6 Turn the key to the STARTING position and the engine should start Release the key immediately when the engine starts 7 Check to see that the oil pressure lamp and charge lamp are off If the lamps are still on immediately stop the engine and determine the cause See CHECKS DURING OPERATION in OPERATING THE ENGINE section NOTE if the oil pressure lamp should be still on immediately stop the engine and check if there is enough engine oil if the engine oil has dirt in it if the wiring is faulty OPERATING THE ENGINE 5 8 Warm up the engine at medium speed without load IMPORTANT
177. or End Engine Alternator Drive Belts and Pulleys Cooling Fan Engine Maintenance Service Schedule See Daily Every Every 100 Every 250 Every 500 Note 25 Hours Hours Hours Hours Maintenance Service Item Remarks Engine Oil Level Deterioration amp Leakage Engine Oil Or Once Change a Year Oil Filter Or Once Change a Year Coolant Level Coolant Leakage Coolant Change Fuel Level Fuel Leakage Fuel Filter Re placement Air Filter Re placement Damaged Worn Or Loose Belts Replace Fuel Hoses Check Radiator Or Once a Year As Necessary Or Once a Year Once a Year Or Every Two Years Or Every Two Years Once a Year Hoses amp Clamps Abnormal Engine Noise Abnormal Generator Noise Muffler Condition Exhaust Gas Condition Engine oil and filter must be changed after the first 50 hours of operation Then every 100 hours or once a year whichever comes first Air filter replacement interval will vary depending on operating conditions Adverse conditions may require frequent service NOTE Under normal operation items such as Belts Hoses and Filters are not covered by Power Technology Southeast Inc Limited Warranty T gt gt 7 9 ENGINE CHECKING ENGINE OIL LEVEL Y ADD mark X FULL mark 1 Maintain the engine oil level between ADD mark and FULL mark on oil level gauge Do not fill cran
178. ore often in dusty conditions than in normal conditions 2 After 6 times of cleaning 9 Consult your local KUBOTA Dealer for this service 4 Replace only if necessary When the battery is used for less than 100 hours in a year check its electrolyte yearly for refillable battery s only The items listed above marked are registered as emission related critical parts by KUBOTA in the U S EPA nonroad emission regulation As the engine owner you are responsible for the performance of the required maintenance on the engine according to the above instruction Please see the Warranty Statement in detail NOTE Changing interval of engine oil 250 Hrs or 1 year whichever comes first 500 Hrs or 1 year whichever comes first API service classification above CF 4 grade Ambient temperature below 35 C 95 F NOTE Lubricating oil With strict emission control regulations now in effect the CF 4 and CG 4 engine oils have been developed for use with low sulfur fuels for On Highway vehicle engines When a Non Road engine runs on high sulfur fuel it is advisable to use a CF or better classification engine oil with a high Total Base Number a minimum TBN of 10 is recommended e Lubricating oil recommended when a low sulfur or high sulfur fuel is employed O Recommendable X Not recommendable Fuel Remarks Low sulfur High sulfur TBN Total Base Number Fuel Diesel Fuel Specification Type and Sulf
179. ors air handlers roof eves and vents Avoid exhausting into confined areas with little or no air circulation Avoid exhausting near neighboring structures as well The exhaust system should be routinely inspected and maintained Local and or State Building Codes may mandate exhaust routing ELECTRICAL CONNECTION In most installations the generator 1s connected to a buildings existing electrical system as a back up electrical supply This means the generator will be wired Into the buildings electrical panel typically through an automatic transfer switch Wiring and connections must be made by a licensed electrician In accordance with Local and or State Building Codes FUEL STORAGE Depending upon the specific application the type of fuel storage tank and capacity must be considered Typically a fuel storage tank which meets UL 142 Specifications 1s required Location and connections may be mandated by Local and or State Building Codes Consult your fuel supplier as to fuel maintenance and extended storage requirements Adding a fuel stabilizer may be necessary to extend the usable fuel life GENERATOR ASSEMBLY INFORMATION EXCITER TYPE GENERATOR The exciter pole pieces contain residual magnetism which sets up lines of force across the air gap to the exciter armature When the exciter begins to rotate a voltage is induced and current flow 15 initiated I the exciter armature AC windings This voltage 15 fed to the rotating rectifier assembly
180. ould drink anti freeze throw up at once and take medical attention e When anti freeze comes in contact with the skin or clothing wash it off immediately Do not mix different types of anti freeze The mixture can produce chemical reaction causing harmful substances Anti freeze is extremely flammable and explosive under certain conditions Keep fire and children away from anti freeze When draining fluids from the engine place some container underneath the engine body Do not pour waste onto the grounds down a drain or into any water source Also observe the relevant environmental protection regulations when disposing of anti freeze Always use a 50 50 mix of long life coolant and clean soft water in KUBOTA engines Contact KUBOTA concerning coolant for extreme conditions 1 Long life coolant hereafter LLC comes in several types Use ethylene glycol EG type for this engine 2 Before employing LLC mixed cooling water flush the radiator with fresh water Repeat this procedure 2 or 3 times to clean up the radiator and engine block from inside 3 Mixing the LLC Premix 5096 LLC with 5096 clean soft water When mixing stir it up well and then fill into the radiator 4 The procedure for the mixing of water and anti freeze differs according to the make of the anti freeze Refer to SAE J1034 standard more specifically also to SAE J814c Vol Freezing Point Boiling Point Anti freeze
181. ould high voltage tests be conducted until the alternator windings have been dried and cleaned as required Insulation Test Procedure Disconnect all electronic components including Avers electronic protection equipment etc If present ground all resistance temperature detection devices Short out all diodes on the rotating rectifier Examine the system under test and look for any connected components that might cause false readings or that could be damaged by the test voltage Conduct the insulation test in accordance with the operating instructions for the test instrument Test the insulation resistance from each phase to phase and from earth to each phase New or unused generators should have insulation values between 10 MO to 25 MO or greater Used generators should be above 1 If the winding resistance is low it must be dried see below or repaired 4 2 2 DRYING METHODS Dry Run In some cases a generator with a low IR value can simply be run without excitation The natural flow of ambient air through the generator will tend to dry the windings This may raise the IR above 1 0 MO and allow the unit to be put into service To do so run the generator for 10 minutes with AVR terminals K1 and K2 open and inspect the windings to see if they look dry Re measure the insulation resistances If all the IR values are above 1 0 MO the windings are good If not use one of the other drying methods Forced Air Drying Remove all covers fro
182. ously and have a 10 overload capability for one hour in 12 hours Standby will operate at the stated full rating for one hour in 12 hours No overload capacity is specified for this rating Injection timing Before T D C 0 09 rad 5 61 o O lt TT 30 SPECIFICATIONS Number of cylinders mm in 100 x 120 3 94 x 4 72 Total displacement L cu in Bore and stroke Type Vertical water cooled 4 cycle diesel 3 69 230 5 rpm rpm Combustion 64 4 1800 3 SAE NET Continuous kW min H P SAEJ1349 SAE Standby kW min H P SAEJ1349 HP min Maximum bare speed m rpm rpm rpm gt H P SAEJ1349 HP 52 8 1800 70 8 1800 1800 V3800 DI T E3BG Maximumbareiding speed Counter clockwise viewed from flywheel side Injection pressure MPa First opening pressure 18 63 190 2275 kgf cm psi Second opening pressure 23 54 240 3128 injection timing Before T D C Lubricant API classification length x width x height 30 26 x 21 08 x 31 38 Starting motor 12V 3 0kW Charging generator 12V 540W Recommended battery capacity 12V 88AH NOTE Specifications are subject to change without notice NOTE FOR E3BG T E3BG type Flywheel type is SAE
183. p fuse SERVICE Frequency of water draining or element replacement is determined by the contamination levels present in diesel fuel If the fuel tank is located higher than the Racor close the fuel tank outlet valve prior to servicing DRAINING THE COLLECTION BOWL Water is heavier than diese fuel and will settle to the bottom of the bowl and appear different in color The bowl must be drained before contaminants reach the bottom of the element or when the Water Detector if equipped indicates it s time to drain water Inspect or drain the collection bowl of water daily 1 Open the drain and operate the pump to drain off contaminants Close the drain MARINE MODELS Hemove the drain plug to drain off contaminants Replace drain plug to bowl snugly ELEMENT REPLACEMENT Element replacement frequency is determined by the contamination level in diesel fuels Fuel flow to the engine becomes restricted as the element slowly plugs with contaminants resulting in noticeable power loss and or hard starting Heplace the element every 10 000 miles every 500 hours of operation every other ail change annually or if a power loss is noticed which ever comes first If vacuum gauge has been installed on the outlet side of the filter change the element between 6 to 10 inches of mercury restriction The actual measurement varies in different fuel systems Note Always carry an extra element as one tankful of excessively contaminate
184. per across i and 4 for 10 120 VAC input leave i amo 4 ABK 450 unconnected far ecO cs0VaAc mput INDICATOR LED Place jumper across and 30 for 30 Hz OR across C and 50 for Hz STABILITY 2 4 4 2 AGR440 INDICATOR LED pnper cross ond 90 for 90 Hz IR across ond 50 fur 50 Hz Power iolation lin amp inarnally fitted FREQUENCY SELECTION UFRO 20 l STABILITY OSA the jurper tn attoch n renote voltage trinner across these twn terrinulz tage Dutput Pill jas tremit Refer ta Datasheet 2 4 4 3 AGR341 Remove the jumper ta garni attach a remate voltage Fitted P 1 trinner across these two terminals Frequency Selection Sensing links standard TS positions For Link E xL TRIP Valtage Output TN justnent 5 Pole 30 Hz Na Link Frequency S election Refer ta 0 Ho Link Beteshert 6 Pole 60 Hz 122 D DIF 1 TM Stobdity Selection UFRO C B re o Cp 3 1 STABILITY INDICATOR LET a 30 320K W 2 4 4 4 AGR321 P4 AMM X 6 7 H l Z FE pig ie r L LIMIT Voltage Output Ad justnent Refer Datasheet 321 3 1 Renove the jumper Frequency attach voltige Salecton across These terrumals x F
185. periods will depend upon the severity of the site conditions Regular inspection of the elements will determine when cleaning is necessary 4 1 1 CLEANING PROCEDURE Remove the filter elements from their housings and wash the elements with a suitable degreaser material Dry the elements completely before charging 4 1 2 CHARGING AIR FILTERS The following must be done before using the unit for the first time and after every filter cleaning Soak the filter element in SAE 20W50 oil or Filterkote Type K Allow elements to completely drain before reassembling the filters and putting the unit into service 4 2 WINDING CONDITION AN Service and troubleshooting procedures performed improperly can result in severe personal injury or death These procedures should only be performed by qualified personnel Before carrying out any service or troubleshooting procedure be sure engine starting circuits are disabled and any anti condensation heater supply is isolated Typical Insulation Resistance Values The following information is provided to assist in determining the condition of the windings In operation generators may be exposed to water Units that have been in storage for may be exposed to temperature and humidity variations which can cause significant condensation Wet windings must be completely dried out before operating the generator Otherwise serious damage to the generator can occur A new or unused generator will have an insulation r
186. plies such as adhesives cleaning agents rags paint or other miscellaneous supplies R Use of other than factory supplied or approved repair parts or procedures Replacement of a failed Power Tech component with a non Power Tech component voids the Power Tech warranty on that component and any and all failures related to that component S Fuel injection pumps repaired by anyone other than the factory authorized dealer or distributor of that engine T Expenses incurred investigating performance complaints unless defective Power Tech materials or workmanship are discovered U Generator sets used in rental applications V Cleaning service or repair of generator sets the have not been kept free of dirt debris or other items that prevent the unit from being able to operate properly W Any generator set not application approved X Loss of excitation due to prolonged storage Y Any damage attributed to low battery monitoring or automatic generator starting systems Z Optional accessories are warranted solely by the manufacturer of that item including but not limited to the following item Block heaters oil pan heaters electric cooling fans air bag isolators compartment heaters fuel tanks trailers battery chargers battery monitors To obtain warranty service For your nearest Power Tech authorized service center on the World Wide Web at http www powertech gen com parts service php Call 1 352 365 2777 or write to Power Tech Warranty Department
187. pment LOW VOLTAGE SHUTDOWN These Chargers are normally supplied with low voltage shutdown which causes the Chargers to reduce 15 output current at any time the battery output terminal voltage drops below 5 volts The charger will shut off completely if the output terminal voltage drops below 2 5 volts This provides reverse polarity and short circuit protection GENERAL Refer to wiring diagram for schematic representation Note that while the transformer winding configuration changes with Charger voltage and current ratings the typical winding configuration 15 representative of the Charger operation A C PATH The A C power is applied to the power transformer primary through circuit breaker CHI or A C Fuse F2 Note that the primary taps shown are factory wiring options to accommodate different battery types The GND terminal ts tied directly to the chassis which is in electrical contact with the cabinet The primary amd secondary circuits are electrically isolated from each other and from chassis or cabinet ground The transformer then isolates the A C power and transforms the voltage to the level required by the battery The regulator circuits has its own regulated power supply to power the circuitry and the reference element providing the double regulated reference voltage far the highly regulated OPER D C PATH The Main power rectifiers D20 amp D21 and SCR are all mounted on the heat sink Rectification is full wave center
188. proximately 1 8 inch the bracket will 13 clear the locating register on the frame Lower the shaft extension until the rotor is resting on the main stator 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 note Before the bearing bracket is seated against the frame a threaded rod may be used tohelp align the inner bearing cap with the bearing bracket BEARING REPLACEMENT Using a bearing puller remove the existing bearing It is strongly recommended that the bearing be replaced any lime the it is removed from the shafl 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 bearing ta a maximum of 100 C 212 F in an oven Apply a thin coat af clean lubricating 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 the shaft prior to being seated against the shoulder a piece of tubing slightly larger than the press fit area can be used todrive the bearing to its final position Using light taps with a soft mallet apply pressure t
189. r Dispose of spent filter cartridges and batteries properly DO NOT pollute the soil or any water source Never pour fluids down a drain CONDUCTING SAFETY CHECKS AND MAINTENANCE e When performing safety checks or engine service be sure the engine 15 level and well supported Use approved stands designed for this type of service DO NOT service an engine that 15 only supported by a lift jack or hoist e Detach the battery from the engine before conducting service Put a NOT OPERATE tag in the key switch to avoid accidental starting e To avoid sparks from an accidental short circuit always disconnect the 12V DC power at the battery e Be sure to stop the engine and remove the key when conducting daily and periodic maintenance servicing and cleaning e Check or conduct maintenance after the engine radiator muffler or muffler cover has cooled off completely e Always use the appropriate tools and jig fixture when performing any service work Be sure to understand and follow the instructions included with these tools e Use ONLY correct engine barring techniques for manually rotating the engine DO NOT attempt to rotate the engine by pulling or prying on the cooling fan and V belt Serious personal injury or damage to the cooling fan may occur e Replace fuel hoses and hose clamps every 2 years or earlier whether they are damaged or not They are made of rubber and are aged gradually e When service is performed with two o
190. r comes first or 36 months from the date of manufacture Parts and labor including diagnostic labor removal and reinstallation are covered for the first 12 months from date in service or 1000 hours whichever comes first Parts and labor are covered only on the following generator and engine parts for 2 years or 3000 hours whichever comes first Generator Parts Main Rotor and Main Stator Engine Parts Cylinder Block cylinder head crankshaft camshaft cylinder head gears connecting rods flywheel and flywheel housing intake and exhaust manifold only if flexible connection is used 3 Stand by Units are covered for a period of 1 year from date of installation or 1000 hours or 24 months from the date of manufacture whichever comes first 4 Replacement Parts are warranted 30 days Excluding the following voltage regulators fuses controllers capacitors brushes and switches WHAT POWER TECHNOLOGY WILL DO Power Tech will at our option repair or replace any part covered by this warranty which becomes defective malfunctions or otherwise fails to conform to this warranty under normal use and service during the term of this warranty WHAT YOU MUST DO TO OBTAIN WARRANTY SERVICE In order to obtain warranty repairs you must deliver the product together with proof of purchase to an authorized Power Tech service facility In the case of repairs pertaining to the engine only you must use an authorized dealer or distributor of that make of e
191. r more people present take care to perform all work safely Be aware of their location especially when starting the engine e Keep first aid kit and fire extinguisher handy at all times OPERATING THE ENGINE PT ECU 64 CONTROLLED ENGINE STARTING CONTROLS 6 7 9 Generator Main Switch must be In the ON Toggle the Start Stop Switch to the Start position Glow Plugs will preheat for 8 seconds LED flashes slowly Preheating will cease during engine cranking cycle LED continues flashing Engine begins an 8 seconds crank cycle After 4 seconds of cranking the PT ECU 64 will check for an AC signal from the generator If an AC signal is verified the engine will start and the LED will remain ON during the normal run operation If the AC signal 1s not verified the PT ECU 64 will terminate the cranking cycle and LED will flash a fault code Starter disengages immediately after engine run 15 verified PT ECU 64 deactivates the Low Oil Pressure and High Water Temperature Switches for 6 seconds this will assure oil pressure build up time If oil pressure does not build up the engine will immediately shut down and go into a fault mode Likewise for a high temperature situation If engine will not start on the first attempt the PT ECU 64 will initiate the start cycle 2 more times before going into a fault mode Glow Plugs will preheat for 8 seconds per attempt Engine will crank for 8 seconds per attempt To shut down
192. rd Athlon offers frame sizes of 16 18 22 27 4 5 and 6 Number of Poles refers to the number of poles in the stator Athlon b generators typically use 4 poles for an input of 1500 RPM for 50 Hz output or an input of 1800 RPM for 60 Hz output Athlon also offers two poles to allow the use of small engines running at higher speeds 3000 RPM yields 50 Hz while 3600 RPM yields 60 Hz Core Designation refers to the core length size which correlates to the KVA output for a given frame size SERIAL NUMBER LOCATION Each generator has a serial number stamped on the Nameplate supplied with each unit It is important to record and preserve this serial number for use when ordering parts or requesting service 27 CONNECTION DIAGRAMS Terminal Ends W6 Double Delta 1PH 3W DOUBLE DELTA 28 Parallel Low Zig Zag 3W T 240 220 Series High Delta 4W L SERIES HIGH DELTA L L0 Y ho L LO Y Y Parallel Low Wye Star 4W L series High Wye Star 3PH 4W Li lt L L0 30 PARALLEL LOW WYE STAR L LO SERIES HIGH WYE STAR APPENDIX PARALLEL OPERATION Paralleling Basics The following points are basic criteria which must be met before two units can be paralleled Additional paralleling circuitry e Voltage regulator parallelin
193. re fuel oil or rags in the generator compartment 15 MARINE APPLICATION RV generator sets do not comply with United States Coast Guard USCG requirements They must not be used for marine applications Use only generator sets specified for marine use In a marine application USCG regulation 33CFR183 requires a generator set to be ignition protected for use in a gasoline fueled environment 16 UNIT STARTS WITHOUT NOTICE To prevent accidental starting on the units with remote start stop switch always disconnect the battery by removing the negative terminal first and then the positive Always disconnect the unit this manner before working on the generator or any equipment connected to it 17 LOOSE COMPONENTS Periodically check for and tighten any fasteners that may have become loose from vibration or road shock Serious damage may possibly occur 1f components become dislodged or misaligned 2 INSTALLATION REQUIREMENTS amp RECCOMENDATIONS Installation requirements may vary with each application depending on generator specification and optional equipment Listed below are general recommendations for installing a Power Technology Stand By Generator Only qualified and licensed personnel should be employed to perform the installation Follow all Safety Procedures outlined In this manual as well as those in the optional equipment manuals Depending on location Local and or State Building Codes may apply to the installation
194. re that they are clean and free of debris Clogged intake alr screens will reduce cooling air flow and result in higher operating temperatures This will reduce generator life and may result in generator damage MUST BE EXERCISED NOT TO COME INTO 2 Al MagnaPLUS generators are equipped with double PERSONAL CONTACT WITH LIVE TERMINALS shielded ball bearings lubricated for the life of the LINKS OR STUDS SERIOUS INJURY OR DEATH bearing Every 1 000 hours check the bearing s for COULD RESULT smooth quiet operation For continuous duty generators recommended practice is to replace the bearing during major overhauls of the engine 7 Start the set and adjust the terminal voltage to the desired value by means of the regulator voltage 3 Periodically inspect the unit for any buildup of 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 t line and line to neutral voltages for balance is recommended practice to record the na load excitation DG voltage to the exciter stator generator terminal voltage and driver speed as a benchmark for future troubleshooting B Close the main circuit breaker to he load contamination dirt oil etc on the winding W the wound components have become coated with heavy concentrations of ail and grime the unit should be disassembled and thoroughly cleaned This operation is
195. rectified and fed to the alternator field which sets up lines of force across the air gap to the alternator stator windings and to the output circuit A static voltage regulator 1s connected to the generator output The regulator will rectify part of the output voltage to provide a DC voltage to the exciter field coils This will increase the density of the lines of force in the exciter increasing the voltage induced into the exciter armature windings and therefore to the rotating rectifiers The rotating rectifier output will be increased which will increase the alternator field strength and generator output will build up its rated voltage Adjustment of the generator output to the rated voltage level 1s accomplished by controlling the current fed to the exciter field coils Regulation is automatic with the static type voltage regulator An additional voltage adjustment range 1s provided if desired by turning the Voltage Adjust Rheostat ELECTRONIC VOLTAGE REGULATION Electronic Voltage Regulator EVR also referred to as an Automatic Voltage Regulator AVR is a very reliable device which uses solid state electronics to maintain voltage accuracy at 2 of the regulated voltage The Voltage Regulator 1s designed to automatically regulate and maintain the generated AC voltage through out the load range that 1s from no load to full load VOLTAGE CONNECTION The generator may be connected at the terminal board to deliver 120 240 volts to a 3 wire g
196. released 5 Stop Position used to stop the engine The switch will return to the original position when released 6 Preheat Prime Preheats combustion chamber before starting Primes fuel system STARTING THE ENGINE 1 Before starting the engine be sure to disconnect the power supply from power line The engine may be hard to start if a load 1s connected 2 Press the Start Stop switch to the Stop position for six 6 seconds This will preheat the combustion chambers and aid in starting IMPORTANT Press the Start Stop switch to the Start position This will engage the starter motor and start the engine Release the Start Stop switch when the engine starts CHECK ENGINE AFTER STARTING l 3 4 Allow the engine to warm up 3 to 5 minutes before applying a load In colder climates allow a few extra minutes longer Check all areas of engine and generator during warm up Visual inspection Listen for abnormal noises Check for abnormal exhaust gas SIOPPING THE ENGINE First disconnect the power load Next press the Start Stop switch to the Stop position the engine will shut down NOTE Failure to follow this procedure may harm the generator and cause a premature malfunction If the engine fails to start on the first attempt wait approximately 30 seconds than follow the starting procedure again Do not run the starter for more than 30 seconds per starting attempt Allow the
197. requency Selection 4 30 Hz P 3 Stability 4 Pole 60 Hz 1 Selection 3 6 Pole 50 Hz 6 Pole 60 Hz 5 3 OPERATION 3 1 TESTING OF GENERATOR SET While testing covers may need to be removed to make adjustments which will expose live circuits and components Only qualified personnel should perform testing and adjustments 3 1 1 TEST EQUIPMENT Use a voltmeter frequency meter and a current and or power meter to perform basic checkout of the generating set Measurements should be made either line to line or line to neutral Using a power factor meter is recommended if applying a reactive load i e inductive or capacitive Be sure the AVR is exposed to make adjustments 3 1 2 STARTING UP FOR THE FIRST TIME Once generator set assembly is complete be sure all of the engine manufacturer s pre start procedures or checkouts have been performed Verify that the generator will not be run beyond 125 of its rated speed by checking the adjustment of the engine governor Damage to the generator may result if the speed governor is set too high Take special care during the initial setting of the speed governor If in doubt set low and slowly increase speed to proper level To adjust the voltage output 1 Connect a voltmeter and frequency meter or a DMM capable of both functions to the output of the generator either line to line or line to neutral Be sure the expected voltage which
198. rform properly consult your local Kubota Engine Distributor first 008 2 WEAR SAFE CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT PPE DO NOT wear loose torn or bulky clothing around the machine that may catch on working controls and e Use additional safety items PPE e g hard hat safety protection safety goggles gloves etc as appropriate or required e DO NOT operate the machine or any equipment attached to it while under the influence of alcohol medication or other drugs or while fatigued projections or into fans pulleys and other moving parts causing personal injury DO NOT wear radio or music headphones while 1AEAAAAAP0130 operating the engine 2 SAFE OPERATION 3 CHECK BEFORE STARTING amp OPERATING THE ENGINE Be sure to inspect the engine before operation Do not operate the engine if there is something wrong with it Repair it immediately Ensure all guards and shields are in place before operating the engine Replace any that are damaged or missing Check to see that you and others are a safe distance from the engine before starting 2 Always keep the engine at least 3 feet 1 meter away f from buildings and other facilities DO NOT allow children or livestock to approach the machine while the engine is running DO NOT start the engine by shorting across starter terminals The machine may start in gear and move Do not bypass or defeat any safety
199. rlier type For optimum setting the LED should light as the frequency falls just below nominal i e 47 Hz on a 50 Hz system or 57 Hz on a 60 Hz system DROOP ADJUSTMENT Generators intended for parallel operation are fitted with a quadrature droop C T which provides a power factor dependent signal for the AVR The C T is connected to S1 S2 on the AVR The DROOP adjustment is normally preset in the works to give 5 voltage droop at full load zero power factor Clockwise increases the amount of C T signal injected into the AVR and increases the droop with lagging power 50 factor cos With the control fully counterclockwise there is no droop TRIM ADJUSTMENT An analog input A1 A2 is provided to connect to a Power Factor Controller or other devices It is designed to accept dc signals up to 5 volts CAUTION Any devices connected to this input must be fully floating and galvanically isolated from ground with an insulation capability of 500 VAC Failure to do this could result in equipment damage The dc signal applied to this input adds to the AVR sensing circuit A1 is connected to the AVR O volts Positive on A2 increases excitation Negative on A2 decreases excitation The TRIM control allows the operator to adjust the sensitivity of the input With TRIM fully counter clockwise the externally applied signal has no effect Clockwise it has maximum effect Normal setting is fully clockwise when used with a Power Factor C
200. rn the engine stop engine idling COOLING DOWN for at least 5 lever to the START position to be ready minutes to let it cool down gradually Then stop the TP engine and take the following inspection and servicing for the next starting in case of manually 1 Check to see if the coolant runs short or if there is any stopping coolant leak 2 Check to see if there is any obstacle around the cooling air inlet or outlet I 3 Check to see if there is any dirt or dust between AM 2i radiator fins and tube 4 Check to see if the fan belt is too loose and 5 Check to see if radiator water pipe is clogged 4 NO pressure lamp The lamp lights up to warn the operator that the engine oil pressure has dropped below the prescribed level If this should happen during operation or should not go off even after the engine is accelerated more than 1000rpm immediately stop the engine and check the following 1 Engine oil level See ENGINE OIL in PERIODIC SERVICE section 1 Speed control lever A IDLING 2 Engine stop lever B OPERATION lamp iB PL The lamp lights up to warn the operator that the battery charge is low If this should happen during operation immediately stop the engine and check the following 1 Cable broken 2 Poor connection at alternator terminal 3 Fan belt too loose or damaged Fuel CAUTION To avoid personal injury Fluid escaping fro
201. rneath the engine body DO NOT pour waste onto the ground down a drain amp into any water source Dispose of waste fluids according to environmental regulations pu E 1BJABAAAPO180 11 CONDUCTING SAFETY CHECKS amp MAINTENANCE When inspecting the engine or servicing place the engine on a large flat surface DO NOT work on anything that is supported ONLY by lift jacks or a hoist Always use blocks or the correct stands to support the engine before servicing Disconnect the battery from the engine before conducting service Put a DO NOT OPERATE tag on the key switch to avoid accidental starting To avoid sparks from an accidental short circuit always uu disconnect the battery s ground cable first and reconnect it last Be sure to stop the engine and remove the key when conducting daily and periodic maintenance service and cleaning Check or conduct maintenance after the engine coolant muffler or muffler cover have cooled off completely Always use the appropriate tools and fixtures Verify that they are in good condition before performing any service work Make sure you understand how to use them 4pjABAAAPO200 before service Use ONLY correct engine barring techniques for manually rotating the engine DO NOT attempt to rotate the engine by pulling or prying on the cooling fan and V belt This practice can cause serious personal injury or premature damage to the cooling
202. rom the machine and keep it indoors in a safe area to be reinstalled just before the next operation Ambient temperature V3800 DI T E3 V3800 DI T E3BG Above 10 50 10 50 F to 5 C 23 F Below 5 C 23 F Limit of continuous use Approx 5 seconds Approx 10 seconds 20 seconds 22 O lt TT 6 OPERATING THE ENGINE STOPPING THE ENGINE CHECKS DURING OPERATION o While running make the following checks to see that all o 1 Return the speed control lever to low peris are wong idle and run the engine under idling lllRadiator Cooling water Coolant conditions IMPORTANT A WARNING e f equipped with a turbo charger allow the engine To avoid personal injury to idle for 5 minutes before shutting it off after a full Do not remove radiator cap until load operation Failure to do so may lead to turbo charger trouble coolant temperature is well below its boiling point Then loosen cap slightly to the stop position to relieve any pressure before removing cap completely 2 The engine should stop with the starter switch placed at the OFF position In case of non stopping set the engine stop lever to the STOP position manually If the coolant temperature warning lamp lights up or if steam or coolant does not stop squirting from the 3 After stopping the engine remove the radiator overflow pipe turn off the load and keep the key Be sure to retu
203. rounded neutral system or 120 volts only to a 2 wire distribution system If any equipment requires 240 volts then the 120 240 volt connection must be used If all equipment requires 120 volts then the 120 volt connection 15 preferred even if two lines leave the same switch box The two lines at the inputs to the switch box are both connected to the un grounded 120 volt lines from the generator The 120 volt connection enables the Electronic Voltage Regulator EVR to hold the voltage very close to the 115 or 120 volts as initially adjusted regardless of the power distribution amount the different distribution lines The 120 volt connection 1s recommended if the entire electrical load requires only 115 or 120 volts Although the 120 240 volt connection may also be used when all loads requires only 110 volts it should be pointed out that this connection the 240 volts 1s regulated and the lightly loaded phase or line will deliver a high line to neutral voltage and the heavily loaded phase will deliver a low line to neutral voltage The heavily loaded line may have such a low voltage that air conditioning will have more difficulty in starting and long starting lines may overload generator and trip circuit breakers EXCITER FIELD COIL VOLTAGE SOURCE Field coil DC voltage 15 obtained by rectifying the voltage from the phase to neutral line of the generator output or either appropriate terminal to provide the needed voltage reference The rectifier
204. ry Fix the engine securely not to fall during operation Do not stand near or under the engine while carrying it The engine is heavy In handling it be very alert not to get your hands and body caught in 1 Use carrier such as crane when carrying the engine or hurt your waist and yourself Support the engine securely with rope not to fall while carrying it 2 When lifting the engine put the hook securely to metal fittings attached to the engine Use strong hook and fittings enough to hang the engine STORAGE CAUTION To avoid personal injury Do not clean the machine with engine running To avoid the danger of exhaust fume poisoning do not operate the engine in a closed building without proper ventilation When storing the engine just after running let the engine cool off Before storing the engine for more than a few months remove any dirt on the machine and 1 8 9 Drain the coolant in the radiator Open the cock at the bottom of the radiator and remove the pressure cap to drain water completely Leave the cock open Hang a note written No water on the pressure cap Since water may freeze when the temperature drops below 0 C 32 F it is very important that no water is left in the machine Remove dirty engine oil fill with new oil and run the engine for about 5 minutes to let the oil penetrate to all the parts Check all the bolts and nuts and tighten if necessary
205. s 3 diodes the negative plate carrying negative biased diodes and the positive 22 plate carrying positive biased diodes Insure that correct polarity diodes are fitted to each respective plate The recommended torque for tightening diodes is 4 06 4 74 Nm 36 42 in Ib Surge Suppressor The surge suppressor is a metal oxide varistor variable resistor used to protect circuits against excessive voltage by acting as a spark gap connected across the two rectifier plates to prevent transient reverse voltages in the field winding from damaging the diodes The varistor should read virtual infinity in both directions with an ohmmeter A defective unit will show visible signs of failure and should be replaced Main Excitation Windings If the output is still low when separately excited the main rotor exciter stator and exciter rotor winding resistances should be checked see Resistance Charts since the fault is in one of these windings The exciter stator resistance is measured across leads X and XX The exciter rotor is connected to six studs which also carry the diode lead terminals The main rotor winding is connected across the two rectifier plates The respective leads must be disconnected before taking the readings Resistance values should be within 10 of the values given in the tables below 23 Winding Resistances rom Row eu sitor Size Rotor Stator Rotor PM Stator _ 1640 052 19 026
206. s procedure is appropriate for use to with either AGR460 AGR440 regulators With the generator set stationary remove the regulator access cover and leads X and XX from the AVR Start the unit and measure voltage across the regulator terminals 7 8 on AGR460 AVR or P2 P3 on AGR440 AVR Stop the set and replace leads X and XX on the AVR terminals If the measured voltage was above 5 volts the generator should operate normally If the measured voltage was below 5 volts follow the process described below Using a 12 volt DC battery as a power supply clip leads from battery negative to AVR terminal XX and from battery positive through a diode to AVR terminal X See figure below AN Important A diode must be used as shown below to insure the AVR is not damaged 12 VOLT DC BATTERY NOTE If the generator set battery is used for field flashing the generator main stator neutral must disconnected from ground Restart the unit and note output voltage from main stator which should be approximately nominal voltage or voltage at AVR terminals 7 and 8 on AGR460 P2 P3 on AGR440 which should be between 170 and 250 volts Stop the unit unclip the battery supply from terminals X and XX reinstall the regulator cover and restart the set The generator should now operate normally If no voltage rise is noted then a fault exists in either the generator or the AVR Follow Section 5 6 to check generator windings and rotating diodes 1
207. s you would for any home appliance Keep away from electrical circuits and wiring while the generator set 1s running Have electrical service performed only by qualified electricians Be sure any unauthorized person especially children are denied access to the generator set Keep the compartment door securely latched or locked at all times Be sure the generator Is properly grounded Never touch electrical leads or appliances with wet hands or when standing on wet ground 1 7 EXPLOSION Never connect the negative battery cable to the positive connection terminal of the starter solenoid or test the battery by shorting terminals together This could ignite fuel vapors or cause the battery to explode To disconnect the battery remove the negative battery cable first and reconnect it last Do not modify the fuel tank or propulsion engine fuel system Your vehicle must be equipped with a fuel pick up arrangement as described in the Fuel System section of this manual Fuel tank and installation must conform to applicable regulations 8 HOT COOLANT Allow engine to cool and release pressure from the cooling system before opening the radiator pressure cap To release the pressure cover the radiator cap with a thick cloth then turn it slowly counterclockwise to the first stop After the pressure 1s released and the engine has cooled remove the cap 9 LETHAL EXHAUST GAS When installing an exhaust system position the tail pipe end so that the d
208. se clamps per standards SAE J20 amp SAE J1508 CAUTION NOI USE HOSE SMALLER THAN THE RECOMMENDED SIZE HOSE AS COOLANT FLOW WILL BE RESTRICTED AND SHORTENED HEATER LIFE WILL RESULT ENSURE HOSE CONNECTIONS ARE ROUTED AS PER INSTRUCTIONS AS COOLANT FLOW MAY BY PASS THE ENGINE RADIATOR CALSING THE ENGINE OVERHEAT CONSULT THE VENDOR FOR DIFFICULT APPLICATIONS Heater Connections Determine the lengths of hose required for the installation Cut hose cleanly and squarely to length Slide clamp onto hose Push hose on fitting until hose bottoms against casting Position hose clamp 1 87 from the end and secure with a screwdriver or wrench Maximum recommended torque is 30 in lbs Do not over tighten WARNING BURN HAZARD ENSURE HOSE CLAMPS ARE PROPERLY TIGHTENED OVER TIGHTENED HOSE CLAMPS MAY DAMAGE HOSES SO THAT THEY LEAK HOT COOLANT UNDER TIGHTENED HOSE CLAMPS MAY CAUSE THE HOSES TO COME LOOSE DUE TO VIBRATION DURING ENGINE OPERATION AND SPRAY HOT COOLANT inlet bottom connection Install the hose nipple in the drain plug hole If there is no drain plug connect the heater inlet hose to the lowest accessible point in the engine block on the suction side of the cooling system pump Use any opening in the lower part of the block or install proper size hose fitting in the lower radiator hose Outlet top connection Near the engine block cut heater hose from passenger heater to engine block inlet slip on hose clamps
209. se this unit A WARNING Indicates a potentially hazardous situation which may possibly result in serious injury or possible death A CAUTION Indicates a potentially hazardous situation which may possibly result in minor injury IMPORTANT Indicates that equipment or property damage may result if instructions are not followed NOTE Indicates helpful information SAFE OPERATION Cautious operation 1s your best insurance against an accident Read and understand this section carefully before operating the engine All operators no matter how knowledgeable they may be should read this and other related manuals before operating the engine or any equipment attached to it It is the owner s responsibility to instruct all operators in safe operation Be sure to observe the following for safe operation OBSERVE SAFETY INSTRUCTIONS e Read understand and follow this OPERATORS MANUAL and LABELS ON THE ENGINE before starting and operating the engine e Learn how to operate and work safely Know your equipment and its limitations Always keep the engine In good condition e Before allowing other people to use your engine explain how to operate and have them read this manual before operation e DONOT modify the engine UNAUTHORIZED MODIFICATIONS to the engine may impair the function and or safety and affect engine life WEAR SAFETY CLOTHING e DO NOT wear loose torn or bulky clothing around machinery Entanglement in rotating
210. sing input is lost In addition this AVR includes an output to trip an optional external circuit breaker Correct setting of the over voltage function can be verified by measuring the voltage across terminals E0 and E1 which should be within 5 of 300V If incorrect the voltage can be adjusted by using a small flathead screwdriver to turn the over voltage potentiometer turning it clockwise will increase the voltage and vice versa If the over voltage setting is incorrect the generator output voltage will drop either when load is removed or when no load is applied and the LED will come on and stay lit Stop the generator to reset 3 1 3 1 4 OTHER ADJUSTMENTS OPTIONS Please refer to the proper AVR datasheet in Appendix E 3 2 1 CONDUIT PASS THROUGH In order to run the output power wires from the generator terminal box a hole will need to be cut into one of the two side panels on the saddle box By default the right panel if facing the back of the generator should be used The left panel can be used if the generator was specially ordered for left side installation Both panels are removable Remove the proper panel before drilling or punching to avoid introducing metal debris inside the saddle box which may cause a short or other damage Some type of conduit pass through should be used to protect the wires from sharp edges and protect the saddle box from exposure to the elements or a harsh operating environment The pass through shoul
211. sion weathering and engine fluids Replace damaged hoses as required Seasonally check hose clamp torque and adjust accordingly Limited Warranty This limited warranty expressly limited to tha Company s products that have been purchased by the original consumer purchaser or for purposes of resale use in tha ordinary course of the purchaser s business The term original consumer purchaser ls definad as a person who purchases Company products for personal family or household use The Company s products are warranted against defects in materials and workmanship for a period of one year from date of purchase by purchasar Tha exclusive remedy for any product found 10 be defective under this limited warranty consists of tha repair replacement of ihe defective product This limiled warranty moi apply l defects which arise from normal wear and tear accident misuse abuse neglect mishandling misapplication faulty installation modification improper or extraordinary use use inconsistent with ary instruction or recommendation issued by the Company The foregoing limited warranty exclusive and in lieu of ail other warranties whether wriltan or oral express Implied or statutory NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL APPLY THE LIMITED WARRANTY CONTAINED HEREIN DOES NOT EXTEND TO INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE USE OF THIS PRODUCT OR ARISING OUT OF A B
212. ss of coolant 5 Check and clean the plug threads and surface and the pucking thims of the water drain plug to prevent dirt and debris from the entering the engine 6 Coolant Radiator cleaner and anti freeze Season Coolant Pure water and anti freeze See Anti freeze in RADIATOR section All seasons E Remedies for quick decrease of coolant 1 Check any dust and dirt between the radiator fins and tube If any remove them from the fins and the tube 2 Check the tightness of the fan belt If loose tighten it securely 3 Check the internal blockage in the radiator hose If scale forms in the hose clean with the scale inhibitor or its equivalent PERIODIC SERVICE 19 llChecking radiator hoses and clamp CAUTION To avoid personal injury Be sure to check radiator hoses and clamp bands periodically If radiator hose is damaged or coolant leaks overheats or severe burns could occur Check to see if radiator hoses are properly fixed every 250 hours of operation or 6 months whichever comes first 1 If clamp bands are loose or water leaks tighten clamp bands securely 2 Replace hoses and tighten clamp bands securely if radiator hoses are swollen hardened or cracked Replace hoses and clamp bands every 2 years or earlier if checked and found that hoses are swollen hardened or cracked Precaution at overheating The event that the coolant temperature is nearly or more than the boiling p
213. st regulator Consult regulator manual Regulator inoperative 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 Voltmeter off or defective Check voltage with a separate meter at the generator terminals Incorrect defective connections Verify generator cannections See drawings supplied with the generator ar 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 generators residual voltage or fram 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 Test the generator using the 12 volt battery test as specified in the testing section If the windings results indicate generator problems perform insulation continutty and diode tests as specified in the testing sectian Regulator inoperative Adjust or replace regulator Consult regulator manual Oy MARATHON A Subatan of Regal hana Corpevuan GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD APPLIED CAUSE Excessive load Large motor starting or low load power factor Driver speed droop or belt slip Reactive droop Line drop
214. t Carefully turn VOLTS control clockwise until rated voltage is reached If instability is present at rated voltage refer to stability adjustment then re adjust voltage if necessary O G N STABILITY ADJUSTMENT The AVR includes a stability or damping circuit to provide good steady state and transient performance of the generator The correct setting can be found by running the generator at no load and slowly turning the stability control counter clockwise until the generator voltage starts to become unstable The optimum or critically damped position is slightly clockwise from this point i e where the machine volts are stable but close to the unstable region UNDER FREQUENCY ROLL OFF UFRO ADJUSTMENT The AVR incorporates an under speed protection circuit which gives a volts Hz characteristic when the generator speed falls below a preset threshold known as the knee point The red Light Emitting Diode LED gives indication that the UFRO circuit is operating The UFRO adjustment is preset and sealed and only requires the selection of 50 60Hz using the jumper link For optimum setting the LED should light as the frequency falls just below nominal i e 47 Hz on 50 Hz system or 57 Hz on a 60 Hz system 41 ATHLON AGR440 AUTOMATIC VOLTAGE REGULATOR SPECIFICATIONS Input Voltage 95 132V or 190 264V AC jumper Frequency 50 60 Hz nominal Phase Single Phase Output Voltage Max 90V DC 207V
215. t often marked with a cautionary symbol such as A These messages are for your protection Before any work is done e Besure installation conforms to all applicable safety and local electrical codes Licensed electricians should perform all installations Never operate the generator with protective access or terminal box covers removed e Before conducting any maintenance be sure to disable the engine start circuits e Avoid accidental closure by disabling closing circuits and any circuit breakers feeding into or from the generator follow OSHA lockout tagout procedures e Insure proper grounding earthing of the generator frame and distribution system in compliance with local and national electrical codes and specific site requirements Lifting or moving your generator involves a hazardous set of operations as noted in the installation and maintenance sections of this manual Improper lifting or moving of the unit may well result in damage to the generator and more importantly injury to service personnel As an initial step in installation insure that all generator leads are properly connected inside the saddle connection box Residual voltage is always present at the generator terminals and at the automatic voltage regulator panel connections Therefore always assume that there will be voltage present at the generator terminals This manual is only a supplement to the proper training of installation and service personnel
216. t Power Single Phase 1 DC out shunt powered regulator m Automatic PMG Input Power optional Voltage 1 phase 300 250 hertz Regulator Sensing Input Single Phase 3 phase optional FIGURE 1 MagnaPLUS Circuit Diagram Main Stator Main Stator Main Rotor AC Output field Cooling Fan Rectifier Im Assembly Drive Disc Optional PMG A dme o Vi mor x fib eS IT d um HILL ITE is qe SERE ur Stator armature Exciter Stator field Exciter Ratar armature FIGURE 2 Typical MagnaPLUS Layout Diagram 3 A Siar af PRINCIPLE OF OPERATION MagnaPLUS generators brushlessself excited 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 the following stators are stationary rotars 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 The generators exciter consists of a stationary field and rotating arm
217. tap with the rectifier output going directly to the SCR 020 Battery charger currentwill Hew when the SCR Silicon Controlled Rectifier is and vice versa The resistor R20 and capacitor C20 form snubber network to prevent false SCR turn on due to line surges or transients When the SCR is turned on by the regulator circuit charge current will flow through the SCR fuse and ammeter and terminal B to the battery positive post The charge current return path is from battery negative through terminal H to the transformer center tap The regulator board has its own regulated power supply which is supplied via the AC pins and terminals 15 and 16 The wiring options shown on the drawing are to provide approximately 12 to the regulator board The return line for this supply is the RET pin which connects to the transformer center tap via terminal B The local regulated supply on board supplies the reference element providing the double regulated reference voltage for low line regulation error VOLTAGE SENSING The regulator senses the battery terminal voltage via the B and terminals The regulator will turn on the SCR sooner in each half line cycle when the sensed battery voltage is below the internal regulated reference voltage Turning on the SCR sooner each half cycle will allow mare charge current to flow When the battery voltage increases with charge level above the fixed reference voltage t
218. tching circuits introduce high frequency harmonics which distort the normal wave form of the generator This creates additional heal in the generator w indings and may cause the generator to over heat Problems which can occur are not limited to the generator Poor wave shape may adversely effect various loads connected to the generator Consult Marathon Electric tor further information relative to nonlinear loads INSTALLATION PREPARATION FOR USE Although the generator has been carefully inspected anc 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 insulatian on lead wires fnr 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 ensure that it rotates smoothly without binding WARNING DISABLE AND LOCKOUT ANY ENGINE CRANKING DEVICES BEFORE ATTEMPTING TO INSTALL OR SERVICE THE GENERATOR FOR ELECTRIC 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 NEVER BAR OVER THE ENGINE GENERATOR SET USING THE GENERATOR S FAN THE FAN IS MOT DESIGNED FOR THIS PURPOSE BARRING OVER THE SET WITH THE FAN COULD
219. tentially hazardous situation which if not avoided COULD result in death or serious injury A CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury IMPORTANT Indicates that equipment or property damage could result if instructions are not followed Gives helpful information SAFE OPERATION 1 4 SAFE OPERATION Careful operation is your best assurance against an accident Read and understand this section carefully before operating the engine All operators no matter how much experience they may have should read this and other related manuals before operating the engine or any equipment attached to it It is the owner s obligation to provide all operators with this information and instruct them on safe operation 22 O 2 TT Be sure to observe the following for safe operation 1 OBSERVE SAFETY INSTRUCTIONS Read and understand carefully this OPERATOR S MANUAL and LABELS ON THE ENGINE before attempting to start and operate the engine earn how to operate and work safely Know your equipment and its limitations Always keep the engine in good condition Before allowing other people to use your engine explain how to operate and have them read this manual before operation DO NOT modify the engine UNAUTHORIZED MODIFICATIONS to the engine may impair the function and or safety and affect engine life If the engine does not pe
220. ter clockwise until the generator voltage starts to become unstable The optimum or critically damped position is slightly clockwise from this point i e where the machine volts are stable but close to the unstable region UNDER FREQUENCY ROLL OFF UFRO ADJUSTMENT The AVR incorporates an under speed protection circuit which gives a volts Hz characteristic when the generator speed falls below a preset threshold known as the knee point The red Light Emitting Diode LED gives indication that the UFRO circuit is operating The UFRO adjustment is preset and sealed and only requires the selection of 50 or 60 Hz and 4 pole or 6 pole using the jumper link For optimum setting the LED should light as the frequency falls just below nominal i e 47 Hz on a 50 Hz system or 57 Hz on a 60 Hz system DROOP ADJUSTMENT Generators intended for parallel operation are fitted with a quadrature droop C T which provides a power factor dependent signal for the AVR The C T is connected to S1 S2 on the AVR see generator wiring diagram for details The DROOP adjustment is normally preset in the works to give 5 voltage droop at full load zero power factor Clockwise increases the amount of C T signal injected into the AVR and increases the droop with lagging power factor cos With the control fully counter clockwise there is no droop TRIM ADJUSTMENT An analog input A1 A2 is provided to connect to a Power Factor Controller or other devices It is desig
221. tor 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 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 motor s locked rotor or stall current and is 5 to 10 times normal full load current When the generator AMBIENT TEMPERATURE C 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 Special Conditions Outdoor Operations Generators subjected to outside operation must be protected from the environments by fiberglass or metal housings with the proper forced air fan ventilation Direct generator contact of rain snow or dust must be avoided Space heaters are also recommended for certain environmental conditions Sand amp Dust Generator windings are protected against harsh environments However severe conditions may demand further protection Special enclosures and filters may be necessary to protect the generator from contam
222. uid see a medical doctor immediately This fluid can produce gangrene or severe allergic reaction Cardboard Magnifying glass 1ABAAAAAP120F o O 2 TT 4 SAFE OPERATION 8 CAUTIONS AGAINST BURNS amp BATTERY EXPLOSION avoid burns be cautious of hot components e g 9 muffler muffler cover radiator hoses engine body coolants engine oil etc during operation and after the engine has been shut off DO NOT remove the radiator cap while the engine is running or immediately after stopping Otherwise hot water will spout out from the radiator Wait until the radiator is completely cool to the touch before removing the cap Wear safety goggles Be sure to close the coolant drain valve secure the pressure cap and fasten the pipe band before operating If these parts are taken off or loosened it will result in serious personal injury The battery presents an explosive hazard When the battery is being charged hydrogen and oxygen gases are extremely explosive DO NOT use or charge the battery if its fluid level is below the LOWER mark Otherwise the component parts may deteriorate earlier than expected which may shorten the service life or cause an explosion Immediately add distilled water until the fluid level is between the UPPER and LOWER marks Keep sparks and open flames away from the battery especially during charging DO NOT strike a match near the battery DO NOT ch
223. uld be conducted by qualified maintenance personnel Replacement parts may be ordered through authorized service center or directly from the factory FIELD FLASHING Restoring Residual Magnetism not applicable on PMG equipped generators To restore residual magnetism to the generator connect a 12 volt battery to the exciter field while the generator using the following procedure 1 Shutdown the generator set Remove the exciter field leads F and F from the regulator CAUTION Failure to remove the exciter field leads from the automatic voltage regulator during flashing procedures may destroy the regulator 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 crawn repeat the procedure 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 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
224. unter clock wise minimum voltage level Set the remote voltage adjust if used to the center position Set the stability control full clockwise maximum stability level Connect the positive lead of a 100V D C voltmeter to F1 and the negative lead of the voltmeter to Fe or use an appropriate AC voltmeter on the generator output leads SYSTEM START UP Start and run the generator at no load and rated speed The generator voltage should build upto a minimum level Actual level isdapendent upon connection If it does build up refer to field flashing section in generator manual Slowly adjust the voltage control until the generator voltage reacnes the nominal value If used adjust the remote voltage rheostat to set the generator voltage to the exact value desired Turn the stability adjust counter clockwise until in stability is shown on either of the voltmeters mentioned in the PRELIMINARY SET UP section With the system operating in an unstable condition slowly adjust the stability control clockwise until generator stability is reached Interrupt regulator power for a short time approximately 1 2 seconds if the generator remains stable no further adjustment I necessary If the generator does not remain stable increase the stability slightly and interrupt regulator power again This procedure should be repeated until system stability is reached and maintained _ Cause Acton gt
225. ur Content ppm used must be compliant with all applicable emission regulations for the area in which the engine is operated Use of diesel fuel with sulfur content less than 0 10 1000 ppm is strongly recommended e If high sulfur fuel sulfur content 0 50 5000 ppm to 1 0 10000 ppm is used as a diesel fuel change the engine oil and oil filter at shorter intervals approximately half DO NOT USE Fuels that have sulfur content greater than 1 0 10000 ppm e Since KUBOTA diesel engines of less than 56 kW 75 hp utilize EPA Tier 4 and Interim Tier 4 standards the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines when operated in US EPA regulated areas Therefore please use No 2 D S500 or 515 diesel fuel as an alternative to No 2 D and use No 1 D S500 or 515 diesel fuel as an alternative to No 1 D for ambient temperatures below 10 14 F 1 No 1 D or No 2 D S500 Low Sulfur Diesel LSD less than 500 ppm or 0 05 wt No 1 D or No 2 D 515 Ultra Low Sulfur Diesel ULSD 15 ppm or 0 0015 wt MAINTENANCE 11 CJ 4 classification oil is intended for use in engines equipped with DPF Diesel Particulate Filter and is Not Recommended for use in Kubota E3 specification engines Oil used in the engine should have classification and Proper SAE Engine Oil according to the ambient temperatures as shown below Above 25 C 77 F SAE30 SAE10W 30 or 15W 40 I o O 2 TT
226. ust be adequately supported to prevent damage l 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 i STORAGE In the event that the generator is not immediately installed on its prime mover it is recommended that the unit be stored indoors clean dry area which is not subject to rapid changes in temperature and humidity If the generator is stored for a long period of generator should be tested cleaned and dried as required before being put into service See the maintenance section of this manual for further information lf the unit has been stored in an area where it has been subject to vibration it is rec is base vale ak PRINCIPLES OF OPERATION PM game Rotating Assembly U U 7 PMG Field Exciter Field Exciter Armature iit atte Main Field Main Armature rator rotor i rotor i stator Li SS d T 3 Phase out 3 Phase AC L Armature stator Rotating Rectifier Assembly i 3 Phase Pul Bridge j X denne S RE EC EE Exciter Field Power Inpu
227. usty place This will get rid of large particles of dust and dirt 2 Wipe the inside air cleaner clean with cloth if it is dirty or wet 3 Avoid touching the primary element except when cleaning 4 When dry dust adheres to the element blow compressed air from the inside turning the element Pressure of compressed air must be under 205 kPa 2 1 kgf cm 30 psi 5 Replace the primary element every year or every 6 cleanings If the primary element is stained heavily replace it soon At this time replace the secondary element too 6 The secondary element should be removed only if it is to be replaced T To protect the engine do not remove the secondary element in servicing the primary element Air cleaner body Cover Primary element 1 2 3 Secondary element 4 5 Evacuator valve IMPORTANT Make sure the hooking clip for the element is tight enough If it is loose dust and dirt may be sucked in wearing down the cylinder liner and piston ring earlier and thereby resulting in poor power output Do not overservice the air cleaner element Overservicing may cause dirt to enter the engine causing premature wear Use the dust indicator as a guide on when to service Cleaning Primary Air Filter Element To clean the element use clean dry compressed air on the inside of the element Air pressure at the nozzle must not exceed 205 kPa 2 1 kgf cm 30 psi Maintain reasonable distance between t
228. ve Solenoid Check Oil Pressure Switch REPLACE Safety Shutdown System Plug Remote Back IN Remove Wire From Water Temperature Switch Replace Switch Has Power NO Power Engine runs OK NO Power Remote OK Problem with Remote Check Shutdown Relay Replace Water T Temperature 13 ENGINE RUNS ROUGH SLOW NO Visible Exhaust Smoke Excessive Exhaust Smoke BLUE Insufficient Fuel to Engine GRAY WHITE Excessive Oil Level Check Replace Fuel Level Fuel Filter Dirty Air Filter Engine Overheated Engine Over Loaded Clogged Muftler Over Fueling Injector Check safety Shutdowns HIGH ALTITUDE And Fuel Solenoid Engine Cold Incomplete Combustion Over fueling Injector Glow Plug Not Activating Check With 12 volt DC Test Light ENGINE WILL SIART Engine Cranks Engine Does NOT Crank Engine Cranks SLOW NO Smoke Exhaust From Smoke Exhaust Oil Viscosity Start TOO HEAVY Switch Check LOW Terminal Battery Siarter Ends Voltage Relay Check Fuel Solenoid NO Check Power While Glow Plug Cranking Relay 2 Check Spark Arrestor Muffler for Clogging Defective Solenoid No Power From Starter Terminal 15 SECTION 3 GENERATOR END SAFETY PRECAUTIONS 1 2 INSTALLATION REQUIREMENTS 3 GENERATOR ASSEMBLY INFORMATION 4 5 ENGINE and GENERATOR DIAGRAM 6 SECTION A GENERATOR MARATHON MAGNAPLUS GENERATOR MANUAL 1 19 Insta
229. which is very low in cetane rating adversely affects the engine Diesel fuel differs in grades depending on the temperature Be careful not to let the fuel tank become empty or air can enter the fuel system necessitating bleeding before next engine start BI Air bleeding the fuel system A CAUTION To avoid personal injury Do not bleed a hot engine as this could cause fuel to spill onto a hot exhaust manifold creating a danger of fire Air bleeding of the fuel system is required if after the fuel filter and pipes have been detached and refitted e after the fuel tank has become empty or before the engine is to be used after a long storage A gravity feed fuel tanks only Fill the fuel tank to the fullest extent Open the fuel filter lever 2 Open the joint bolt on top of the fuel injection pump 3 Turn the engine continue it for about 10 seconds then stop it or move the fuel feed pump lever by hand optional 4 Close the Joint bolt on top of the fuel injection pump IMPORTANT Always keep the air vent cock on the fuel injection pump closed except when air is vented or it may cause the engine to stop PERIODIC SERVICE 13 GRAVITY FEED SYSTEM igi 19 ok su 1 Joint bolt 2 Fuel feed pump NOTE For the engine equipped with automatic venting optional no manual bleeding of fuel lines is required PROCEDURE fuel tanks lower than injection pump
230. y Sustain as a result of the purchase use malfunction or defective condition of our products ANY IMPLIED WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED IN DURATION TO THE PERIOD SET FORTH ABOVE Some states do not allow limitations on how long an implied Warranty lasts or the exclusion or limitation of incidental or consequential damages so the above Limitations or exclusions may not apply to you This Warranty gives you specific legal rights and you may have other rights which vary from state to state This Warranty is in lieu of all other Warranties expressed or implied and of any other obligations or liability on our part Our responsibility for any and all losses and IN NO EVENT WILL WE BE LIABLE FOR LOSS OF USE LOSS OF PROFITS INCONVIENCE COMMERCIAL LOSS OR OTHER INCIDENTIAL OR CONSEQUENTIAL DAMAGES WHATSOEVER Power Technology S E Inc P O Box 490133 Leesburg FL 34749 USA Z code 04 20 2010 POWER TECHNOLOGY SOUTHEAST INC Export Warranty on All Power Technology Products The Power Technology standard commercial warranty shall be modified as follows for all sales and delivery of products outside of the United States and Canada The terms of the warranty shall be for a period of 12 months from the delivery to the first retail user Dealer shelf life shall be 6 months from date of shipment In no case shall the warranty period exceed 18 months from date of shipment
231. y fing terminals Ring terminal sizes are amp mm 280 Series Frames and 10 mm 360 and 430 Senes Frames Torque link board connections to the following specifications 280 frame 5 4 NM 4 Ft Lb 360 amp 430 frame 27 NM 20 Ft Lb 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 foating See national and local codes and or the system distribution wiring schematic diagram for the proper rvcuannectiorrof 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 intemally connected inside the generator and brought out as a single lead TO Ten lead generators can only be connected in a wye configuration HIGH WYE CONNECTION VOLTAGE HIGH WYE AGE HIGH DELTA 650 110 Na ess ZJMARATHON _ i A af Rega Beitr Capai DOUBLE DELTA SINGLE PHASE CONNECTION Note Single phase KW KVA ratings are approximately equal ta 50 of the generator s three phase ratings Nate Single phase KW KVA ratings are approximat
232. ys remove wristwatch rings or other jewelry before handling a battery Any compartment containing batteries should be well ventilated to prevent the accumulation of explosive gases To avoid sparks never disturb the battery charging connections while the battery is being charged Always turn off the battery charger before disconnecting terminal clips 4 ELECTROCUTION Failure to install a generator set with an electrical system consistent with governing regulations and standards is UNLAWFUL and may cause ELECTROCUTION of vehicle occupants Your generator set must not be used to Back Feed by connecting it to a building or outdoor electrical circuit Back feeding can cause serious injury or death to utility personnel working to repair a power outage and may also seriously injure persons in your vehicle Unauthorized connections are unlawful in some states and or localities A transfer switch must be installed to prevent interconnection of the generator set power and outside power 5 MOVING PARTS Keep hands feet and clothing away from belts and related pulleys when unit 1s running Replace guards covers and screens before operating the generator set Serious personal injury may occur from contact with moving parts 6 HIGH VOLTAGE Remember the function of a generator set is to produce electricity Wherever electricity is present there 1s a potential danger of electrocution Apply the same precautions to the vehicles electrical appliances a

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