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PT20-EC

PT20-ECRR

PT25-EC

PT25-ECRR

Operators

Manual

Power Technology Southeast, Inc.

634 State Road #44 Leesburg, FL 34748-8103

♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦

9/2008

MANPT20EC

FORWARD

You are now the proud owner of a Power Technology Generator powered by a Kubota engine.

This engine is a product of Kubota’s quality engineering and manufacturing. The engine is 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.

TO OUR CUSTOMERS

Thank you for your purchase of a Power Technology Generator. The information contained in this

manual applies to PT20-EC, PT20-ECRR, PT25-EC, and PT25-ECRR generators. 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. If required, a Major Service Manual may be ordered through

Power Technology’s Customer Service Department.

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

TABLE of CONTENTS

SECTION 1: “SAFETY”

SAFE OPERATION 1-4

SECTION 2: “ENGINE”

PRE-OPERATION CHECK 1

OPERATING THE ENGINE 2-12

ENGINE SPECIFICATIONS 13

ENGINE MAINTENANCE SERVICE SCHEDULE

ENGINE OIL MAINTENANCE

ENGINE COOLANT MAINTENANCE 16

OPERATING HOURS AND SERVICE LOG 17

SECTION 3: “GENERATOR END”

“MAGNAPLUS” SERIES EXCITER TYPE GENERATOR ___________ _ 1-20

GENERATOR EXPLODED VIEW and PARTS NUMBERS_________________ 21

MARATHON SE350 VOLTAGE REGULATOR___________________________ 22-24

WIRING SCHEMATICS and RESISTANCE CHARTS______________________ 25

SECTION 4: “INSTALLATION”

SAFETY PRECAUTIONS 1-2

GENERATOR INSTALLATION in RECREATIONAL VEHICLES 3-9

SYSTEMS CONNECTION

10-13

ELECTRICAL CONNECTIONS 14-19

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

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 use this unit.

WARNING: Indicates a potentially hazardous situation, which

may possibly result in serious injury or possible death.

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 is 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

• Read, understand and follow this “OPERATORS MANUAL”

and “LABELS ON THE ENGINE” before starting and operating

the engine.

• Learn 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.

WEAR SAFETY CLOTHING

• DO NOT wear loose, torn or bulky clothing around machinery.

Entanglement in rotating parts, controls or projections may cause

personal injury.

• Use additional safety items, e.g. hardhat, eye protection,

gloves, etc., as appropriate or required.

• DO NOT operate machinery or equipment while under the

influence of alcohol, medication, or other drugs, or

while fatigued.

• DO NOT wear radio or music headphones while operating engine.

CHECK BEFORE OPERATING THE ENGINE

• If the engine is malfunctioning DO NOT operate until repairs

are made.

• Be sure all guards and shields are in place before operating

the engine. Replace any that are damaged or missing.

• Check to see that the area around the engine is clear of foreign

objects before starting.

• 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.

• DO NOT start the engine by shorting across starter terminals.

KEEP AREA AROUND THE ENGINE CLEAN

• 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.

SAFE HANDLING OF FUEL AND LUBRICANTS

• 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. 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.

EXHAUST GASES AND FIRE PREVENTION

• 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

• Relieve all pressure in the air, oil and cooling systems

before any lines, fittings or related items are removed or

disconnected.

• Be alert for possible pressure release when disconnecting any device

from a system that is pressurized. DO NOT check for

pressure leaks with your hands. High-pressure oil or fuel can

cause personal injury.

• Escaping hydraulic fluid under pressure has sufficient force to

penetrate skin causing serious personal injury.

• 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.

• 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.

• 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.

• Be sure the radiator drain valve / petcock and hose clamps are

tighten. Check radiator pressure cap and oil fill cap before operating

the engine.

• The battery presents an explosive hazard. When the battery is

being activated, hydrogen and oxygen gases are extremely explosive.

• Keep sparks and open flames away from the battery, especially

during charging. DO NOT strike a match near the battery.

• DO NOT check a batteries charge by placing a metal object across

the terminals. Use a voltmeter or hydrometer.

• 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

• 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.

• Be sure to stop the engine before adjusting belt tension or checking

the cooling fan.

• DO NOT run the engine without safety guards installed. Be sure the

safety guards are properly aligned and securely fastened before operating

the engine.

ANTI-FREEZE AND DISPOSAL OF FLUIDS

• Anti-freeze contains toxic chemicals. Wear rubber gloves when

handling anti-freeze. In case of contact with skin, wash immediately

to avoid personal injury.

• 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.

• Be mindful of the environment. Before draining any fluids, be

prepared to dispose of them in a manner consistent with

environmental protection regulations in your location.

• When draining fluids from the engine, use appropriate containers to

hold the different fluids, do not mix fuel, oil or coolant together.

• 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

• When performing safety checks or engine service, be sure the engine is level

and well supported. Use approved stands designed for this type of service.

DO NOT service an engine that is only supported by a lift jack or hoist.

• Detach the battery from the engine before conducting service. Put a

“DO NOT OPERATE!” tag in the key switch to avoid accidental starting.

• To avoid sparks from an accidental short circuit always disconnect

the 12V DC power at the battery.

• Be sure to stop the engine and remove the key when conducting

daily and periodic maintenance, servicing and cleaning.

• Check or conduct maintenance after the engine, radiator, muffler, or

muffler cover has cooled off completely.

• 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.

• 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.

• 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.

• When service is performed with two or more people present, take care

to perform all work safely. Be aware of their location especially when

starting the engine.

• Keep a first aid kit and fire extinguisher handy at all times.

SECTION 2

“ENGINE”

PRE-OPERATION CHECK 1

Engine Break-in Period

Daily Check

OPERATING THE ENGINE 2-12

Power Control Module

Feature Summary

Operating Behavior

Automatic Generator Start (AGS)

Safety Monitoring and Shutdown

LED Sequences

Troubleshooting Guides

12V DC Power Control Module Wiring Schematic

ENGINE SPECIFICATIONS 13

Kubota Model V2203-M and V2003-M-T

Service Parts

ENGINE MAINTENANCE SERVICE SCHEDULE 14

ENGINE OIL MAINTENANCE 15

Checking Engine Oil Level

Lubricating Oil Specifications

Engine Refill Capacities

Lubricating Oil Viscosity Recommendations

ENGINE COOLANT MAINTENANCE 16

Coolant Recommendations

Ethylene Glycol / Propylene Glycol

Checking Radiator Coolant Level

Coolant Service Life

Checking Reservoir Tank Coolant Level

Cleaning Radiator Core

OPERATING HOURS AND SERVICE LOG 17

PRE-OPERATION CHECK

ENGINE BREAK-IN PERIOD

During the engine break-in period, observe the following recommendations:

1. Change the engine oil and oil filter cartridge after the first 50 hours of operation.

(See “ENGINE OIL” in ENGINE MAINTENANCE SERVICE SCHEDULE).

2. In ambient temperature above 32°F (0°C) approximately 3-5 minutes without a load is sufficient

for engine warm up. Allow additional warm up time when temperatures are below 32°F (0°C)

before placing an operating load on the engine.

DAILY CHECK

To prevent future engine problems from occurring, it is important to know and keep track of the engines

condition. Below are items to be Inspected and Checked on a daily basis.

CAUTION:

To avoid personal injury:

• Be sure all safety shields and guards are attached to the engine when operating.

• To prevent a fire hazard, keep foreign materials, fuel and oil away from the battery, wiring, muffler

and engine. Check and clear them daily. Be aware of the muffler and exhaust gas heat underneath the

engine compartment, this heat may ignite grass or other flammable materials.

• Follow all safety precautions as outlined in the “SAFE OPERATION” section.

1. For accurate readings the engine should be on level ground when checking engine fluids.

2. Check fluids before starting the engine. (Cold Engine)

• Lubrication System: Check Engine oil level

Check for Engine oil leaks

• Cooling System: Check coolant level and condition

Check for coolant leaks

Check for proper installation of the radiator cap

• Fuel System: Check for sufficient quantity of fuel

Check for fuel leaks

3. Check engine after starting. (Warm Engine)

• Proper Operation: Check for easy engine start

Check for fluid leaks

Check for abnormal engine noises

Check for abnormal exhaust gas

Power Controller Module

(PCM)

And Display

(PCMD)

Feature Summary

The PowerTech PCM controls all of the start and run processes and characteristics of any PowerTech

generator. The features of the application are:

Internal Ambient Temperature Sensor

Provides an on-board temperature sensor.

Oil Pressure Sensor / Switch Input

Allows input from an external oil pressure sensor or switch. Will shut down the generator if

sufficient pressure is not detected after a start-up period.

Coolant Sensor / Switch Input

Allows input from an external coolant temperature sensor or switch. Will shut down the generator if

extreme temperature is detected.

Auxiliary (Generic) Shutdown Switch Input

Allows input from any external active low (ground) switch. An active state of this switch will shut

down the generator immediately.

DC Power Supply Voltage Measurement

Measures the voltage level of the DC power supply. The DC voltage is monitored for a minimum

and will shutdown the Generator if it falls below a threshold (configuration parameter). This is also reported

on the PCM.

AC Output Voltage Measurement

Measures the voltage level of the AC output. This information is monitored to detect limit

conditions. It also is reported on the PCM. Over and Under Voltage conditions are reported.

AC Output Current Measurement

Measures the current level of the AC output. The data is reported on the PCM and is used for

current, wattage, and load measurement.

AC Output Frequency Measurement

Measures the frequency level of the AC output. This info is monitored to detect a valid start as well

as limit conditions. It also is reported on the PCM. Over and Under Frequency conditions are reported.

Warm Start

Adjusts the Pre-Heat glow plug activation time according to the coolant temperature.

One-Touch Remote Start Trigger

In addition to control via PCM, the unit will respond to an active high digital input. The unit can be

configured to either start or stop in response to activation of a momentary switch or a toggle switch.

Blink Code Fault Reporting

Simple diagnostic data is available through blink codes on a dedicated active high output. The PCM

state as well as fault codes are displayed.

Event Recording

A portion of non-volatile memory is dedicated to recording diagnostic and other events. If a clock is

available on the network, the time and date of the event is included. Events include diagnostic messages,

starts, stops, and configuration changes. Total event capacity is roughly 2,000 events.

Load Profiling

The unit records the total amount of time the generator spends in each of several load intervals.

The information is recorded each time the generator stops, showing the usage profile for that specific cycle.

AGS

Automatic Generator Starting for low battery voltage. Programmable at the factory

voltage threshold and run time. Unit can sense genset battery voltage or any other battery voltage as

required. Enabled or disabled by an external switch.

Ignition Sensing

Will shutdown genset or prevents genset from starting if DC voltage is applied from any

external source. (Example: vehicle ignition, shore power sensor, or transfer switch, etc…)

Operating Behavior

Starting

The generator starts in response to the “START” button being depressed for 1 second. The PCM

goes into the Pre-Heat State, followed by the Cranking State, then finally, the Running State. The

PCM attempts to start the generator a specific number of times (configuration parameter) before

declaring a Fault. The shutdown inputs are checked before the start is attempted. If any of these

inputs are active, the start process is aborted.

See the following sections for more detailed information about each state.

Stopping

The generator stops in response to the “START” button being depressed for 1 second. All relays

are returned to their reset condition (OFF). Inputs to the PCM are not actively monitored, except

the Start/Stop Button. The LED is turned off. The PCM enters the Idle State.

Power Cycle/Reset

If the power to the PCM is cycled, it will immediately shut down all relay outputs, stopping the

generator. The unit will start with all fault and status flags reset. There may be a pause of

several seconds before all the configuration information is processed and the unit is ready to

accept input.

Idle State

The Idle State is the initial state of the PCM after a Power Cycle/Reset. The PCM returns to this

state after a Stop Command. The LED is not lit.

Pre-Heat State

The Pre-Heat State is necessary to energize the Glow Plugs for the Cranking State. The Fuel

Pump is active. The duration of this state is determined by using the coolant temperature

according to the formula:

< 23 ºF cranking time = 15 seconds

23 ºF – 50 ºF cranking time = 8 seconds

> 50 ºF cranking time = 5 seconds

The LED blinks.

Cranking State

The Cranking State attempts to start the generator combustion. The starter and fuel pump are

active. Successful sustaining combustion is determined by measuring the AC Line 1 output

frequency. The LED blinks.

Running State

After an initial “ignore” time (configuration parameter), inputs are monitored for out-of-bounds

limits and, if needed, a shutdown command is issued. The LED is lit.

Fault State

The Fault State is entered if an input reaches an out-of-bounds limit. The generator is

immediately stopped. A Power Cycle/Reset is required to exit the Fault state. The LED blinks the

Fault Code(s) (see next section).

Automatic Generator Start (AGS)

The Automatic Generator Start (AGS) allows the generator to start based upon the battery level.

The trigger voltage is configurable via a configuration parameter. The entire feature can be

enabled/disabled by a configuration parameter. The AGS feature is currently disabled, by default.

Safety Monitoring And Shutdown

The PCM monitors inputs for safety limitations which might damage the generator. If any input is

outside of the safe operating range, the generator is immediately shutdown and the PCM enters

the FAULT state. The PCM remains in the FAULT state until a power cycle or reset occurs. The

shutdown reason is displayed by blinking the LED.

The thresholds used in determining faults are set by configuration parameters.

These inputs are only monitored when the generator is in the RUNNING state. Before starting the

generator, the following inputs are checked to see whether a start should be attempted: High

Coolant Temperature, Auxiliary switch, Ignition Sense, DC Voltage and High Ambient

Temperatures.

These inputs are averaged over 0.6 seconds to help eliminate noise and settling issues. This

averaging helps to eliminate falsely signaled shutdowns.

Shutdown Reasons

Fault Reason Fault Code Description

Failure to Start 1

The generator was not able to start.

High Coolant

Temperature

The generator coolant temperature has reached a

high threshold.

Low Oil Pressure 3

The generator oil pressure has reached a critically

low pressure.

High Ambient (Air)

Temperature

The PCM measures an ambient air temperature

above a specific threshold.

NOTE: Temperature inside the Control Box.

AC Fault 5

A Fault with the AC was detected.

DC Fault 6

A Fault with the DC (Battery) was detected.

Auxiliary Input Active 7

The Auxiliary input is active.

Sensor Malfunction 8

One of the sensors has malfunctioned..

Ignition Sense 9

Ignition Sense is active.

The fault codes are displayed on the LED by blinking a number of times equal to the fault code,

then going dark for two seconds. Multiple fault codes are displayed in the order that they have

occurred. This cycle repeats until the fault is cleared by a power cycle, reset or via RV-C.

LED Sequences

The LED on the Start Button is used to communicate the state of the generator in addition to any

fault conditions. The PCM states are different from the Fault Codes in that the states are

displayed continuously (i.e. no two second pause).

PCM State

PCM State LED Notes

Idle State

off

Pre-Heat

Blink (25% duty cycle)

Cranking State

Blink (50% duty cycle)

Running State

Fault State

<various> See “Shutdown Reasons”

Section

CODE 2 or 8

Replace Defective

Parts as Needed

Check Wiring

From Sensor to

Terminal 13 on PCM

If “OK”

Check Sensor

CODE 1 or 6

ENGINE TROUBLE SHOOTING

ENGINE STARTS BUT WON’T RUN

Check Flash Code

Indicator at

PCMD

Engine High

Water Temp.

Fill System

With 50/50 Mix

Check Coolant

Level/Condition

Check Radiator

Air Flow / Belts

Clean Core

Tighten / Replace

Belts

Failure

To Start

Check Fuel

Filter/Supply

Check Battery

Voltage

Check Circuit

To Actuator

If “OK” Check

Fuel System

If “OK” Replace

Actuator

Bleed Air

From System

Check Fuel

Pump / Circuit

If “OK”

Check Wiring

From Sensor to

Terminal 12 on PCM

If “OK” Check

Oil Pres. Sensor

Replace Defective

Parts as Needed

CODE 5 CODE 3 or 8

ENGINE STARTS BUT WON’T RUN

CONTINUED

ENGINE TROUBLE SHOOTING

Check Flash Code

Indicator at

PCMD

No AC Signal

If “Tripped”

Check Generator

Check Main AC

And Voltage

at Breakers

Low Oil

Pressure

Check Oil

Level/Condition

Check Terminal

Connections at

2&3 on PCM

Check Generator

Wiring

Replace Defective

Parts as Needed

If AC Signal

Present Replace

PCM

ENGINE WILL NOT START

ENGINE DOES NOT CRANK ENGINE CRANKS ENGINE CRANKS

SLOW

No Exhaust

Smoke

Smoke From

Exhaust

Check Fuel

Solenoid

NO Power

While

Cranking

Check Fuel

Supply

Check Fuel

Pump

Air in

Fuel System

Replace

Solenoid

YES NO

No Power

From

PCMD

Check

Glow Plugs

Check Spark

Arrestor

Muffler for

Clogging

Oil Viscosity

Too Heavy

Main Switch Battery

Dead

Check

Terminals

Turn Switch

Start Switch

Starter Motor

Low Battery

Voltage

Engine Cold

Incomplete

Combustion

Over Fueling

Injector

Excessive

Oil Level

BLUE SMOKE

Replace

Fuel Filter

Check

Fuel Level

Air in

Fuel System

Check Safety

Shutdowns

And Fuel Solenoid

Insufficient

Fuel to Engine

No Visible

Exhaust Smoke

Check

Fuel Pump

ENGINE RUNS ROUGH OR SLOW

Excessive Exhaust Smoke

BLACK SMOKE

Dirty Air Filter

Engine Overheated

Engine Overloaded

Clogged Muffler

Over Fueling Injector

High Altitude

GREY/WHITE SMOKE

Glow Plug Circuit

Not Operating

Excessive

Oil Consumption

Check Main

Breakers are

“

”

Check Brushes

Applicable

ZERO or LOW

VOLTAGE

Main Coil

Output to

Breakers

Turn “ON”

Breaker / s

BAD

Wiring To

Panel

Defective

Breaker / s

Check Ohm’s

On Main

Stator Leads

Replace

Stator

Check Rotor

Ohm’s

OFF

OKBAD

VOLTAGE TEST

Zero

Low Volta

High

Voltage

Overload

Output

Voltage

Check

Main Breaker / s

On Generator

Check

Regulator

Check AMP

Draw

From equipment

Check

Gen End

OVERLOAD CONDITION

Check AMP Draw

heck Load

Engine Problem

See Engine

Troubleshooting

Check

Stator Coil

Resistance

lace Stator

12 VOLT DC WIRING SCHEMATIC

POWER CONTROL MODULE and ELECTRONIC GOVERNOR

for

KUBOTA “M” SERIES ENGINES

ENGINE SPECIFICATIONS

MODEL V2203-M V2003-M-T

SERVICE PARTS

Power Technology Part #

Filters:

Oil ----------------------------------------------------------------------------------- 01FO091

Fuel ---------------------------------------------------------------------------------- 08FF081

Air with Plastic Canister---------------------------------------------------------- 04FA2E1

Belts:

With Alternator ------------------------------------------------------------------- 03BF0203

Air Induction Naturally Aspirated Turbo-Charged

Continuous Output 32.5 HP @ 1800 rpm 36.6 HP @ 1800 rpm

Cubic Capacity 134.07 in³ (2.19L) 121.99 in ³ (2.19L)

Bore and Stroke 3.43 x 3.64 3.27 x 3.64

(87x92.4mm) (83x92.4mm)

Cylinder Arrangement 4 In-Line 4 In-Line

Firing Order 1-3-4-2 1-3-4-2

Compression Ratio 23:1 22:1

Engine Oil Capacity 8.5 qts. (8.04L) API Class CF 8.5 qts. (8.04L) API Class CF

Fuel and Type Diesel 4 Cycle Diesel 4 Cycle

Minimum Fuel Consumption See Specification Chart See Specification Chart

Engine Maintenance Service Schedule

* Engine oil and filter must be changed after the first 50 hours of operation. Then every 150

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.

Maintenance

Service Item

*See

Note

Daily

Every 150

Hours

Every 500

Hours

Every 1000

Hours

Remarks

Engine Oil Level

Deterioration &

Leakage

Engine Oil

Change

Or Once

a Year

Oil Filter

Change

Or Once

a Year

Coolant Level

Coolant Leakage

Coolant Change

Or Once a

Year

Fuel Level

As Necessary

Fuel Leakage

Fuel Filter Re-

placement

Or Once a

Year

Air Filter Re-

placement

Or Once a

Year

Damaged Worn

Or Loose Belts

Or Every

Two

Years

Replace Fuel

Hoses

Or Every

Two

Years

Check Radiator

Hoses & Clamps

Once a Year

Abnormal Engine

Noise

Abnormal

Generator Noise

Muffler Condition

Exhaust Gas

Condition

ENGINE OIL MAINTENANCE

Ambient Temperature Oil Viscosity

Above 25°C (77°F)

SAE 10W-30

SAE 30 or

SAE 10W-40

0 to 25°C (32° to 77°F)

SAE 10W-30

SAE 20 or

SAE10W-40

Below 0°C (32°F)

SAE 10W-30

SAE 10W or

SAE 10W-40

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 crankcase above “FULL” mark.

2. Remove the oil filler cap and add oil, if

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.

KUBOTA V2203-M & V2003-M-T ENGINE

REFILL CAPACITY

Crankcase Oil Sump 8.5 Qts. (8.04L)

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 is anticipated.

LUBRICATING OIL

SPECIFICATION

Use only good quality

lubricating oil, which meets

the following Specification

API Class

Engine Oil

ENGINE COOLANT MAINTENANCE

COOLANT SERVICE LIFE

Coolant Type Service Life

Commercial Heavy-Duty

Coolant/Antifreeze that 3000 Service Hours

Meets “ASTM D5345” or Two Years

Commercial Heavy-Duty

Coolant/Antifreeze that 3000 Service Hours

Meets “ASTM D4985” 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 is 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 is 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.

COOLANT RECOMMENDATIONS

For optimum performance, Power Technology

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. Fill to the bottom of the fill neck and

check after every 25 hours of operation.

OPERATING HOURS and SERVICE LOG

THIS SERVICE LOG IS PROVIDED TO HELP YOU KEEP AN ACCUMULATIVE 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

SECTION 3

“GENERATOR END”

“MAGNAPLUS” SERIES EXCITER TYPE GENERATOR ASSEMBLY 1-20

NOTE: Pages 7 & 8 , 21 & 22 are Omitted.

GENERATOR EXPLODED VIEW and PARTS NUMBERS 21

MARATHON SE350 VOLTAGE REGULATOR 22-24

WIRING SCHEMATIC and RESISTANCE CHART ________________________ 25

120 / 240 Volt Connection “M” Series Exciter Type

GENERATOR

280–430 Frame

Installation, Operation,

and Maintenance Manual

Marathon Electric Mfg. Corp.

A REGAL-BELOIT COMPANY

P.O. Box 8003

Wausau, WI 54402-8003

Phone: (715) 675 3359

Fax: (715) 675 8026

www.marathonelectric.com

CONTENTS

Safety 2

Receiving and Storage 2

Principles of Operation 3 - 4

Installation 4 - 6

Wiring Connections 6 - 9

Operation 9 - 10

Maintenance 11 - 12

Testing 12 - 13

Service 13 - 15

Troubleshooting 15 - 18

Specifications 19

Parts List & Recommended Spare Parts 20 - 22

SAFETY

PLEASE REMEMBER SAFETY FIRST. If you are not sure of

the instructions or procedures contained herein, seek

qualified help before continuing.

This service manual emphasizes the safety precautions

necessary during the installation, operation, and

maintenance of your MagnaPLUS

generator. Each section of

this manual has caution and warning messages. These

messages are for your safety, and the safety of the equipment

involved. If any of these cautions or warnings 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 generator set driver. Proper grounding

(earthing) of the generator frame and distribution system in

compliance with local and national electrical codes and

specific site requirements must be provided. These safety

precautions are necessary to prevent potential serious

personal injury, or even death.

The hazards associated with lifting or moving your

MagnaPLUS

generator are pointed out in the installation and

maintenance sections. Incorrect lifting or moving can result in

personal injury or damage to the unit.

Prior to start up of the unit ensure that all generator leads are

properly connected to the generator link board located inside

the connection box. Always assume that there will be voltage

present at the generator terminals whenever the generator's

shaft is rotating, and proceed accordingly. Residual voltage is

present at the generator terminals and at the automatic

voltage regulator panel connections even with the regulator

fuse removed. Caution must be exercised, or serious injury or

death can result.

This manual is not intended to be a substitute for properly

trained personnel. Installation and repairs should only be

attempted by qualified, trained people. The cautions and

warnings point out known conditions and situations that are

potentially hazardous. Each installation may well create its

own set of hazards.

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

Upon receipt of the generator, it is recommended that it be

carefully examined for possible shipping damage. The

generator was given to the freight carrier in good condition;

thus, the carrier is responsible for the product from the

factory dock to the destination. Any damage should be noted

on the freight bill before accepting the shipment. Any claims

for damage must be promptly filed with the delivering carrier.

UNPACKING AND HANDLING

Carefully read all instruction tags shipped with the unit. When

lifting, attach an overhead crane to the lifting lug(s) on the

generator frame. Apply lifting forces in a vertical direction.

When transporting single bearing generators, the generator’s

rotor must be adequately supported to prevent damage.

THE 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.

STORAGE

In the event that the generator is not immediately installed on

its prime mover, it is recommended that the unit be stored

indoors in a clean, dry area which is not subject to rapid

changes in temperature and humidity. If the generator is

stored for a long period of time, the generator should be

tested, cleaned and dried as required before being put into

service. See the maintenance section of this manual for

further information. If the unit has been stored in an area

where it has been subject to vibration, it is recommended that

the bearing(s) be inspected and replaced as necessary.

PRINCIPLES OF OPERATION

FIGURE 1 -- MagnaPLUS

Circuit Diagram

FIGURE 2 -- Typical MagnaPLUS

Layout Diagram

PRINCIPLE OF OPERATION

MagnaPLUS

generators are brushless, self 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 terminology, note the following:

stators are stationary, rotors rotate, a field is a DC electrical

input, and an armature is an AC electrical output. These

system components are electrically interconnected as shown

in Figure 1 and physically located as shown in Figure 2.

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 regulator automatically

monitors the generator's output voltage against an internal

reference set point and provides the necessary DC output

voltage to the exciter field required to maintain constant

generator terminal voltage. The generator's terminal voltage

is changed by adjusting the regulator's reference set point.

Consult the 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 starting current is equivalent to the motors

locked rotor or stall current and is 5 to 10 times normal full

load current. When the generator supplies this in-rush of

starting current, the generator voltage dips temporarily. If the

motor is too large for the generator, the generator’s voltage

dips greater than 30 percent. This may result in the motor

starter de-energizing or the motor stalling. MagnaPlus

generators generally supply .3 to .4 horsepower per

generator KW in motor starting capability. For specific data

contact Marathon Electric.

PARALLEL OPERATION

All MagnaPlus

generators are built with 2/3 pitch main

stator windings and full amortisseur (damper) windings.

These features make the MagnaPlus® generators suitable for

parallel operation when equipped with the proper voltage

regulators and voltage regulator accessories. Consult with the

factory for further information relative to parallel operations.

NONLINEAR LOADING

Solid state electronic control devices (variable frequency

drives, precision motor controls, battery chargers, etc.) utilize

electronic switching circuits (thyristors, SCRs, Diodes, etc.).

These switching circuits introduce high frequency harmonics

which distort the normal wave form of the generator. This

creates additional heat in the generator windings 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 for further information relative to

nonlinear loads.

INSTALLATION

PREPARATION FOR USE

Although the generator has been carefully inspected and

tested in operation prior to shipment from the factory, it is

recommended that the generator be thoroughly inspected.

Check all bolts for tightness and examine the insulation on

lead wires for chafing prior to proceeding with installation.

Remove all shipping tapes, bags, skids and rotor support

blocking. For two bearing units, rotate the shaft by hand to

ensure that it rotates smoothly without binding.

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 NOT

DESIGNED FOR THIS PURPOSE. BARRING OVER

THE SET WITH THE FAN COULD DAMAGE THE FAN

AND RESULT IN PERSONAL INJURY OR

EQUIPMENT DAMAGE.

GENERATOR MOUNTING

Single Bearing Units.

Single bearing units are provided with an SAE flywheel

housing adapter flange and flexible drive discs. Coupling the

generator's shaft to the engine flywheel is accomplished with

special steel drive discs bolted to the shaft. In addition to the

drive discs, there may be a hub spacer, spacer discs, or a

combination of hub spacer and spacer discs inserted

between the drive discs and the shaft to achieve the proper

shaft extension ("G" dimension per SAE J620c). Holes are

provided in the periphery of the coupling discs which

correspond to tapped holes in the prime mover's flywheel.

The outside diameter of the drive discs fit in a rabbet in the

flywheel so that concentricity is assured.

Grade 8 place bolts and hardened washers are recommended

to mount the drive discs to the flywheel. DO NOT USE SPLIT

TYPE LOCK WASHERS. Split lock washers when biting into

the drive disc cause stress risers which may result in the disc

fracturing.

The SAE flywheel housing adapter ring and the engine

flywheel housing are designed to match each other with no

further alignment necessary. Use grade 5 or greater

mounting bolts. MagnaPLUS

generator frames are

constructed with two or three bolt holes per foot. The feet

should be shimmed where necessary to obtain solid contract

with the sub-base. With the frame securely bolted to the

engine flywheel housing, there is no side thrust or pull on the

generator frame, thus no real need to secure the feet with

more than one bolt per foot.

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. It may be

necessary to shim the generator feet for proper

support and alignment. Secure the feet of the generator with

grade 5 or greater bolts through the holes provided in the

mounting feet. Consult the coupling manufacturer's

instructions for alignment specifications and procedures.

GENERATOR MOUNTING

Two Bearing Units -- Belt Driven

Two bearing MagnaPLUS

generators can be belt driven

provided belts are sized and applied correctly. Please refer to

your supplier of belts and sheaves for correct sizing and

tensioning specifications. A bearing life calculation should be

performed. Marathon Electric recommends a minimum B-10

life of 40,000 hours. If cog type belts are used, a vibration may

be introduced which could lead to premature failure of the

bearings.

HYDRAULIC DRIVE WITH SHAFT SPLINE

Two Bearing Units

All 280 PDL MagnaPLUS

two bearing hydraulic drive

generators are equipped with a Zerk grease fitting mounted in

the drive end of the shaft. Prior to assembly to the hydraulic

drive motor, lightly coat the hydraulic drive motor shaft, and/or

grease the generator spline per the greasing instructions in

the MAINTENANCE section, page 12. DO NOT assemble

the generator to the hydraulic drive motor with the spline

dry.

END PLAY TESTING

Refer to the engine manual for recommended end play

specifications and measurement procedures. If end play is

not to specification, it is an indication that the generator shaft

is not moving freely in the assembly, and normal life of the

thrust bearing could be impaired. Probable causes of this

problem are:

1. Improper seating of drive discs in the flywheel resulting in

misalignment.

2. Improper mating of generator frame to engine flywheel

housing resulting in misalignment.

3. Improper "G" dimension per SAE J620c on either the

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 on the entire rotating system. IT IS

THE RESPONSIBILITY OF THE GENERATOR SET ASSEM-

BLER 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.

ENVIRONMENTAL CONSIDERATIONS

The MagnaPLUS

generator is designed for heavy duty

industrial applications; however, dirt, moisture, heat and

vibration are enemies of rotating electrical machinery.

Excessive exposure to the elements may shorten generator

life. The temperature of the cooling air entering the intake

openings of the generator should not exceed the ambient

temperature shown on the generator’s nameplate. Generators

intended for outdoor application should be protected with

housings having adequate ventilation. Although the standard

insulation systems are moisture and humidity resistant, space

heaters are recommended for extreme conditions. If the

generator is to be installed in an area where blowing sand

and dust are present, the enclosure should be fitted with

filters. Filters reduce erosion on the generator's insulation by

blocking high velocity abrasive particles generated by the flow

of cooling air through the generator. Consult the factory for

appropriate filters and generator deratings required.

WIRING CONNECTIONS

Wiring of the generator and accessories should be

done in accordance with good electrical practices.

Follow government, industry and association

standards.

The generator conduit box construction allows cable entry

from multiple sides. A hole saw or other appropriate tool may

be used to provide for conduit entrance. Protect the interior of

the generator from shavings when drilling or sawing. An

approved connector must be used in conjunction with the

conduit. To minimize the transmission of vibration, it is

essential that flexible conduit be used for all electrical

entrance to the generator conduit box.

All MagnaPLUS

generators are equipped with link boards

(terminal strips) for both internal and external connections. All

connections made to the studs of the link board should be

made with high quality ring terminals. Ring terminal sizes are:

6 mm (280 Series Frames) and 10 mm (360 and 430 Series

Frames). Torque link board connections to the

following specifications: 280 frame -- 5.4 NM (4 Ft Lb); 360 &

430 frame -- 27 NM (20 Ft Lb).

Refer to the connection diagram supplied with the generator

and / or the proper diagrams shown in this manual. Install all

inter component and external wiring in accordance with

national and local electrical codes. The neutral in the

following connection diagrams shown below may be either

grounded (earthed) or left above ground potential (floating).

See national and local codes and / or the system distribution

wiring schematic diagram for the proper connection of the

neutral.

The following connection diagrams are shown for twelve

lead generators. Ten lead generators have the same

terminal designations except for leads T10, T11, and T12.

These three leads are internally connected inside the

generator and brought out as a single lead (T0). Ten lead

generators can only be connected in a wye configuration.

HIGH (SERIES) WYE CONNECTION

L - L0

L - L

12 Lead

VOLTAGE (HIGH WYE)

Hz L-L L-Lo

60 380 219

416 240

440 254

460 266

480 277

50 380 219

400 231

415 240

440 254

DEDICATED SINGLE PHASE CONNECTION

HIGH VOLTAGE - SERIES CONNECTED

VOLTAGE (DEDICATED)

Hz L-L L-N

60 240 120

220 110

50 220 110

200 100

SINGLE PHASE CONNECTION - SINGLE VOLTAGE PARALLEL

VOLTAGE

L-L

60 HZ 120

50 HZ 110

Note: For 120 volt only service. Use an

AVC63-4A or a VR63-4C voltage regulator to

replace the standard SE350 regulator.

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.

2. Bar the set over by hand for at least 2 revolutions to be

sure that there is no interference and that the set turns

freely. If the set does not turn freely, check for clearance

in the generator and exciter air gap.

3. Check all wiring against the proper connection diagrams,

and ensure that all connections and terminations are

tight and properly insulated.

4. Verify that all equipment is properly grounded (earthed).

MAGNAPLUS

GENERATORS MAY HAVE VOLTAGE

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. FAILURE TO

DO THIS MAY RESULT IN PERSONAL INJURY OR

EQUIPMENT DAMAGE.

5. Clear the surrounding area of any materials that could be

drawn into the generator.

6. Check all fasteners for tightness.

7. Check all access plates, covers, screens and guards. If

they have been removed for assembly or inspection,

reinstall and check for security.

8. Review all prime mover prestart up instructions, and

ensure that all recommended steps and procedures have

been followed.

9. Remove any masking materials affixed during painting.

Inspect the generator, prime mover, and any accessory

equipment to ensure that nameplates, and all safety

warning / caution signs and decals provided with the

equipment are in place and clearly visible.

Note: It is strongly recommended that the authority

having jurisdiction over the installation site be

consulted to determine if any additional warning or

caution notices, or additional safety devices are

required by local codes / standards. Any such

required notices or devices should be installed prior

to initial startup.

START-UP

The following procedure should be followed when starting the

generator set for the first time.

1. The generator output must be disconnected from the

load. Be sure that the main circuit breaker or fused

disconnect is in the open position.

2. Open the input power to the automatic voltage

regulator. Remove the fuse or disconnect and insulate

one of the regulator input power leads. (See separate

regulator manual)

3. Verify that all prime mover start-up procedures have

been followed.

4. If the unit is provided with space heaters, ensure that

they are de energized. In some installations, a set of

auxiliary contacts on the main circuit breaker or transfer

switch will automatically open the space heater circuit

when the generator is connected to the load.

5. Start the prime mover, and adjust it for proper speed. See

generator nameplate.

6. The purpose of this initial test with the regulator out of the

circuit is to detect any wiring mistakes without exposing

the unit to undue risk. Check all line to line and line to

neutral voltages for balanced voltage. If voltages are

balanced, shut down the set and reconnect the

regulator. If voltages are unbalanced, shut down the

equipment and check for improper wiring. If the

problem persists, consult the factory.

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.

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 RESULT.

7. Start the set and adjust the terminal voltage to the

desired value by means of the regulator voltage

adjustment. If the regulator is equipped with a stability

adjustment, follow the instructions in the regulator

manual to adjust the stability. Again, check all line to line

and line to neutral voltages for balance. It is

recommended practice to record the no load excitation

(DC voltage to the exciter stator), generator terminal

voltage, and driver speed as a benchmark for future

troubleshooting.

8. Close the main circuit breaker to the load.

9. Monitor the generator output current to verify that it is at

or below nameplate value.

10. Check generator speed (frequency) under load. Adjust as

necessary. (Refer to prime mover or governor manuals)

SHUTDOWN PROCEDURE

There are no specific instructions for shutting down the

generator; however, several good practices should be

observed to prolong equipment life.

1. It is advisable to disconnect all loads (open main circuit

breaker or disconnect) prior to shutdown. This is

especially important if loads can be damaged by low

voltage or low frequency conditions during generator

"coast down".

2. Isolate all conditions that could apply voltage to the

generator terminals while the generator is at rest. Failure

to comply could result in personnel injury or equipment

damage.

3. If the unit is equipped with space heaters, verify that the

heater circuit is energized.

MAINTENANCE

The following maintenance procedures should be followed to

ensure long equipment life and satisfactory performance.

Maintenance intervals will depend upon operating conditions.

1. Routinely check intake and exhaust air screens to ensure

that they are clean and free of debris. Clogged intake air

screens will reduce cooling air flow and result in higher

operating temperatures. This will reduce generator life

and may result in generator damage.

2. All MagnaPLUS

generators are equipped with double

shielded ball bearings lubricated for the life of the

bearing. Every 1,000 hours check the bearing(s) for

smooth, quiet operation. For continuous duty generators,

recommended practice is to replace the bearing during

major overhauls of the engine.

3. Periodically inspect the unit for any buildup of

contamination (dirt, oil, etc.) on the windings. If the

wound components have become coated with heavy

concentrations of oil and grime, the unit should be

disassembled and thoroughly cleaned. This operation is

not one that can be accomplished effectively on site, but

rather one that should be conducted by an authorized

service center equipped with the appropriate apparatus

and solvents necessary to properly clean and dry the

generator.

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 RESULT.

4. Every 2,000 operating hours or in conjunction with

scheduled engine maintenance, check the DC no load

excitation voltage per item #7 in the startup procedure.

Compare this voltage with the value recorded during

initial startup. If this value of no load excitation voltage is

markedly higher than the 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 a 500 volt

mega-ohm meter. The minimum acceptable reading is 2

mega-ohms. If the reading drops below the minimum, the

generator should be cleaned and dried at an authorized

service shop. Consult Marathon Electric for more

information.

DRYING WINDINGS

Generators in service may inadvertently have their windings

exposed to splashing or sprayed water. Units that have been

in transit or storage for long periods of time may be

subjected to extreme temperature and moisture changes

causing excessive condensation. Regardless of the source of

moisture, wet windings should be thoroughly dried out before

operating the unit. If this precaution is not taken,

serious damage to the generator can result. The following

procedures may be utilized in drying the generator’s

windings. 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. This

process can be accelerated by enclosing the unit with a

covering and inserting additional heating units. A hole should

be left at the top of the covering to permit the escape of

moisture. Care should be taken not to overheat various

accessory equipment mounted with the generator.

Forced Air

Another method to dry the generator is to run the set with no

excitation (see startup procedure item #2). The natural flow of

ambient air through the generator will tend to dry the

windings. This method can be accelerated by adding a source

of heat at the air intake to the generator. Heat at point of entry

should not exceed 80 C (180° F).

HYDRAULIC DRIVE GENERATORS,

SHAFT SPLINE LUBRICATION

The shaft spline should be greased prior to initial assembly to

the driver, and every three (3) months to reduce maintenance,

and prolong the life of the spline coupling per the following

procedure:

1. Material: Molybdenum Disulfide - sometimes referred to

as “Molly Grease.”

2. Turn the rotor assembly so that the Zerk fitting is in line

with the access hole in the top of the drive end bearing

bracket as illustrated in Figure 3.

3. Using a hand held grease gun with a solid coupling,

apply a small amount of grease into the fitting. DO NOT

OVER GREASE. Limit the amount of grease to one (1)

trigger pull of the grease gun.

Figure 3--Drive End Bearing Bracket

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 generator’s air gaps (main rotor and exciter) are free

from obstructions. If possible, rotate the generator manually

to ensure free rotation. Never “bar over” the engine generator

set using the generator fan.

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 RESULT.

CONSTANT EXCITATION TEST

(12V BATTERY TEST)

The generator “no load” voltage is dependent on exciter input

voltage and generator speed. With the generator operating at

rated speed and 12 volts dc applied to the exciter field, the

generators terminal voltage will be near rated value.

1. Shutdown the generator set and connect a voltmeter on

the generator terminals.

2. Disconnect the regulator’s F+ (F1) and F- (F2) leads and

connect them to a 12V battery. Caution should be taken

to ensure that the battery is not exposed to any

potential arcing.

3. With no load on the generator (main breaker open) run

the generator at rated speed. Measure the generator’s

terminal voltage and compare this value with values

recorded during installation.

If voltage readings are normal, the main generator and

excitation are operating properly. Troubleshooting should

continue with the regulator. If readings are not normal the

problem is in the generator. Continue testing diodes, surge

suppressor, and windings.

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 precision equipment to make accurate

measurements; however, a standard ohm meter will provide a

good indication of winding continuity.

Shaft Mounted

Zerk Fitting

Grease Gun

Access Hole

Insulation Test

Insulation resistance is a measure of the integrity of the

insulating materials that separate the electrical windings from

the generator’s steel core. This resistance can degrade over

time or be degraded by contaminants: dust, dirt, oil, grease,

and especially moisture. Most winding failures are due to a

breakdown in the insulation system. In many cases, low

insulation resistance is caused by moisture collected when

the generator is shutdown

Insulation resistance is measured with a megger (mega-ohm

meter). A megger measures insulation resistance by placing

500 volts between the winding and the frame of the

generator. Caution must be taken to remove all electronic

devices (regulators, diodes, surge protectors, capacitors,

protective relays, etc.) from the winding circuit before

checking the insulation. Winding insulation can be checked on

the main stator, main rotor, exciter stator, and exciter rotor.

Minimum resistance is 2 mega-ohms. If the winding

resistance is low it must be dried (see maintenance section)

or repaired.

DIODE TESTING

If the generator is close coupled to an engine, it may be

necessary to "bar over" the engine in order to gain access to

a given area of the rectifier assembly. NEVER use the

generator's fan as a fulcrum to accomplish this. Use the

engine manufacturer's recommended practice to manually

turn over the engine. To prevent possible injury to personnel,

and damage to the equipment, ensure that the engine

cannot start during this procedure.

Remove the two main rotor leads and the three exciter rotor

leads from the rectifier assembly (Figure 5). The rectifier

assembly is now electrically isolated from the generator. The

diodes remain mounted and the diode leads remain

connected to the terminal posts. Using an ohmmeter or a

battery light continuity tester, place one test probe on the

diode lead terminal post. In succession, touch the other test

probe to the lead screw hole in each heat sink. Reverse the

probes and repeat the procedure. You have now tested the

three diodes connected to this terminal post in both the

forward and reverse direction. Repeat the procedure using

the other diode terminal post.

FIGURE 4: DIODE POLARITY

When the positive test probe is connected to the diode's

anode and the negative test probe is connected to the diode's

cathode (forward biased), the diode will switch on and

conduct electricity (Figure 4). This is observed by a low

resistance reading when using an ohm meter or the lighting

of the bulb when using a battery light continuity tester.

Reversing the test leads (reverse biased) will result in the

diode switching off and no electricity will be conducted. The

results of these tests should indicate one of three conditions:

1. Good diode: Will have a much greater resistance in one

direction than the other. Typical reverse biased resistance

will be 30,000 ohms or greater, while forward biased

resistance will be less than 10 ohms. The battery light

tester will have the light "on" in one direction and "off" in

the other.

2. Shorted condition: Ohmmeter reading will be zero, or

very low in both directions. The continuity tester will have

the light "on" in both directions.

3. Open condition: Ohmmeter will have a maximum

(infinity) reading in both directions. Continuity tester light

will be off in both directions.

Diode failure after a 25 hour "run in" period is generally

traceable to external causes such as a lightning strike,

reverse current, line voltage spikes, etc. All 6 diodes are

essentially in the same circuit. When a diode is stressed to

failure, there is no easy method to determine remaining life in

the other diodes. To avoid possible continued failures, it is

recommended that the entire rectifier assembly be replaced

rather than replacing individual diodes.

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 should be conducted by qualified maintenance

personnel. Replacement parts may be ordered through an

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.

Terminal End

Anode

(+)

Cathode

(-)

Stud End

Cathode

(-)

Anode

(+)

Forward

Reverse

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 drawn, 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

out, the rotor will drop on the main stator core. Having the

rotor in this position will limit the amount of rotor drop to that

of the air gap. Visually inspect the bearing bore for damage or

wear. If worn or damaged, replace prior to reassemble.

Opposite Drive End Bearing Bracket Removal.

Prior to proceeding with bracket removal, disconnect exciter

field leads F+ and F- from the automatic voltage regulator and

ensure that they are free to move when the bearing bracket is

removed. Remove the bearing bracket retaining bolts. Using a

pair of screw drivers, wedge the bracket off the frame. After

approximately 1/8 inch, the bracket will clear the locating

the main stator core. Continue to pull the bracket free from the

bearing. Visually inspect the bearing bore and o-ring (if

equipped) for damage or wear. If worn or damaged, repair or

replace prior to reassembly.

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 before proceeding further. A

hoist and sling, jack, or some other means of support with a

capacity of 2 tons should be used.

Remove the bearing bracket retaining cap screws. Using a flat

bladed screw driver or chisel, pry the bracket back from the

frame. After approximately 1/8 inch, the bracket will clear the

locating register on the frame. Lower the shaft extension until

the rotor is resting on the main stator core. 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.

Reassembly note: Before the bearing bracket is seated

against the frame, a threaded rod may be used to help align

the inner bearing cap with the bearing bracket.

BEARING REPLACEMENT

Using a bearing puller, remove the existing bearing. It is

strongly recommended that the bearing be replaced any time

the it is removed from the shaft. ALWAYS install the same

type and size bearing that was supplied as original

equipment. Order by part number from the parts list, and

include the unit serial number and part number when

ordering. Heat the bearing to a maximum of 100°C (212°F) in

an oven. Apply a thin coat of clean lubricating oil to the press

fit area of the rotor shaft. Using suitable heat resistant gloves,

install the bearing over the end of the shaft until it seats

against the shaft shoulder. The bearing should slide on the

shaft and be seated without excessive force. Should the

bearing bind on the shaft prior to being seated against the

shoulder, a piece of tubing slightly larger than the press fit

area can be used to drive the bearing to its final position.

Using light taps with a soft mallet, apply pressure to the inner

race only.

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 5). 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 resoldered

on the replacement.

RETURNED GOODS

Contact Marathon Electric Manufacturing Corporation for

authorization before returning any product. We can not be

responsible for any items returned without authorization.

Single bearing generators must have their rotor

assembly properly secured to prevent damage during

transit to the factory, or to an authorized service cen-

ter.

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

steps have been arranged in an attempt to do the easy

checks first and prevent further damage when

troubleshooting a disabled machine.

The first step of troubleshooting is to gather as much

information as is possible from operating personnel and

individuals present during the failure. Typical information

includes: how long the unit had been operating; what loads

were on line; weather conditions; protective equipment that

did or did not function. In addition, information as to the

operating condition of the generator's prime mover is vital.

Has the prime mover been maintaining constant speed? If

not, have there been extended periods of under speed

operation? Has the prime mover experienced an over-speed

condition? If yes, what was the maximum speed, and how

long did the unit operate at that elevated speed?

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.

430 FRAME 280 / 360 FRAME

A - Exciter Rotor Lead, B - Main Rotor Lead, C - Red (+) Suppressor Lead, D - Black (-) Suppressor Lead

FIGURE 5: ROTATING RECTIFIER ASSEMBLY

HIGH VOLTAGES MAY BE PRESENT AT THE GENERATOR’S TERMINALS WHEN THE UNIT IS RUNNING. SOME

ACCESSORY EQUIPMENT SUCH AS SPACE HEATERS MAY BE ENERGIZED FROM AN OUTSIDE POWER SOURCE

WHEN THE UNIT IS AT REST. TOOLS, EQUIPMENT, CLOTHING AND YOUR BODY MUST BE KEPT CLEAR OF

ROTATING PARTS AND ELECTRICAL CONNECTIONS. SPECIAL PRECAUTIONS MUST BE TAKEN DURING

TROUBLESHOOTING SINCE PROTECTIVE COVERS AND SAFETY DEVICES MAY BE REMOVED OR DISABLED TO

GAIN ACCESS AND PERFORM TESTS. BE CAREFUL. SERIOUS PERSONAL INJURY OR DEATH CAN RESULT FROM

THESE HAZARDS. CONSULT QUALIFIED PERSONNEL WITH ANY QUESTIONS.

GENERATOR PRODUCES NO VOLTAGE

CAUSE CHECK AND REMEDY

Voltmeter off or defective Check voltage with a separate meter at the generator terminals.

Incorrect or 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 windings Test the generator using the 12 volt battery test as specified in the testing section. If

the results indicate generator problems, perform insulation, continuity, and diode tests

as specified in the testing section.

Regulator protection operating Adjust 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 or defective connections Verify generator connections. See drawings supplied with the generator or lead

connection diagrams in this manual. Inspect all wiring for grounds, open circuits and

short circuits.

Loss of regulator power Check regulator fuse and input power. Input power is produced by the generator’s

residual voltage or from an optional PMG.

Regulator adjustment Adjust regulator settings. Consult regulator manual.

Regulator incorrectly connected Review the generator connection diagram or reference the regulator manual.

Defective diodes, suppressor, or windings Test the generator using the 12 volt battery test as specified in the testing section. If

the results indicate generator problems, perform insulation, continuity, and diode tests

as specified in the testing section.

Regulator inoperative Adjust or replace regulator. Consult regulator manual.

WARNING

GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD APPLIED

CAUSE CHECK AND REMEDY

Excessive load Reduce load. The load on each leg should be evenly balanced, and rated current

should not be exceeded on any leg.

Large motor starting or low Motor starting currents are too large for the generator. When starting multiple motors,

load power factor sequence the motors and start the largest motors first. Reduce lagging power factor

load.

Driver speed droop or belt slip Check driver. If belt driven, check belt tension. Check under frequency setting on

regulator. Under frequency voltage roll-off may be activated.

Reactive droop If the generator is equipped for parallel operation, some droop is normal as reactive

load increases. When operating as a single unit, the parallel CT can be shorted to

eliminate this effect. Refer to Regulator manual.

Line drop If voltage is proper at generator terminals but low at load terminals, increase external

wire size.

Defective diodes, suppressor, or windings Test the generator using the 12 volt battery test as specified in the testing section. If

the results indicate generator problems, perform insulation, continuity, and diode tests

as specified in the testing section.

GENERATOR PRODUCES FLUCTUATING VOLTAGE

CAUSE CHECK AND REMEDY

Fluctuating engine speed Check engine and governor systems for malfunctions. Check load for fluctuation.

Regulator stability Adjust Regulator stability. Refer to Regulator manual.

Regulator external rheostat Replace defective or worn rheostat. Use shielded cable to minimize electrical noise.

Defective rectifier assembly Check assembly for loose connections. Test the diodes as specified in the test section.

Loose terminal or load connections Improve connections both mechanically and electrically.

Defective regulator Replace regulator.

GENERATOR PRODUCES HIGH VOLTAGE

CAUSE CHECK AND REMEDY

Faulty metering Check voltage with separate meter at generator terminals.

Incorrect connections Verify generator connections. Refer to drawings supplied with the generator or

connection diagrams in this manual.

Regulator adjustments Adjust regulator. Consult regulator manual.

Leading power factor Check the power factor of the load. If power factor is leading, change load

configuration. Excessive leading power factor (capacitors) can cause voltage to climb

out of control.

Incorrect regulator connection Verify regulator voltage sensing is connected correctly. Consult regulator manual.

Defective regulator Replace regulator.

GENERATOR BUILDS VOLTAGE FROM STARTUP,

THEN GOES TO LOW (RESIDUAL) VOLTAGE

CAUSE CHECK AND REMEDY

Regulator protective circuit operating Check indicators on regulator. Correct problems and adjust regulator as is required.

Refer to regulator manual.

GENERATOR IS OVERHEATING

CAUSE CHECK AND REMEDY

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.

Insufficient circulation of 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 guard fasteners.

EQUIPMENT RUNS NORMALLY ON UTILITY POWER,

BUT WILL NOT RUN ON GENERATOR SET

CAUSE CHECK AND REMEDY

Distorted voltage waveform Analyze load. Excessive SCR (thyristor) loading will cause distortion. Some equipment

may be sensitive to distorted waveforms. Refer to Marathon Electric..

Improper generator voltage or frequency Check name plates of devices comprising the load. Compare required voltage and

frequency with that of the generator. Adjust driver speed and/or generator voltage as

necessary to match generator output to load requirements.

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

STATOR ROTOR

281, 282, 283, 284, 285, 286, 287 18.0 .120

361, 362, 363 -- three phase 23.5 .120

361, 362, 363 -- dedicated single phase 23.0 .135

431, 432, 433 -- three phase 18.5 .120

431, 432 -- dedicated single phase 18.0 .105

EXCITER FIELD

MODEL GENERATOR RESISTANCE NO LOAD VOLTS

STATOR* ROTOR 480 V / 60 HZ

281PSL1500 4.20 .400 11.0

281PSL1501 4.15 .400 11.0

281CSL1502 0.47 0.72 6.40

281PSL1502 3.20 .439 9.0

282PSL1703 1.07 0.34 14.70

282CSL1504 1.24 0.80 6.20

282PSL1704 1.07 0.34 14.70

282CSL1505 0.87 0.90 5.80

282PSL1705 0.74 0.37 14.35

283CSL1506 0.54 1.00 8.20

283PSL1706 0.45 0.40 12.95

283CSL1507 0.44 1.18 9.20

283PSL1707 0.39 0.46 11.20

284CSL1508 0.29 1.36 10.00

284PSL1708 0.27 0.52 14.18

284CSL1542 0.27 1.36 8.30

284PSL1742 0.22 0.54 14.00

285PSL1700 0.20 0.58 11.90

286PSL1701 0.14 0.72 10.68

287PSL1702 0.12 0.79 10.9

361CSL1600 .381 .750 11.8

361CSL1601 .264 .810 12.5

361CSL1602 .181 .990 14.1

362CSL1604 .138 1.05 12.2

362CSL1606 .098 1.20 10.8

363CSL1607 .069 1.37 12.2

431CSL6202 .021 .811 15.1

431CSL6204 .048 .637 13.6

431CSL6206 .037 .679 13.82

431CSL6208 .013 .715 12.20

432PSL6210 .021 .811 15.1

432PSL6212 .023 .866 14.1

433PSL6216 .012 1.067 16.2

433PSL6220 .012 .974 15.6

DEDICATED EXCITER FIELD

SINGLE GENERATOR RESISTANCE NO LOAD VOLTS

PHASE STATOR ROTOR 480 V / 60 HZ

281PSL1500 4.20 .400 11.0

281CSL1513 0.47 0.72 4.3

281PSL1511 1.420 .381 8.3

281PSL1512 1.106 .395 8.1

281PSL1513 .632 .430 8.7

282CSL1515 0.21 0.82 6.2

282PSL1714 0.19 0.35 13.0

282PSL1715 0.19 0.35 13.0

282PSL1716 0.11 0.36 12.4

283CSL1517 0.08 1.14 12.7

283PSL1717 0.5 0.41 11.8

283PSL1718 0.07 0.46 10.1

284CSL1518 0.06 1.41 12.5

284CSL1550 0.05 1.48 16

284PSL1750 0.05 0.55 11.1

285PSL1711 0.04 0.58 11.0

286PSL1712 0.03 0.71 9.7

287PSL1713 0.02 0.78 12.3

361PSL1611 .070 .750 17.5

361PSL1612 .043 .857 16.1

361CSL1613 .037 .926 13.6

362CSL1615 .019 1.20 17.0

363CSL1617 .012 1.35 23.0

431PSL6222 .025 .516 9.9

431PSL6224 .013 .615 13.8

431PSL6226 .009 .643 15.1

432PSL6228 .007 .852 11.2

* Stator resistance measured line to line in a high wye

connection.

PARTS LIST – SINGLE BEARING

Typical Generator Cross Section

13 14

20 19

Reference Part Name Reference Part Name

Number Number

1 End Bracket (under end cover 360 & 430 frames) 11 Main Stator

2 Bearing 12 Main Rotor

3 O-ring (280 and 360 frame only) 13 Rotor Integral Keyway

4 Rectifier Assembly 14 Fan

5 Air Intake Cover 15 Mounting Adapter (SAE)

6 Exciter Rotor 16 Shaft

7 Exciter Stator 17 Drive Hub

8 Link Board (terminal block) 18 Drive Disk (SAE)

9 Conduit Box 19 Exhaust Screen (drip cover not shown)

10 Generator Frame 20 Mounting Base

Note: Illustration above is a 360 frame MagnaPLUS

. Other Frame sizes are typical. Optional PMG not shown. The generator

model and serial numbers are required when ordering parts.

DESCRIPTION PART NUMBER

1. END COVER 02HB30

2. ROTOR BEARING 02BRG30

3. EXCITER ROTOR 02RTR30EXC

4. EXCITER STATOR 02STA30EXC

5. GENERATOR ASSEMBLY 02GEN1517

VOLTAGE REGULATOR 06REG350SE

“MAGNAPLUS” SERIES EXCITER TYPE GENERATOR ASSEMBLY

MARATHON SE350 VOLTAGE REGULATOR

The SE350 electronic voltage regulator is designed to control the output of a brush less AC

generator by regulating the current into the exciter field. Features include frequency compensation,

automatic voltage build-up and EMI suppression. The SE350 attaches to the generator with spade

type wire terminals for a secure connection. The SE350 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 a sealing compound, which provides protection from environmental

hazards.

SE350 Specifications:

Sensing and Power Input 190 – 240V AC

Burden 500VA

Output Power – Continuous 73V DC at 3.5 Amps DC (255W)

Output Power – Forcing 105V DC at 5 Amps DC (525W)

(240V AC input Power)

Regulation 1.0%

Frequency Compensation Adjustable

Roll Off Frequency 54 - 61 Hz for 60 Hz Operation

45 - 51 Hz for 50 Hz Operation

Voltage Build-Up Internal provisions for automatic voltage build-up

From generator residual voltage as low as 10V AC

EMI Suppression Internal Electromagnetic Interference Filter (EMI Filter)

3 ADJUSTABLE POTENTIOMETERS, ACCESSED FROM OTHER SIDE

JUMPER JUMPER

MARATHON SE350 VOLTAGE REGULATOR

WARNING: To prevent personal injury or equipment damage, only a qualified service

technician should install, operate or service this device.

IMPORTANT: DO NOT megger or high-pot the generator while the regulator is

connected. DO NOT high-pot the regulator.

VOLTAGE ADJUST:

A screwdriver adjustable potentiometer adjusts the generator output voltage. Adjustment

clockwise increases the generator output voltage.

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. If

the stability of the regulator is decreased too much, the generator will tend to hunt under

steady state conditions. A 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 stability 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 the 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 counterclockwise until the voltage starts to

drop off. Then adjust the potentiometer clockwise until the voltage returns to rated. Re-

adjust engine speed to rated speed.

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

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 240V AC.

A 4 Amp 250V – 5x20 mm fuse is supplied with

the re

ulator.

MARATHON SE350 VOLTAGE REGULATOR

START-UP PROCEDURE:

Ensure the voltage regulator is correctly connected to the generator. Refer to the specific connection

diagram supplied with the generator. Set the regulator voltage adjust to full counter-clockwise

(minimum voltage level). Set the stability control full clockwise (maximum stability level). Connect the

positive lead of a 100V DC voltmeter to F1 and the negative lead of the voltmeter to F2 or use an

appropriate AC voltmeter on the generator output leads.

Start and run the generator at no load and rated speed. The generator voltage should build up to a

minimum level. (Actual level is dependent upon connection). If it does not build up, refer to field

flashing section in generator manual. Slowly adjust the voltage control until the generator voltage

reaches the normal value. Turn the stability adjust counter-clockwise until instability is shown on the

voltmeter. 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 is necessary. If the generator does not

remain stable increase the stability slightly and interrupt regulator power again. Repeat this procedure

until system stability is reached and maintained.

TROUBLESHOOTING

SYMPTOM CAUSE ACTION

Residual Voltage

No Output

Residual Voltage at regulator power

input wires 3&4 below 10V AC.

Acceleration time to rated speed too long.

Field leads F1, F2 not connected.

Power input leads not connected.

Blown or missing fuse.

Defective regulator.

Defective generator.

Check wiring diagram for proper

connections.

Flash generator field.

Reduce acceleration time.

Interrupt power input to regulator after

achieving rated speed.

Connect field leads F1, F2.

Connect power input leads 3,4.

Replace fuse.

Replace regulator.

Consult generator manual.

Output Voltage Low Incorrect connections.

Voltage adjust turned down.

Defective regulator.

Check wiring diagram for proper

connections.

Rotate voltage adjust CW until desired

voltage is reached.

Replace regulator.

Output Voltage High Voltage adjust turned too high.

Rotate voltage adjust CCW until desired

voltage is reached.

Output Voltage High

No Adjustment

Defective regulator. Replace regulator.

Generator Output

Voltage Hunting

Stability adjust not set properly. Rotate the stability adjust in a CW

direction until hunting stops.

Poor Regulation Defective regulator. Replace regulator.

120 / 240 VOLT CONNECTION “M” SERIES EXCITER TYPE

RESISTANCE CHART

Marks Color

Main Stator Less Than 1.0

Ohm / Phase

T1-T2 T3-

Black / Black

Main Rotor 2.10 N/A N/A

Exciter Stator 23.0 – 28.0 F+ – C Black / Black

Exciter Rotor 0.655 – 0.720 N/A N/A

Aux. Winding 1.0 – 1.4 E1 – E4 Black / Black

SECTION 4

“INSTALLATION”

SAFETY PRECAUTIONS 1-2

Hot Piping

Dangerous Fuels

Explosive Battery Gases

Electrocution

Moving Parts

High Voltage

Explosion

Hot Coolant

Lethal Exhaust Gas

Excessive Noise

Electrical Shock

Backfire

Flash Fire

Fire Hazard

Marine Application

Unit Starts Without Notice

Loose Components

GENERATOR INSTALLATION in RECREATIONAL VEHICLES 3-6

Introduction

Marine Application

General Information

Specification Charts

Fuel Consumption in Gallons per Hour

Installation Factors

Generator Compartment Size

Compartment Frame

Air Requirements

SYSTEMS CONNECTION 7-10

Remote Radiator Cooling System

Fuel System

Exhaust System

Fuel Line Diagram

ELECTRICAL CONNECTIONS 11-13

Electrical Wiring

AC Load Lead Connections

Motor Loads

Kilowatt De-Rating

Electrical Loads

Appliance Loads

Extension Cords

SAFTEY PRECAUTIONS

A generator set can be potentially 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. Always 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 is 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 is a potential danger of electrocution. Apply the same precautions to the

vehicles electrical appliances as you would for any home appliance. Keep away from

electrical circuits and wiring while the generator set is 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.

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 is 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

discharged 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 in 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 store 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 in 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 if components become

dislodged or misaligned.

GENERATOR INSTALLATION

In RECREATIONAL VEHICLES

INTRODUCTION

Use this section as a guide when installing a generator set in a recreational vehicle, and then refer

to the appropriate operation section for specific instructions. When installing a EC generator set the

installation must comply with the current Safety Standards of ANSI / RVIA EGS-1-2003, ANSI A 119.2

/ NFPA 501C and applicable articles of ANSI / NFPA 70 of the National Electrical Code. Generator set

installations must also comply with state and local requirements.

MARINE APPLICATION

EC generator sets do not comply with United States Coast Guard (USCG) requirements and must

not be used for marine applications. Use only generator sets specified for marine use in marine

installations. USCG regulation 33CFR183 requires a generator set to be “ignition protected” when used

in a gasoline fueled environment.

GENERAL INFORMATION

This information section covers the EC generator set models listed below. To determine which

model is involved, check the model number found on the Power Technology nameplate attached to the

frame of the generator being installed. Follow all instructions to ensure proper installation and operation.

Each generator set features a Kubota diesel engine, rotating-field alternating current generator,

and a control box. The generator is directly connected to the engine for permanent alignment. Each

control box includes a Start / Stop switch, and a On /Off switch to reset the control module or lockout

any remote switch to prevent starting while service is being performed. After the set is attached to the

frame of the vehicle, all that is usually required to make it operational is the following.

1. Attaching the exhaust system.

2. Add proper amount of radiator coolant.

3. Add oil to crankcase, to the dipstick FULL mark.

4. Connect fuel lines, remote switch, load leads and battery terminals.

(Consult the Specification Charts on the Following Pages for Requirements)

NOTE: * Dimensions and Weight may differ depending on options and configuration variables.

MODELS PT20-EC PT20-ECRR PT25-EC PT25-ECRR

DIMENSIONS L x W x H * 56” x 28 ” x 28 ” 56” x 28 ” x 28 ” 56” x 28 ” x 28 ” 56” x 28 ” x 28 ”

WEIGHT * 950 lbs. 950 lbs. 950 lbs. 950lbs.

ENGINE Kubota V2203-M Kubota V2203-M Kubota V2003-M-T Kubota V2003-M-T

RPMs 1800 1800 1800 1800

KW RATING 20 20 25 25

AC VOLTAGE 120 / 240 120 / 240 120/240 120/240

AMPERAGE 166/83 166/83 200/100 200/100

Hz 60 60 60 60

PHASE 1 1 1 1

GENERATOR

COMPARTMENT

FREE AIR OPENING

400

Square Inches

400

Square Inches

400

Square Inches

400

Square Inches

RADIATOR AIR

REQUIREMENTS

2120 CFM 2120 CFM 2120 CFM 2120 CFM

SPECIFICATION CHARTS

FUEL CONNECTION ¼” NPT

FUEL RECOMMENDATION DIESEL FUEL No.1-D or No.2-D ASTM / D975

BATTERY VOLTAGE 12 VOLTS DC

BATTERY CRANKING AMPS 420

BATTERY COLD CRANKING AMPS 590 MINIMUM

BATTERY GROUND NEGATIVE

CHARGING AMPS. 40

FUEL CONSUMPTION IN GALLONS PER HOUR

LOAD PERCENTAGE 20KW 25KW

25% .39 GPH .45 GPH

50% .79 GPH .90 GPH

75% 1.18 GPH 1.35 GPH

100% 1.57 GPH 1.80 GPH

INSTALLATION FACTORS

Each generator set is received as a unit except for the optional exhaust system components,

which are shipped loose for assembly after the set is installed in the vehicle. When preplanning the

installation, the following factors must be considered.

1. COMPARTMENT SIZE: Will there be sufficient room around the set to maintain

the minimum clearance of one (1) inch?

2. AIR REQUIREMENTS: Are the compartment air inlets and outlets sized to allow

adequate circulation of air for cooling and combustion?

3. COMPARTMENT FLOOR: Is the compartment floor strong enough to support the

weight of the generator set?

4. COOLING SYSTEM: Is the cooling system large enough to adequately cool the

generator set? **

5. FUEL SYSTEM: Is the fuel system properly designed to prevent fuel

starvation of either the main engine or generator engine?

6. EXHAUST SYSTEM: Will the exhaust system meet all Local, State and Federal

safety requirements?

7. ELECTRICAL CONNECTIONS: Will all systems, (battery, load and remote switch)

be compatible with the vehicles system?

** NOTE: When using a radiator not supplied by Power Technology consult your radiator

manufacturer to ensure that heat rejection values are met.

GENERATOR COMPARTMENT SIZE

In planning the size of the generator compartment allow for the minimum clearance of one (1)

inch necessary to adequately cool the generator set. The thickness of insulation and sound deadening

material used to line the compartment must be taken into consideration when planning this clearance. To

maintain minimum clearance it may be necessary to enlarge the compartment.

NOTE: For Gensets mounted inside an enclosure please refer to the section on “Generator Enclosures”

for additional information and mounting requirements.

The generator set must be securely fastened to avoid unwanted movement from vibration and

road shock. If the unit is equipped with a mounting tray the tray is usually supported with structural

framing. Be sure to use all mounting holes in the tray to secure the tray to the structural framing. Units

not equipped with mounting tray are secured by attaching Genset mounts (two front and two rear)

directly to the structural framing. Skid mounted units can either be affixed to a tray for tray mounting or

attached directly to the structural framing. The generator is easily moved in and out of the coach by

incorporating a slide rack carriage with rollers into the structural framing. When designing the

compartment allow sufficient access for routine maintenance and for removal when major service is

required. Also keep in mind that the compartment or door must have an air intake opening equal to or

greater than that specified under the “Air Requirements” section of this manual. Make sure that the

compartment is vapor tight and completely sealed off from the inside of the vehicle to prevent any

hazardous fumes from entering the vehicle. Avoid road splash and the possibility of igniting

combustible materials beneath the coach by enclosing all unnecessary free space beneath the generator

compartment.

Line the compartment with a good sound deadening material. The material selected must be

fireproof or highly fire resistant. 3-layer foam sound mat is very efficient for absorbing generator noise.

This type of material is easily cut to size and can be quickly installed using the appropriate fire resistant

adhesive. Other materials such as fiberglass insulation with heat barrier may also be used.

NOTE: Since a Genset is flexibly mounted the minimum clearance of one (1) inch will assure that the

unit will not rub the sides of the compartment while the unit is in operation or while the vehicle is in

transit.

COMPARTMENT FRAMING

The generator must be bolted to a structural frame, which is either bolted or welded to the frame

of the vehicle. This structural frame must be designed to withstand a minimum force of 5Gs in any

direction. The structural frame must support the entire outer perimeter and center section of the unit’s

base. Additional framing may be required if excessive movement or vibration occurs.

AIR REQUIREMENTS

Each Genset is equipped with a high ambient temperature shutdown switch and a high water

temperature shutdown switch, which will automatically shut down the Genset if the ambient temperature

or water temperature rises too high. To prevent the generator set from shutting down make sure the

compartment openings are large enough to allow adequate circulation of cooling air. The minimum free

air opening into the compartment is 400 sq. in. or 2580 sq. cm. Remember that louvers, screens and

protective grills will restrict airflow. A relatively open mesh screen can restrict airflow by as much as

45%. The intake opening will need to be increased in size to compensate for such restrictions.

NOTE: Ambient temperature is defined as the generators normal operating temperature within its

mounting area. In an RV application this area is referred to as a compartment or enclosure.

AIR REQUIREMENTS CONT’D

*Combustion Air Temperature: The output of the engine will decrease about 1% for

every 10°F of air temperature above 77°F or 25°C.

IMPORTANT: Insulation and Sound Absorbing Material used inside of the generator compartment

Must Not reduce the specified airspace clearance of one (1) inch or restrict the airflow around the

generator. Such reduction in airspace may lead to an overheating situation and reduced generator

performance. Also be sure the air inlet and outlet openings meet the specified requirements. Allow

clearance inside the generator compartment for easy access when routine maintenance is required.

WARNING: The generator compartment Must Be sealed to prevent hazardous fumes and vapors from

entering the vehicles other compartments and interior spaces. Plugging holes and sealing all seams will

greatly reduce this hazard.

WARNING: Drip Proofing! When installing a generator, the area directly beneath the generator end of

the unit must incorporate a non-flammable barrier. This barrier needs to be made of sufficient material

able to withstand and prevent molten metal, burning insulation, flaming or sparking particles from

penetrating the compartment floor or dripping beneath the compartment.

20 / 25 KW

ENGINE SPEED IN RPM 1800

OUTPUT IN HORSEPOWER 32.5 / 36.6

WATER FLOW – GAL. / MIN. 8.75

ENGINE INLET WATER TEMP. N/A

THERMOSTAT – RATING 180°F

THERMOSTAT FULL OPEN 195°F

ENGINE OUTLET WATER TEMP.MAX. 235°F

HIGH TEMP. SHUTDOWN SWITCH 230°F

HEAT REJECTION – BTU / MIN. 1650

HEAT REJECTION – BTU / HR. 99,000

REMOTE RADIATOR

AIR FLOW – CU. FT. / MIN.

1920

ENGINE OIL TEMP. MAX. 268°F

COMBUSTION AIR TEMP. * N/A

SYSTEMS CONNECTION

REMOTE RADIATOR COOLING SYSTEM

Use the following data in designing and installing the generator set cooling system. To insure a

safe effective installation, be sure the cooling system selected follows these parameters. Power

Technology offers radiator assemblies, which meet these requirements and will adequately cool the

generator. Select the radiator assembly best suited for the generator installation.

Due to the multitude of coach manufacturers and the variety of generator installations, only

general guidelines are provided. Adapt these recommendations to the installation. In a typical

installation the radiator assembly is installed in the same compartment as the generator. If a blower fan

radiator assembly is used, cooling air is drawn across the generator and engine and then through the

radiator. If a suction fan radiator assembly is used the suction fan pulls cooling air through the radiator

and then past the generator set. If the radiator assembly alone is used the installer must supply an electric

blower or suction fan to circulate the cooling air. See the specification table for total air requirements.

Depending on space limitations the radiator can be located in front of, adjacent to, or in a ventilated

remote location from the engine compartment, no more than 10 feet from the generator. To prevent re-

circulation of heated air be sure to maintain a tight seal between the radiator and the discharge chute.

Generally the discharge chute opening should be approximately one and one half times the size of the

radiator core.

NOTE: If the radiator is to be located in a compartment separate from the engine, refer to the engine

combustion air and heat rejection requirements of the generator and engine block when designing the

cooling system. A supplemental cooling fan capable of 500cfm (28.m³/min) should be installed to

supply air to the generator compartment for these requirements.

Connect the radiator fan motor to the generator output leads L1 and L2. Be sure the radiator fan

motor rotates in the correct direction and is of the proper voltage. To protect against overload and short

circuits it is recommended that the motor be adequately fused. Install fuses between the motor and

L1 / L2 connection. A close relationship exists between the cooling system design and the generator

compartment size. Availability of space is often the determining factor in the cooling system design. See

the “Compartment Size” section of this manual prior to designing and installing the generator cooling

system.

CAUTION: The fill inlet and reservoir tank must be located at the highest point in the cooling system.

If the fill inlet is not located as directed, coolant will not completely fill the engine. The cooling system

must be purged of all air pockets for the system to function properly. If air pockets remain in the engine

the high water temperature shutdown switch will malfunction and cause the engine to over heat. Also if

the cooling system is not completely full, the low water level shutdown switch will prevent normal

engine operations.

REMOTE RADIATOR ASSEMBLY

SYSTEMS CONNECTION

FUEL SYSTEM

The diesel fuel system for the generator set must be designed to operate independently from the vehicles

main engine if both engines are to be operated at the same time. The best way to do this is to have separate fuel

tanks, but this is usually impractical because of space restrictions. In most installations both engines operate

from a common fuel tank with separate pick-up tubes for each engine, not a Tee fitting arrangement. This

prevents either or both engines from being starved for fuel. The generator set fuel pick-up tube is generally

shorter than the vehicles; therefore fuel may not be available to the generator when fuel supply is low. This will

prevent the generator from depleting the fuel supply needed by the main engine.

NOTE: Using a simple Tee fitting to supply both engines from a common fuel line is not recommended. This

practice may possible cause a fuel starvation situation to either or both engines. Also, if excessive pressure were

to build up in the main supply line it could possible cause a failure of the generators fuel lines or connectors and

a hazardous fuel leak may occur.

Care must be taken when routing the fuel line from the main tank to the generator set. Keep the fuel line

as short as possible while maintaining adequate clearance from the exhaust system. Fuel lines must be run along

the frame side rails or coach under carriage. Never run fuel lines inside of the coach. Securely fasten the fuel

lines with hardware that is recommended for the type of fuel line used. The fuel lines should enter the generator

compartment at a point nearest to the generators fuel line connection fittings. Allow for a minimum of 8inches

of flexible fuel line to make the connection. Use proper size fuel line to accommodate the fuel flow needed.

Steel fuel line or high quality fuel hose is recommended, either one should have a minimum of ¼” ID and

strong enough to withstand road and climatic conditions.

EXHAUST SYSTEM

Exhaust system components will vary from one installation to another; therefore a muffler and tailpipe

may not always be furnished with the Genset. However, it is imperative to install a muffler and tailpipe to

reduce exhaust noise and direct exhaust gases beyond the vehicles perimeter and away from the normal head-on

air stream. Install a tail pipe with as few bends as possible to prevent excessive backpressure. A properly

installed exhaust system must be vapor tight, quiet and completely safe for the vehicle, its occupants and

surroundings. Installation of an approved Spark Arrestor is required.

The exhaust system components must be approved and properly installed to meet the codes and

regulations required by Federal and State agencies.

Laws pertaining to application and maintenance of a Spark Arrestor may vary depending on your

location and State regulations. Federal laws apply on Federal lands. If a generator is used in a forest, on brush or

grass covered unimproved land it must be equipped with a Spark Arrestor. It is the responsibility of the vehicle

owner or operator to install and maintain the entire exhaust system in good working condition.

CAUTION: Any person (s) who installs an unapproved Muffler, Spark Arrestor or other exhaust system

component, and/or modifies an exhaust system or component that may result in a hazardous condition is liable

for damages, injuries or warranty expense caused by such unapproved installation and/or modification.

EXHAUST SYSTEM

IMPORTANT SAFETY TIPS:

When exhaust system components are not furnished by Power Technology as part of the Genset, the

installer is responsible for meeting the following requirements.

1) Only use exhaust system components, which do not restrict exhaust flow. A restricted exhaust

system will create excessive backpressure and may cause poor engine performance and possible

engine damage. The maximum allowable backpressure for the engines listed in this manual is

1.57in Hg, (40mmHg).

2) Muffler shall be fabricated of aluminized steel or other corrosion resistant material and be of a

welded or crimp construction.

3) Maintain a minimum of 3 inches (76mm) between the exhaust system components and any

surrounding combustible materials. If the minimum clearance cannot be maintained, an

insulating shield must be installed to prevent the combustible material from exceeding

temperatures of 117°F

(65°C) above ambient temperature.

4) Extend the exhaust system a minimum of 1 inch (25mm) beyond the vehicles perimeter. Never

terminate the exhaust system underneath the vehicle.

5) Terminate the exhaust system in a direction, which prevents the exhaust gases from being drawn

back into the generator compartment and re-circulated.

6) If the exhaust system in located in an area which may become susceptible to road damage from

curbs, speed bumps, or other road obstacles a protective device such as a skid bar or plate should

be installed.

7) To prevent excessive movement and vibration of the exhaust system, install hangers and clamps

designed for use in exhaust systems.

8) Never join or tee the generator exhaust system and the vehicle exhaust system together. Doing so

may cause excessive back pressure on the generator engine, also condensation from one engine

can damage the other engine.

WARNING: LETHAL EXHAUST GAS! When installing the exhaust system position the tail pipe end so

that discharged exhaust gases are not drawn into the vehicle interior through windows, doors, air

conditioners, etc. During operation an engine discharges deadly carbon monoxide with its exhaust. Carbon

monoxide is particularly dangerous since it is odorless, tasteless, and non-irritating. It can cause death if

inhaled for even a

short period of time. Be especially careful if operating the generator set when parked under calm, windless

conditions. Gases may accumulate in these conditions. Park your vehicle so that the exhaust discharges

downwind. Always be aware of others in your vicinity. Make sure that your exhaust discharges away from

other vehicles and buildings.

CAUTION: Make sure the exhaust system components are positioned well away from drain openings

beneath the generator set. Also, be sure not to block access to the oil drain plug.

ELECTRICAL CONNECTIONS

ELECTRICAL WIRING

All wiring must be applicable with local electrical codes. A qualified licensed electrician must

perform all electrical wiring connections. Ground Fault (GFCI) breakers must be installed to protect all

vehicle branch circuits. All switches and controls must be securely mounted to prevent damage and

accidental opening or closing from vibration, road shock and vehicle motion.

Battery, load leads and the remote switch panel connections are necessary for completing the

installation. Make final connections to the battery only after all other connections have been made, as this

will prevent unintentional starting. Some specific details on each connection are stated in the following

paragraphs. Refer to the wiring diagram for specific details. All wiring to the generator set shall be securely

supported or harnessed to prevent abrasion. Additional support is required to prevent exposure to the exhaust

system and any possible leakage of fuel, oil, or grease. At least 2 inches of clearance must be maintained

between electrical wiring and hot exhaust parts. Wiring must not be located directly below or close to the

fuel system, oil fill and drain locations. If the coach is equipped with a mechanism for removing the

generator set from the compartment such as a mounting base or slide rack, be certain all wiring is long

enough to allow for free movement of the generator for servicing.

A separate 12-volt battery is recommended for the generator set. With a separate battery, cables

should be kept short in length thus eliminating problems with excessive voltage drop. See the Table below

for cable size (AWG) to length requirements.

NOTE: A heavy gauge #4 ground strap must be connected between the ground lug on the generator set and

the frame of the vehicle. All wiring connections made at the time of installation should be readily accessible

for periodic inspection and servicing.

DISTANCE BETWEEN

GENERATOR SET AND

BATTERY

CABLE SIZE (AWG) REQUIREMENTS

AT VARIOUS TEMPERATURES

0°F (-18°C) 32°F (0°C) 75°F (24°C)

40’ (12.2M) 00 0 1

30’ (9.2M) 0 1 2

25’ (7.6M) 1 2 4

20’ (6.1M) 2 2 6

15’ (4.6M) 2 4 6

10’ (3.0M) 4 6 8

5’ (1.5M) 6 6 8

2.5’ (0.8M) 8 8 8

AC LOAD LEAD CONNECTIONS

Some generator sets have four color-coded leads. The Black leads (L1 & L3) are hot. The White or

Gray lead (L2) is neutral and the Green lead is ground. The load leads can be routed directly from the

junction box to the vehicle AC circuit or transfer switch connection. All installations require that the load

leads be routed through flexible conduit from the generator end bracket to the junction box location. The

load lead junction box must be accessible for servicing and inspection.

AC load lead (L2) White or Gray is always the neutral lead on PTS generator sets. Make sure the

neutral of the AC circuit in the vehicle is connected to the (L2) White or Gray lead. If equipment ground type

plugs and receptacles (3 prong) are used in the vehicle, the green wire must be connected to the chassis

ground. On vehicles, which also have provisions for using an outside AC, power source, the neutral lead as

well as the Black (L1 & L3) hot leads must be completely isolated from the generator set when power is

switched to the outside source.

MOTOR LOADS

When figuring generator set capacity requirements for installation involving motor loads, do not

overlook the high current demanded by the motor during start-up. The “In-Rush” of starting current may

be 2 to 5 times higher than that required when the motor reaches normal operating speed. Reserve

capacity must be allowed for in rush demands plus other loads, which could be on the line as the motor

starts.

Air conditioning units are the most common type of motor loads for a generator set in a

recreational vehicle. The starting characteristics of the different makes of air conditioners vary greatly.

For example, a particular 12,000 BTU unit may have lower starting requirements than a 10,000 BTU

unit of another make. When only one unit is involved there is usually no starting problem provided of

course the lighting and appliance load is not too high when unit is started.

The trend seems to be toward larger capacity air conditioners and the use of more than one unit in larger

vehicles. Simultaneously starting two large units can present a problem if the capacity is marginal.

Because of the variation in starting characteristics of the different makes of air conditioners, no definite

statement can be made in this publication regarding multiple-motor starting capabilities.

Delayed starting or use of “easy starting” devices on air conditioner units should be considered

whenever simultaneous starting of more than one motor is involved. The starting and running

requirements of some motor loads common to mobile applications are listed in the table below. Use this

as a guide when selecting generator set capacity requirements involving motor loads. Also note the

Kilowatt De-rating factor for generator set capabilities regarding air conditioners. Capabilities will vary

according to “Kilowatt De-rating”.

BASED ON CODE “G” ELECTRIC MOTOR ELECTRIC MOTOR

HORSEPOWER

STARTING WATTS RUNNING WATTS

½ 2000 1100

1 3800 1800

2 6000 2800

3 8000 4000

4 11000 5500

5 13000 6500

KILOWATT DE-RATING

All units are rated at 1.0 power factor. The Kilowatts of the generator set will decrease 3.5% per

1,000 feet (305m) above 500 feet (152m) above sea level. De-rate 1% for every 10 °F (5.5°C) above

68°F.

ELECTRICAL LOADS

While the electrical load of the vehicle should have been calculated prior to purchase of the generator

set, you may want to recheck the load before installing the set to make sure the capacity is ample to meet

the demands without possible overloading.

The lighting load is usually easiest to calculate in most cases, simply add the wattage of each

lamp to be operated off the generator set. Note that in many applications, not all of the lights or lamps

are in the generator sets AC circuit. Some are DC powered by the 12-volt battery in the vehicle. Make

sure the total includes only lights actually on the generator sets AC circuit. The lighting load is usually

not to heavy in mobile installations however it must be accurately calculated to prevent overloading. For

example, if all lights are on at the same time and the air conditioner or other motor equipment starts up,

this may possibly cause an overload situation.

APPLIANCE LOADS

Generator sets in recreational vehicles are often used to supply AC voltage for appliances. With

the exception of a resistance-type load such as a water heater, requirements for appliances are usually

low. However, such loads must not be overlooked when calculating the total wattage requirements. To

avoid an overload situation, reserve capacity should also be calculated for unanticipated appliance loads.

The average power requirements for some common electrical appliances are listed below as a guide.

DETERMINING ALTERNATOR LOAD REQUIREMENTS

CHECK √ APPLIANCE WATTS REQUIRED

VCR 70

LIGHT BULB 100

RADIO 100

TELEVISION 100

STEREO 100

FRY PAN 150

HOME COMPUTER 150

VACUUM CLEANER 250

ATTIC FAN 1/4 HP 400

SUMP PUMP 1/3 HP 500

REFRIGERATOR 500

FURNACE FAN 1/3 HP 600

FREEZER 800

JET WATER PUMP ¾ HP 900

ELECTRIC STOVE ELEMENT 1000

SUBMERSIBLE WATER PUMP 1 HP 1000

TOASTER 1000

COFFEE MAKER 1200

DISHWASHER 1200

HAIR DRYER 1200

MICROWAVE OVEN 1500

SUBMERSIBLE WATER PUMP 2 HP 1600

WATER HEATER 3000

OVEN 4500

TOTAL WATTS CHECKED

EXTENSION CORDS

An extension cord is normally used to provide electrical power from the generator set to a remote

location. The extension cord size (AWG#) and length must be adequate to safely maintain the amperage

requirements. A proper size extension cord will help minimize the voltage drop between the generator

set and remote location.

AMPS LOAD IN WATTS CORD LENGTH

120 VOLTS 240 VOLTS AWG#10 AWG#12 AWG#14

5 600 1200 500 FT 300 FT 200 FT

10 1200 2400 250 FT 150 FT 100 FT

20 2400 4800 125 FT 75 FT 50 FT

30 3600 7200 60 FT 35 FT 25 FT

40 4800 9600 30 FT 15 FT 10 FT

50 6000 12000 15 FT ----- -----

PowerTech PT20-ECRR Handleiding

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