Manual MagnaMax


MAGNAMAXDVR
GENERATOR
INSTALLATION
OPERATION, AND
MAINTENANCE
MANUAL
1
TABLE OF CONTENTS
TABLE OF CONTENTS ............................................................................................................... 2
SAFETY.......................................................................................................................................... 6
GENERAL INFORMATION ........................................................................................................ 7
MECHANICAL DESIGN ......................................................................................................................7
General ............................................................................................................................................................... 7
Conduit Box ....................................................................................................................................................... 7
MagnaMAXDVR UnirotorTM Construction ...................................................................................................... 7
Adapters and Drive Discs.................................................................................................................................. 7
ELECTRICAL DESIGN........................................................................................................................8
Temperature Rise .............................................................................................................................................. 8
Standby Generator Ratings .............................................................................................................................. 8
Premium Insulation System.............................................................................................................................. 8
Power Factor...................................................................................................................................................... 8
MagnaMAXDVR Voltage Regulator.................................................................................................................. 8
HOW TO READ A MODEL NUMBER...............................................................................................9
INSTALLATION.......................................................................................................................... 10
RECEIVING YOUR MAGNAMAXDVR GENERATOR ..................................................................10
UNPACKING AND HANDLING .......................................................................................................10
STORAGE .............................................................................................................................................10
PREPARATION FOR USE .................................................................................................................10
GENERATOR MOUNTING - SINGLE BEARING .........................................................................11
GENERATOR MOUNTING-TWO BEARING ................................................................................11
BELT DRIVE ........................................................................................................................................11
ENVIRONMENTAL CONCERNS.....................................................................................................11
ELECTRICAL CONNECTIONS ................................................................................................ 12
GENERATOR LEAD CONNECTIONS ............................................................................................12
12 LEAD HIGH WYE CONNECTION..............................................................................................13
12 LEAD LOW WYE CONNECTION...............................................................................................13
12 LEAD HIGH DELTA CONNECTION .........................................................................................14
12 LEAD LOW DELTA CONNECTION ..........................................................................................14
10 LEAD HIGH WYE CONNECTION..............................................................................................15
10 LEAD LOW WYE CONNECTION...............................................................................................15
6 LEAD WYE CONNECTION ...........................................................................................................16
6 LEAD DELTA CONNECTION .......................................................................................................16
3 LEAD DELTA CONNECTION .......................................................................................................17
4 LEAD WYE CONNECTION ...........................................................................................................17
2
DOUBLE DELTA -- SINGLE PHASE CONNECTION ..................................................................18
LOW ZIG ZAG -- SINGLE PHASE CONNECTION ......................................................................18
HIGH ZIG ZAG -- SINGLE PHASE CONNECTION .....................................................................18
PARALLELING OPERATIONS................................................................................................. 19
PRIME MOVER...................................................................................................................................19
VOLTAGE REGULATOR..................................................................................................................19
SWITCHGEAR.....................................................................................................................................19
PARALLELING BASICS....................................................................................................................19
REACTIVE LOAD CONTROL..........................................................................................................20
PARALLELING CIRCUITRY ...........................................................................................................20
THYRISTOR OR SCR LOADING .............................................................................................. 21
OPERATION................................................................................................................................ 21
PRE-START INSPECTION ................................................................................................................21
STARTING-UP THE GENERATOR.................................................................................................22
FIELD FLASHING ..............................................................................................................................22
VOLTAGE ADJUSTMENTS..............................................................................................................22
OTHER ADJUSTMENTS ...................................................................................................................23
MAINTENANCE ......................................................................................................................... 23
GENERAL INFORMATION ..............................................................................................................23
AIR INTAKE AND EXHAUST...........................................................................................................23
ELECTRICAL CONNECTIONS, WINDINGS ................................................................................24
LUBRICATION....................................................................................................................................24
DRYING ELECTRICAL INSULATION...........................................................................................26
Space Heaters................................................................................................................................................... 26
Oven.................................................................................................................................................................. 26
Forced Air ........................................................................................................................................................ 26
“Short Circuit” Method .................................................................................................................................. 26
CLEANING METHODS......................................................................................................................27
Solvents............................................................................................................................................................. 27
Cloth and Compressed Air ............................................................................................................................. 27
Brushing and Vacuum Cleaning .................................................................................................................... 27
Shell Blasting.................................................................................................................................................... 27
Steam Cleaning ................................................................................................................................................ 27
DISASSEMBLY ........................................................................................................................... 28
REMOVAL FROM PRIME MOVER................................................................................................28
CONDUIT BOX REMOVAL ..............................................................................................................29
EXCITER STATOR (FIELD) REMOVAL .......................................................................................30
EXCITER ARMATURE (ROTOR) REMOVAL..............................................................................30
3
PMG STATOR REMOVAL................................................................................................................31
MAIN ROTOR REMOVAL................................................................................................................33
FRONT END BRACKET REMOVAL...............................................................................................35
EXCITER INSPECTION ............................................................................................................ 35
EXCITER STATOR.............................................................................................................................35
EXCITER (ROTOR) ARMATURE....................................................................................................36
PMG INSPECTION..................................................................................................................... 37
PMG STATOR......................................................................................................................................37
PMG ROTOR .......................................................................................................................................37
MAIN ROTOR INSPECTION .................................................................................................... 37
BEARING..............................................................................................................................................37
FAN ........................................................................................................................................................38
MAIN ROTOR CORE AND WINDINGS..........................................................................................40
DRIVE DISCS (SINGLE BEARING GENERATORS ONLY) .......................................................40
FRONT (EXCITER) END BRACKET INSPECTION .............................................................. 40
DRIVE END BRACKET OR SAE ADAPTER INSPECTION.................................................. 41
MAIN STATOR INSPECTION................................................................................................... 42
FRONT END BRACKET INSTALLATION .............................................................................. 42
MAIN ROTOR INSTALLATION ............................................................................................... 42
PMG INSTALLATION................................................................................................................ 45
EXCITER INSTALLATION ....................................................................................................... 46
CONDUIT BOX INSTALLATION ............................................................................................. 47
ASSEMBLY TO PRIME MOVER .............................................................................................. 48
TROUBLESHOOTING ............................................................................................................... 50
INTRODUCTION.................................................................................................................................50
SYMPTOM: ..........................................................................................................................................51
NO VOLTAGE OR RESIDUAL VOLTAGE............................................................................................... 51
LOW VOLTAGE - .......................................................................................................................................... 52
NO LOAD ........................................................................................................................................................ 52
LOW VOLTAGE WHEN LOAD IS APPLIED ........................................................................................... 53
HIGH VOLTAGE ........................................................................................................................................... 53
VOLTAGE IS FLUCTUATING .................................................................................................................... 54
OPERATES SATISFACTORILY WHEN COLD, BUT SHUTS DOWN WHEN WARM ..................... 54
BUILDS VOLTAGE FROM STARTUP,THEN GOES TO LOW (RESIDUAL) VOLTAGE................ 54
EQUIPMENT RUNS NORMALLY ON UTILITY POWER, BUT WILL NOT RUN ON GENERATOR
SET ................................................................................................................................................................... 54
GENERATOR TESTING ............................................................................................................ 55
VISUAL INSPECTION........................................................................................................................55
4
CONSTANT EXCITATION (12V BATTERY) TEST.......................................................55
MEASURING VOLTAGES.................................................................................................................56
Generator Output Voltage ................................................................................................................................. 57
Regulator Output (Exciter Stator Input) ............................................................................................................ 57
Regulator Sensing.............................................................................................................................................. 57
Regulator Input Volts (PMG Output Volts) ..................................................................................................... 57
CURRENT (AMP) MEASUREMENTS.............................................................................................57
MEASURING RESISTANCE .............................................................................................................58
Main Stator ...................................................................................................................................................... 58
Exciter Rotor.................................................................................................................................................... 58
TESTING DIODES (RECTIFIERS) ..................................................................................................58
INSULATION RESISTANCE - MAIN STATOR.............................................................................59
GENERATOR TESTING ....................................................................................................................59
INSULATION RESISTANCE - MAIN ROTOR...............................................................................59
INSULATION RESISTANCE - EXCITER STATOR......................................................................60
INSULATION RESISTANCE - EXCITER ROTOR........................................................................60
MAIN ROTOR FIELD AC IMPEDANCE TEST .............................................................................60
MAGNAMAX EXPLODED VIEW ....................................................................................................61
STANDARD TOOLS.................................................................................................................... 65
SPECIAL TOOLS ................................................................................................................................65
MISCELLANEOUS .............................................................................................................................66
PREPARATION FOR SHIPMENT OR EXTENDED STORAGE........................................... 66
SHIPPING INSTRUCTIONS..............................................................................................................66
STORAGE INSTRUCTIONS..............................................................................................................66
TABLE 12-1: MAGNA MAX - FASTENER AND TORQUE SPECIFICATIONS ................. 68
TABLE 12-2: CAPSCREW TORQUE VALUES........................................................................ 69
TABLE 12-3:EXCITATION DATA -60 HZ - 1800 RPM .......................................................... 70
TABLE 12-4:EXCITATION DATA -50 HZ - 1500 RPM .......................................................... 71
TABLE 12-5: RESISTANCE VALUES - MAIN WINDINGS................................................... 72
TABLE 12-6: RESISTANCE VALUES - EXCITER WINDINGS............................................ 73
5
SAFETY
PLEASE REMEMBER SAFETY FIRST. If you are not sure of the instructions or procedures,
seek qualified help before continuing.
This service manual emphasizes the safety precautions necessary during the installation, opera-
tion, and maintenance of your generator.
Each section has caution and warning messages. These messages are for your safety and the
safety of the equipment involved. If any of the cautions or warnings is not readily understood,
seek clarification from qualified personnel before proceeding.
Before any service work is done, disconnect all power sources and, where appropriate, lock out
all controls, to prevent an unexpected start-up of the generator set. Proper grounding in
compliance with local and national electrical codes must be provided. These safety precautions
are necessary to prevent potential serious personal injury, or even death.
The hazards associated with lifting or moving the generator are pointed out in the installation and
service sections; incorrect lifting or moving can result in personal injury or property damage.
Whenever the generator is running, always assume and proceed as if voltage is present. Residual
voltage is present at the generator leads and at the regulator panel connections, even with the
regulator fuse removed. Caution must be observed, or serious personal injury or death can result.
Whenever solvents, cleaners, or flammable liquids are present, adequate ventilation must be
available to avoid fire, explosion, and health hazards. Always avoid breathing vapors and use
suitable personal protective equipment to prevent personal injuries. (Such as eyes, face, and hand
protection.)
This manual is not intended to be a substitute for properly trained personnel. Only qualified
trained people should attempt repairs. The cautions and warnings point out known conditions
that are potentially dangerous. Each installation will create its own set of circumstances. No
manual can cover every possible situation.
When in doubt, ask. Don’t be embarrassed to ask, “dumb questions”. Remember that dumb
questions are much easier to handle than dumb mistakes.
6
GENERAL INFORMATION
MECHANICAL DESIGN
General MagnaMAXDVR UnirotorTM

Construction
All single and two bearing units are
manufactured with cast iron end brackets An aluminum die cast rotor core affords
and adapters, and fabricated steel frames. high mechanical integrity and low vibration
Flexible drive discs and SAE adapters are at operating speeds. Amortisseur winding
machined to SAE standards. Pre-lubricated, and coil supports are die cast as an integral
regreasable, shielded ball bearings are used part of the rotor. Laminations are 4-pole,
on MagnaMAXDVR generators. Standard one piece laminations which are shrunk fit
units are fully guarded. Drip proof shields and keyed to the shaft. No dovetails, cross
are available as an option. bolts or other pole to shaft connecting
devices are used. The cast unidirectional
Conduit Box aluminum alloy ventilation fan provides
The large end mounted conduit box is con- even air distribution to maximize cooling
structed of formed sheet steel that will allow and generator efficiency.
the addition of top mounted control
packages. Refer to Marathon Electric for top
mounted controls of more than 240 lbs. Adapters and Drive Discs
There is ample room inside the conduit box
for a circuit breaker (through 800A Frame) All single bearing units are available with
and other options. The conduit box cover several adapters and drive disc
properly directs outside ventilating air arrangements. These can be shipped to order
through the generator. or can be changed in the field with standard
shop tools. When changing flexible drive
discs, spacers are used between the discs and
the cast iron hub to maintain SAE standard
dimensions.
7
ELECTRICAL DESIGN
All standard products have 2/3 pitch main cycles of the main winding, plus a final coat
windings to eliminate the third harmonic. of epoxy, make the standard winding
This serves to lower operating temperatures, moisture and fungus resistant. The
give lower harmonic content and better MagnaMAXDVR rotor is wet wound with
waveform, and extend the overall life of the thermo-setting epoxy applied between each
generator. layer, plus a final coating of epoxy for
moisture and abrasion resistance.
Temperature Rise
All ratings and frame sizes are based on MagnaMAXDVR generators can be ordered
NEMA and CSA Class F and Class H with an epoxy vacuum pressure impregnated
temperature rises on both the rotor and stator insulation system as an option.
windings. Ratings for British, German, (MagnaMAXDVR generators with form
French, IEC and all popular marine agencies wound coils include VPI as standard.)
are available.
Standby Generator Ratings Power Factor

Synchronous generators used on emergency All standard generators are designed for
backup power can have temperature rises up operation at rated kVA at 0.8 lagging power
to 25°C above those for continuous factor but can be operated at rated kVA over
operation. (NEMA MG1 -22.40 and MG 1- the 0.8 to 1 .0 power factor range.
22.84).
MagnaMAXDVR Voltage Regulator
Premium Insulation System The standard voltage regulator is a fully

encapsulated, static types with a solid state
All MagnaMAXDVR generators are built build up circuit. Standard features include 3-
with Class H or better insulation materials. phase RMS sensing, paralleling, adjustable
All standard generators are suitable for under frequency protection, and over
continuous duty at Class F temperature rise excitation protection. The regulator meets
and will give equivalent or better winding EMI suppression to Mil Std-461C, part 9.
life expectancy to generators supplied with An optional feature is adjustable armature
Class A or B insulation systems operated current limiting. See the regulator manual
within their temperature limits. The for more information.
varnishes and epoxies used are synthetic,
non-hygroscopic. Multiple dip and bake
8
HOW TO READ A MODEL NUMBER
It is extremely important to properly identify the machine when requesting parts or service.
Always have the generator model number and serial number when requesting information from
the factory. We cannot help you without this information.
An Example For MagnaMAXDVR Generators 431RSL 4009
Character Category Description

1st three characters Frame Number
4th character Winding type R—Random Wound
F—Form Wound
5th character Bearing arrangement S—1 Bearing
D—2 Bearings
6th character Voltage range L—Up to 480 volts
M—1000-6600 volts
S—600 volts
7th Character Product style 4-Magna
8th Character Type
9th & 10th Character Wk2 Code
11th Character Modification A-Z assigned sequentially
12th Character Mounting Arrangement A-Y see chart figurer 2-1
13th, 14th & 15th characters Modification numbers For internal use only
Arrangement Adapter SAE Size Drive Disc SAE Size

A 3 11-1/2
B 2 11-1/2
C 4 8
D 3 10
E 1 11-1/2
F 1 14
G 4 7-1/2
H 1 Delco
J 1/2 14
K 2 10
L 1/2 Delco
M 0 14
N 2 Small Delco
0 None None
P 0 18
S 0 Delco
U 00 18
V 4 6-1/2
W 00 21
Y 4 10
Figure 2-1
9
INSTALLATION
RECEIVING YOUR MAGNAMAXDVR STORAGE
GENERATOR
In the event that the generator is not to be
Upon receipt of the generator, it is installed on the prime mover immediately, it
recommended that it be carefully examined is recommended that it be stored in a clean,
for possible damage incurred in shipment. dry area that is not subject to rapid changes
The generator was given to the Freight in temperature and humidity. See
Company in good condition, and they are "STORAGE INSTRUCTIONS" for more
responsible for the product from our dock to information.
yours. Any damage should be noted on the
freight bill before accepting the shipment.
Claims for damages must be promptly filed PREPARATION FOR USE
with the Freight Company.
Although the generator is carefully
inspected and tested in operation before it
UNPACKING AND HANDLING leaves the factory, it is recommended the
unit be thoroughly inspected. The insulation
Read all instruction cards carefully. When on the wire should be inspected and all bolts
lifting, attach an overhead crane to the should be checked for tightness.
lifting lugs on the generator frame. Apply
lifting forces in a vertical direction. Remove all shipping tapes, bags, blocks, and
skids, which are used to prevent vibration
WARNING and rotor movement during shipment. Dry,
THE LIFTING LUGS ON THE low-pressure compressed air of
GENERATOR ARE DESIGNED TO approximately 30 PSI (206 KPA) can be
SUPPORT THE GENERATOR ONLY. used to blow out the interior of the
DO NOT LIFT COMPLETE generator. In the case of two bearing
GENERATOR SET BY MEANS OF machines, it is possible to turn the rotor by
LIFTING DEVICES ON THE hand to make sure that it rotates smoothly
GENERATOR. PERSONAL INJURY without binding.
OR QUIPMENT DAMAGE MAY
OCCUR. If the machine has been in storage for a year
or longer it is recommended that it be
lubricated according to the lubrication
instructions and chart supplied in the
maintenance section.
If the machine has been exposed to damp,
humid conditions the insulation resistance
should be checked. Refer to the instructions
supplied in this manual.
10
GENERATOR MOUNTING - SINGLE GENERATOR MOUNTING-TWO
BEARING BEARING
Single bearing generators are provided with Two bearing generators are provided with a
an SAE flywheel adapter and flexible drive shaft extension and key way. For direct-
discs. Very close tolerances are maintained coupled sets the assembler furnishes a flexible
in the manufacture of the generator so that coupling which is installed between the driver
the alignment procedure is extremely and the generator shaft.
simple. A coupling hub of nodular iron is
shrunk on the shaft and special steel drive IMPORTANT: Aligning the two machines
discs are bolted to the hub. Holes are as accurately as possible will reduce
provided in the periphery of the coupling vibration, increase-bearing life, and insures
disc, which correspond to tapped holes in minimum coupling wear. It may be
the flywheel. The outside diameter of the necessary to shim the generator feet for
discs fits in a rabbet in the flywheel so that proper support and alignment. Consult the
concentricity is assured in all cases. coupling manufacturer’s instructions for
alignment specifications and procedures.
WARNING
DO NOT APPLY ANY FORCE TO THE BELT DRIVE
GENERATOR FAN FOR LIFITNG OR Please refer to Marathon Electric for
FOR ROTATING THE GENERATOR applications involving belt driven
ROTOR. DISREGARDING THESE installations.
INSTRUCTIONS MAY CAUSE
PERSONAL INJURY OR EQUIPMENT ENVIRONMENTAL CONCERNS
DAMAGE Dirt, moisture, heat, and vibration are
enemies of electrical equipment. The
CAUTION: GRADE 8 CAPSCREWS ambient temperature should not exceed the
OR GRADE 8 PLACE-BOLTS AND value shown on the generator nameplate.
HARDENED WASHERS ARE REC- Generators for outdoor application should be
OMMENDED TO MOUNT THE DRIVE protected from the elements by housings
DISCS TO THE FLYWHEEL.DO NOT with proper openings for ventilation. This
USE HELICAL OR OTHER LOCKING protection should be designed to prevent the
DEVICES UNLESS APPROVED. direct contact of wind driven rain, snow, or
dust with the generator. In moist or humid
The SAE adapter and the flywheel housing areas, such as the Tropics and marine serv-
are designed to match each other with no ice, additional protection is recommended.
further alignment necessary. Shims may be Although the standard windings are
necessary under the feet of the generator to humidity and moisture resistant, special
insure a solid mounting. See THE SERVICE insulation and accessories such as space
SECTION for more information. heaters can increase generator life. In
extremely dirty and dusty environments a
means of providing filtered cooling air to the
generator is recommended. Please refer to
Marathon Electric for filter kits that are
available.
11
ELECTRICAL CONNECTIONS
The generator conduit box construction

allows conduit to enter the top, bottom, or GENERATOR LEAD CONNECTIONS
either side of the box. A hole-saw or any
suitable tool can be used to provide for the The electrical connections in the conduit box
conduit entrance. Protect the interior of the should be made in accordance with the
generator from shavings when drilling or appropriate “connection diagram.” Use the
sawing. An approved connector must be diagram appropriate for the number of leads
used in conjunction with the conduit. and voltage range required. Refer to the
drawings supplied with the generator and to
To minimize the transmission of vibration, it drawings in this section.
is essential that flexible conduit be used for
all electrical cable entrance to the generator. The final voltage setting is established
within the selected range by an adjustment
Refer to the connection diagram supplied of the voltage regulator.
with the generator and / or the proper
diagrams shown in this section. Install all CAUTION: SOME GENERATORS
intercomponent and external wiring in HAVE MULTIPLE, IDENTICALLY
accordance with the regulations of the MARKED, CABLES FOR EACH LEAD.
national and local electrical codes. Clean all CONNECT ALL IDENTICALLY
contact surfaces to assure good electrical MARKED CABLES TOGETHER
bonding with the generator lugs or bus bars. WHEN MAKING CONNECTIONS.
Use heavy-duty terminal lugs or good
quality clamps for making all connections.
Insulate all connections in accordance with
national and local regulations.
Be sure the generator frame is grounded to

all the other components of the system with
a ground wire in accordance with national
and local regulations.
12
12 LEAD HIGH WYE CONNECTION
L1
V O LTA G E
T1
L -L L -N
60 48 0 27 7
T4 HZ 46 0 26 6
44 0 25 4
T7 41 6 24 0
L-L 38 0 21 9
T10
T12 50 416 240
HZ 400 231
T9 T11 380 219
T6
T8
T3 T5
L3 T2 L2
L-N
12 LEAD LOW WYE CONNECTION

L1
V O LTA G E
T7 T1 L -L L -N
60 2 40 1 39
L-L HZ 2 30 1 33
T10 T4 2 20 1 27
T12 T5 2 08 1 20
1 90 1 10
T9 T2
T6 T11 50 208 120
L3 T3 T8 L2 HZ 200 115
190 110
L-N
13
12 LEAD HIGH DELTA CONNECTION
L1
T12 V O LTA G E
T1
` L -L L -N
T9 T4
T6 T7 L-L
60 240 120
HZ 277 139
T3 T10
L3 L2 50 200 100
T11 T8 T5 T2 HZ 220 110
240 220
L-N
12 LEAD LOW DELTA CONNECTION

L1
V O LTA G E
L -L L -N
T12 T1
T6 T7 L-L 60 120 N A
HZ 139
T9 T4
T3 T10
50 100 N A
T11 T8 HZ 120
L3 L2
T5 T2
L-L
14
10 LEAD HIGH WYE CONNECTION
L1
V O LTA G E
T1
L -L L -N
60 48 0 27 7
T4 HZ 46 0 26 6
44 0 25 4
T7 41 6 24 0
L-L 38 0 21 9
T0
50 416 240
HZ 400 231
T9 380 219
T6
T8
T3 T5
L3 T2 L2
L-N
10 LEAD LOW WYE CONNECTION

L1 V O LTA G E
L -L L -N
T7 T1
60 2 4 0 1 3 9
HZ 2 3 0 1 3 3
L-L 2 2 0 1 2 7
T0 T4 2 0 8 1 2 0
T5 1 9 0 1 1 0
T9 T2 50 208 120
T6 HZ 200 115
190 110
L3 T3 T8 L2
L-N
15
6 LEAD WYE CONNECTION
L1
V O LTA G E
T1 L -L L -N
13800 7967
6600 3811
4160 2400
60 H Z 3300 1905
T7 240 139
L-L 230 1363
T 220 127
T 4 203 120
6
190 110
T3 T5
50 H Z 11000 6351
6600 3811
L3 T2 L2 3300 1905
L-N 208 120
200 115
190 110
6 LEAD DELTA CONNECTION

L1
T6 V O LTA G E
T1
L -L L -N
L-L 60 7967 NA
HZ 2400
T3 T4
50 6351 NA
L3 L2 HZ 1905
T5 T2
16
3 LEAD DELTA CONNECTION
L1 V O LTA G E
L -L L -N
T1
60 H Z 7967 NA
2402 NA
L-L
50 H Z 6351 NA
1905 NA
T3 T2
L3 L2
4 LEAD WYE CONNECTION
L VO LTAG E
1
T1
L-L L-N
13800 7967
6600 3811
60 HZ 4160 2400
3300 1905
2400 1386
L-L 600 346
480 277
T 380 219
0
11000 6351
50 HZ 6600 3811
T3 3300 1905
416 240
L3 T2 400 231
L2 380 219
L-N
17
DOUBLE DELTA -- SINGLE PHASE CONNECTION
T3 T11
T5 T9 V O LTA G E
L -L L -N
T6 T8 60 24 0 12 0
T2 T12
H Z 22 0 11 0
L2 T1 T4 T7 T10 L1
20 0 10 0
50 22 0 11 0
L-N L-N
H Z 20 0 10 0
L-L
LOW ZIG ZAG -- SINGLE PHASE CONNECTION
T6 T2 V O LTA G E
T12 T8 L -L L -N
T3
T5
60 24 0 12 0
T9 T11 H Z 22 0 11 0
T4 T1 20 0 10 0
L2 T10 T7 L1 50 22 0 11 0
L-N L-N H Z 20 0 10 0
L-L
HIGH ZIG ZAG -- SINGLE PHASE CONNECTION

T12 T1
T4
V O LTA G E
T9
H Z L -L L -N
T6 T7 6 0 4 8 0 2 4 0
4 4 0 2 2 0
T3 T10 T11 T8 T5 T2
5 0 4 4 0 2 2 0
L2 L1 4 0 0 2 0 0
L-N L-N
L-L
18
PARALLELING OPERATIONS generators operate in parallel, the voltage regulator
must have paralleling provisions (either internally
MagnaMAXDVR generators come standard or external to the regulator) to control the reactive
with amortisseur windings die cast as an or VAR load while it is in parallel operation. A
integral part of the rotor. This exclusive, separate paralleling current transformer is required
UnirotorTM, construction makes all to sense the reactive current and signal the voltage
MagnaMAXDVR generators suitable for regulator. This additional paralleling circuitry is
paralleling operations when the proper control absolutely necessary to control the reactive current
equipment is added. Paralleling with other flowing between the generator sets.
generator sets and / or with the utility power
grid offers a number of advantages. Multiple
unit installations increase power capacity; they SWITCHGEAR
can be added or removed from the line
depending on the load requirements; they can There are additional relays and breaker controls
be better maintained and repaired (since single that are necessary to insure safe, trouble free
source breakdown would mean total loss of operation of paralleled units. Reverse power relays
power), and they often provide more reliable, monitor the direction of power flow to insure that
efficient, and economical operation. the generator is delivering power, not accepting it.
These power relays control breakers, which are a
Successful parallel operation means that the means of connecting and disconnecting the gen-
generators deliver power to the external erator from the load. The total system can include
system without delivering power to each over-voltage, over-current protection, under fre-
other, or accepting power from the load bus or quency protection, power factor correction provi-
power grid. Additional equipment is necessary sion and a variety of associated control equipment
to insure safe and successful operation. from manual switchgear to microprocessors. The
amount of control gear and level of sophistication
will be determined by the needs and requirements
PRIME MOVER of the particular application.
The prime mover provides the speed and PARALLELING BASICS

torque which will be necessary to keep the
machines in synchronized operation. A The following points are basic criteria which must
governor controls the prime mover's speed. be met before two units can be paralleled. THIS IS
The governor will directly control the watt or NOT MEANT TO BE SPECIFIC
kW output and frequency of the unit. The INSTRUCTIONS FOR PARALLELING
governor must have special paralleling OPERATION.
provisions to permit parallel operation with
the other machines. 1. Additional paralleling circuitry
A. Voltage regulator-paralleling provisions
B. Paralleling current transformer(s)
VOLTAGE REGULATOR C. Paralleling provisions on governor controls
D. Switchgear
The voltage regulator controls the generator
output voltage and the reactive power supplied 2. The voltage and frequency must be the same for
by the generator. When two or more ac all sets with voltages in phase.
19
3. The voltage regulation characteristics of the The circuit must meet the following criteria:
individual generators should be similar.
A. All paralleling current transformers for all the
4. The generators must have the same phase generators being paralleled must be included in
rotation. the secondary interconnection loop.
5.The driving engines should have the same B. When different size generators are paralleled
speed regulation characteristics and the all paralleling current transformers must have the
governors should be adjusted to give the same same proportional ratios that give approximately
speed regulation. the same secondary current.
Before operating generator sets in parallel, C. Voltage regulator paralleling circuitry must be
each set should be checked by starting, the same.
operating, and adjusting the sets as individual
units before attempting paralleling. D. Current transformer secondary and the
generator lines must be isolated electrically.
REACTIVE LOAD CONTROL
When two identical generators are operating E. It is also desirable to have an auxiliary contact
together in parallel and an unbalance occurs in on the main generator breaker to short the parallel
field excitation, circulating currents begin to CT secondary when that breaker is open (not
flow between the generators. This current will connected to the load bus).
appear as a lagging power factor or inductive
load to the highly excited generator, and as a Because of the above criteria, reactive differential
leading power factor or capacitive load to the compensation cannot be used when paralleling
generator with the lower field current. This is with the utility power grid. There is no limit,
known as the reactive circulating current and however, in the number of generators that can be
there are two methods of controlling it in included in this type of circuit.
parallel operation:
1. Reactive droop compensation. (Formerly PARALLELING CIRCUITRY

known as parallel droop compensation.)
The bus voltage droops, or decreases, as the Because of the number of variables involved in
reactive lagging power factor load is paralleling generator sets, every installation will
increased. have its own circuitry and methods or procedure
of bringing paralleled units on line. There are
2. Reactive differential compensation. numerous ways of connecting paralleled units and
(Formerly known as cross current an almost unlimited variety of applications and
compensation.) The reactive differential associated equipment.
compensation circuit allows parallel
generators to share reactive loads with no When parallel operation is desired, it is important
decrease or droop in generator voltage. that the control manufacturer, the generator manu-
facturer, and the systems engineer work together
to insure the proper selection of all components.
Please refer to Marathon Electric for application
assistance.
20
THYRISTOR OR SCR LOADING 1. A visual inspection should be made to check
for any loose parts, connections, or foreign
Solid state electronic control devices which materials
utilize thyristors or SCR firing circuits (such
as variable frequency induction motor 2. Check for clearance in the generator and exciter
controls, precision motor speed controls, no- air gap. Be sure the generator set turns over freely.
break powered battery chargers, etc.) can Bar the generator over by hand at least 2
introduce high frequency harmonics which revolutions to be sure there is no interference.
adversely affect or destroy the normal
waveform of the generator. This creates WARNING
additional heat in the generator stator and DO NOT APPLY ANY FORCE TO THE
rotor, and can cause overheating. These GENERATOR FAN FOR LIFITNG OR
devices can and do present problems to non- FOR ROTATING THE GENERATOR
utility power generating equipment or any ROTOR. DISREGARDING THESE
limited power bus system. The problems that INSTRUCTIONS MAY CAUSE
can occur are not limited to the generator PERSONAL INJURY OR EQUIPMENT
itself, but can effect the solid state control DAMAGE
device, the equipment it controls, other
associated loads, monitoring devices or a 3. Check all wiring against the proper connection
number of combinations over the entire diagrams and make sure all connections are
system. properly insulated. Support and tie leads to keep
them from being damaged by rotating parts or by
MagnaMAXDVR generators can supply power chafing on sharp corners.
to thyristor or SCR loads when properly
applied. The standard voltage regulator is 4. Be sure the equipment is properly grounded.
PMG powered and senses 3 phase RMS
voltages for maximum stability against 5. Inspect for any remaining packing materials and
severely distorted waveforms. SCR type remove any loose debris, building materials, rags,
applications such as cranes, shovels, etc., etc. that could be drawn into the generator.
require special consideration of the generator
insulation system due to greater dielectric 6. Check fasteners for tightness.
stress and severe environmental conditions. It
is important that the control manufacturer, the 7. Check to be sure no tools or other hardware
generator manufacturer, and the systems have been left inside or near the machine.
engineer work together to insure the proper
selection of all components. Please refer to 8. Install and check to be sure all covers and
Marathon Electric for application assistance. guards are in place and secure.
OPERATION WARNING
RESIDUAL VOLTAGE IS PRESENT AT THE
GENERATOR LEADS AND AT THE
PRE-START INSPECTION
REULATOR PANEL CONNECTIONS EVEN
Before operating the generator for the first WITH THE REGULATOR FUSE REMOVED.
time, the following checks are recommended. CAUTION MUST BE OBSERVED OR
SERIOUS PERSONAL INJURY OR DEATH
CAN RESULT.
21
STARTING-UP THE GENERATOR FIELD FLASHING
The following procedure should be followed The standard MagnaMAXDVR generator is supplied
for starting-up the generator for the first time: with a PMG (permanent magnet generator). It will
never require field flashing. In rare cases where a
1.The generator output must be disconnected special generator may be furnished without a
from the load. Be certain that the main circuit PMG, refer to the factory for more detailed
breaker is open. information. Include the complete generator model
and serial number.
2.Disable the voltage regulator by removing
the fuse. VOLTAGE ADJUSTMENTS
The voltage regulator controls the generator output
WARNING voltage. There is a cover to access the control
DO NOT OVERSPEED THE panel on the side of the generator conduit box
GENERATOR. EXCESSIVE
CENTRIFUGAL FORCES COULD
DAMAGE THE ROTATING FIELDS. BE
PREPARED FOR AN EMERGENCY
SHUTDOWN.
3.Follow the manufacturer's instructions and

start the prime mover. Check the speed and
adjust to the RPM shown on the generator
nameplate.
4. Replace the regulator fuse and adjust the

Figure 4-1
voltage to the required. Check all line to line
and line to neutral voltages to be sure they are
correct and balanced. If the voltages are not
correct shut down immediately and recheck all
connections.
5. Close the main circuit breaker and apply the

load.
6. Monitor the generator output current to

verify it is at or below nameplate amps.
7. Adjust engine speed at full load to 1800 Figure 4-2 Regulator Access
rpm for 60 hertz, 1500 rpm for 50 hertz.
(Refer to prime mover/governor instruction Refer to the regulator manual for detailed
manuals.) information. In cases where special or remote
mounted regulators are used, refer to instructions
8. Before stopping the engine, remove the load supplied by the generator set assembler and to the
by tripping the main circuit breaker. voltage regulator manual.
22
OTHER ADJUSTMENTS produced internally will tend to keep it dry but can
collect in the generator when it is shut down. The
Depending upon application, adjustments to problem will be worse in humid environments or in
other protective and control gear may be areas where extreme temperature changes cause
required. Refer to instructions provided by the condensation (dew) to form inside the generator.
by the supplier of the generator set.
Space heaters, air filters, and premium insulation
The standard MagnaMAX DVR
voltage systems, such as our VPI process, should be
regulator also has many protective and control considered in difficult environments.
circuits.
Accumulations of dust and dirt not only contribute
It is imperative that the set up instructions for to insulation breakdown, but they can also increase
any regulator supplied be followed. temperature by restricting the dissipation of heat.
Materials such as talc, lint, rock dust, or cement
dust may obstruct the ventilation.
MAINTENANCE
The most harmful types of foreign materials include
GENERAL INFORMATION carbon black, metallic dust and similar substances
that not only impede ventilation, but also form a
conductive film over the insulation, increasing the
Dirt, heat, moisture, and vibration are
possibility of insulation failure.
common enemies of a generator. Keeping the
generator clean and dry, maintaining proper
Machines operating in dirty places should be
alignment of the generator and its prime
disassembled and cleaned periodically.
mover, and preventing overloads will result in
efficient operation and long life. AIR INTAKE AND EXHAUST
Generators that are outdoors should be
Check the area around the air intake and exhaust
protected from the elements by suitable
openings to be sure they are unobstructed.
houses or enclosures.
Dirt and dust will conduct electricity between

points of different electrical potential.
Moisture will aggravate the problem further.
Insulation system failure can result if
corrective action is not taken. Measuring
insulation resistance can test the condition of
the insulation system.
(See Generator Testing.).
Insulation resistance should be checked when

putting the generator into service after it has
been in storage and anytime contamination by
moisture and dirt is suspected. .
Figure 5-1
Normally, moisture buildup is not a problem
while the generator is running, since heat
23
ELECTRICAL CONNECTIONS, To add or renew grease, proceed as follows:
WINDINGS
1. Stop unit.
Inspect for loose or contaminated connections
Check wires for cracked or frayed insulation. 2. Wipe the grease plugs and surrounding parts to
Tighten connections and replace defective or insure they are clean.
oil soaked insulation.
3. Remove both the fill and drain plugs.
If inspection shows that varnish coatings on See figure 5-2
the windings have deteriorated, they should be
coated with insulating varnish. 4. Insert 1/8” N.P.T. grease fitting in fill pipe.
Please refer to Marathon Electric for 5. Free the drain holes of any hard grease, using a
insulation system requirements. piece of wire it necessary.
6. Using a low-pressure grease gun, add grease

LUBRICATION according to the amounts in table 5-3.
All generators are lubricated before leaving 7. Start unit with drain plug removed - fill pipe
the factory and are ready for operation. As a may be open or closed. Allow unit to run 15
general rule, bearings should be re-lubricated minutes to allow excess grease to drain.
annually or at the indicated intervals in table
5-3, whichever occur first. 8. Stop unit, wipe off any drained grease, and
replace filler and drain plugs.
Unusually severe operating conditions, such
as high ambient or dusty environments,
require more frequent lubrication (every six
months or one half the table intervals,
whichever occurs first).
Use Chevron SRI or equivalent anti-friction

type high quality, grease with a lubrication
temperature’ range of -22° to +350° F (-30°
to +175° C)
Figure 5-2
24
The amount of grease added is very important! Only enough grease should be added to replace
the grease used by the bearing.
CAUTION: TOO MUCH GREASE CAN BE AS HARMFUL AS INSUFFICIENT
GREASE. USE THE PROPER AMOUNT.
Type Frame Bearing Intervals ---
Size Size Amount of Grease Max. hours or
annually
Ounces Cubic Inches Teaspoons 60 Hz 50 Hz
Single 431,432, 433 314 1.2 2.1 7.0 6500 8400
Bearing 571,572,
Units 573, 574 316 1.5 2.6 8.3 5600 7200
741, 742, 322 2.4 4.2 14.0 3000 4500

743,744
431,432 318 1.7 3.0 9.9 4600 6200
Double 571, 572,
Bearing 573, 574 318 1.7 3.0 9.9 4600 6200
Units
741, 742, 322 2.4 4.2 14.0 3000 4500
743, 744
TABLE 5-3
During an overhaul, the grease reservoir should b thoroughly cleaned and new grease added. The
reservoir should be 1/3 to 1/2 filled with new grease
25
DRYING ELECTRICAL INSULATION
“Short Circuit” Method
Electrical components must be dried before Using this method can dry out the generator
placing in operation if tests indicate that the quickly and thoroughly.
insulation resistance is below a safe value.
(See Generator testing for test procedure.) WARNING:
BE SURE THAT ALL OF THE
Machines that have been idle for sometime FOLLOWING STEPS ARE
in unheated and damp locations, may have PERFORMED AND ALL PRECAU-
absorbed moisture. Sudden changes in TIONS TAKEN AS PERSONAL
temperature can cause condensation or the INJURY OR SERIOUS DAMAGE TO
generator may have become wet by THE GENERATOR COULD RESULT.
accident. Windings should be dried out
thoroughly before being put into service. 1. Disconnect exciter leads Fl and F2 from
The following are recommended drying the regulator.
methods.
2. Connect a battery or other dc power source
Space Heaters approximately 20-35 volts to the exciter lead
Electric space heaters can be installed inside Fl and F2. An adjustable voltage source
of the generator. When energized (from a desirable, however, a rheostat (rated
power source other than the generator) they approximately 2 amps) in series with the dc
will heat and dry the inside of the generator. power source will work.
If an alternate source of electricity is not
available, enclose the generator with a 3. Short circuit the generator output lead
covering and insert heating units to raise the wires to each other (L1 to L2 to L3). If using
temperature 15-18 degrees F (8-10 degrees jumpers, be sure they are large enough to
C) above the temperature outside of the carry full load amps.
enclosure. Leave a hole at the top of the
enclosure to permit the escape of moisture. 4. Start the generator and measure the
current through the output leads with a clip-
Oven on ammeter.
Place the machine in an oven and bake it at a
temperature not to exceed 194 F (90°C). The 5. Adjust the voltage source to produce
voltage regulator and any electronic approximately 80% of the rated ac
component accessories must be removed nameplate current but in no case exceed
from the generator when using this method. nameplate amps. If a adjustable source is not
available and current is excessive, use a
Forced Air lower dc source voltage or larger resistor in
A portable forced air heater can be used by series with the source.
directing heat into the air intake (conduit
box) and running the generator with no load Running time will be determined by the
and without excitation (this can be amount of moisture present in the machine.
accomplished by removing the regulator Insulation resistance checks should be taken
fuse). Heat at point of entry should not every one to four hours until a fairly
exceed 150° F (66° C). constant value obtained. (See section -
26
Generator testing for instructions on recommended. CAUTION: A SOLVENT
measuring insulation resistance.) THAT DOES NOT ATTACK EPOXY OR
POLYESTER BASED MATERIALS
6. After the generator is dry and the SHOULD BE USED.
insulation resistance is brought up to
specification remove the short circuit from Apply the solvent with a soft brush or rag.
the line lead disconnect the dc source and Be careful not to damage the magnet wire or
reconnect the F and F2 leads at the insulation on the windings.
regulator. Be sure all connections are tight Dry components thoroughly with moisture-
and correct before attempting to run the free, low pressure compressed air.
generator.
Cloth and Compressed Air
CLEANING METHODS Cleaning with a dry cloth may be
When electrical components get dirty, the satisfactory when components are small, the
insulation must be cleaned. There are a surfaces are accessible and only dry dirt is
number of acceptable methods for cleaning removed. Blowing dirt out with compressed
the generator, each of which will necessitate air is usually effective particularly when the
disassembly of the unit. The kind of dirt, and dirt has collected in places that cannot be
when the unit must be returned to service reached with a cloth. Use clean dry air at 30
will determine the method of cleaning. PSI (206 KPA).
Drying after cleaning is necessary.
Brushing and Vacuum Cleaning
Whenever the generator is disassembled, the Dry dust and dirt may be removed by
windings should be given a thorough brushing with bristle brushes followed by
inspection and the insulation cleaned, if vacuum cleaning. Do not use wire brushes.
necessary. The inspection should include the Vacuum cleaning is an effective and
connection of the windings, insulation, and desirable method of removing dry and loose
varnish coverage. Check the winding ties dirt.
and coil supports. Look for any signs of coil
movement or looseness and repair as Shell Blasting
required. Air blasting with ground nut shells may be
satisfactory for removal of hard dirt deposits
An electric motor repair shop in your area from insulation. Use mild abrasives such as
can normally assist with the proper cleaning 12-20 mesh ground walnut shells.
of the generator windings. They may also be
experienced in special problems (such as Steam Cleaning
seacoast, marine, oilrig, mining, etc.) that If the generator is completely disassembled,
may be peculiar to a certain area. including bearings and electronic
components, steam cleaning of the major
Solvents parts and windings is very effective.
A solvent is usually required to remove However, the machine must be thoroughly
accumulated soil containing oil or grease. dried in an oven to remove all moisture
Only petroleum distillates should be used for before the generator can be put back into
cleaning electrical components. Petroleum service.
solvents of the safety type with a flash point
greater than 100° F (38° C) are
27
DISASSEMBLY 2. Disconnect all external wiring from the
generator leads inside the conduit box.
REMOVAL FROM PRIME MOVER
3. Remove all conduits or ducting from the
conduit box.
BE SURE ALL POWER IS OFF
BEFORE SERVICING. FAILURE TO
4. Attach a suitable hoist to the generator
FOLLOW ALL SAFETY
lifting
INSTRUCTIONS CAN RESULT IN
SERIOUS INJURY OR DEATH.
5. For single bearing generators, remove the
bolts mounting the screen assembly to the
NOTE:Before disconnecting any electrical
SAE adapter and remove the screen.
wiring, be sure it is marked and can be
(Figure 6-3.)
identified for reinstallation. Re-label as
required.
1. Remove conduit box covers

(Figure 6-1 and 6-2)
.
Figure 6-3
(NOTE: Do not remove the drip cover from

the screen assembly if so equipped )Remove
the cap screws attaching the drive discs to
the flywheel and remove the cap screws
Figure 6-1 attaching the SAE adapter to the flywheel
housing.
For two-bearing generators, disconnect the
coupling or sheave and belts between the
generator and prime mover. (Follow the
coupling manufacturer’s instructions for
direct connection.)
WARNING
DO NOT APPLY ANY FORCE TO THE
GENERATOR FAN FOR LIFTING OR
ROTATING THE GENERATOR
Figure 6-2
28
CONDUIT BOX REMOVAL
1. Note the location and markings (re-mark 3. Remove bolts holding conduit box in
as required) and remove connections from place. (Figure 6-6.)
voltage regulator (Figure 6-4), capacitor
(Figure 6-5), and any other conduit box
mounted controls.
Figure 6-6
Figure 6-4
4. Remove conduit box. (Figure 6-7).
Figure 6-5
2. On generators equipped with bus bars,

mark all connections and disassemble main
stator (power) leads from the generator side
Figure 6-7
of the bus bars.
29
EXCITER STATOR (FIELD) REMOVAL EXCITER ARMATURE (ROTOR)
REMOVAL
1. Disconnect Fl and F2 leads from the
corresponding Fl and F2 terminals on the 1. Note markings and disconnect the main
regulator. rotor leads coming out of the lead hole of
the aluminum standoff plate from the
2. Remove all cable ties so the Fl and F2 rectifier aluminum angle. (Figure 6-10.)
leads can be removed with the exciter stator.
Remove the four cap screws and Belleville
washers holding the exciter stator in place.
(Figure 6-8.)
Figure 6-10
2. Remove the cap screw and Belleville

washer that holds the exciter (rotor)
armature to t generator shaft. (Figure 6-11.)
Figure 6-8
Remove the exciter stator. Using a lifting

strap or fixture. (Figure 6-9.)
Figure 6-11
3.Use a six inch, 3/4-16NF, cap screw for a

puller (See section 9.) The hole that the
mounting bolt goes through is threaded.
Screw the pull bolt into the hole and it will
push against the end of the shaft. (Figure 6-
12.)
Figure 6-9
30
PMG STATOR REMOVAL
1. Remove exciter armature. (Follow

instructions found earlier in this section.)
2. Remove the PMG output leads from the

capacitor (Figure 6-14) and loosen all cable
ties so the leads can be removed with the
PMG stator.
Figure 6-12
Carefully feed the main rotor leads through

the hole as the exciter armature is removed.
(Figure 6-13.)
Figure 6-14
3. Note the position of the PMG stator leads

that exit at the left inboard side or mark the
stator so it can be reinstalled in the same
position.
4. Remove the four mounting cap screws.

(See Figure 6-15.)
Figure 6-13
CAUTION:
DO NOT TIGHTEN THE PULLER
BOLT BEYOND THE END OF THE
THREADS. IF A BOLT WITH
SUFFICIENT THREAD LENGTH
CANNOT BE FOUND, USE A PIECE
OF THREADED ROD WITH A NUT
WELDED ON THE END.
Figure 6-15
31
5. Carefully remove the PMG stator from its
mounting pads and slide over the PMG
rotor. The magnets used in the PMG are
very strong and will resist removal of the
PMG stator. (Figure 6-16.)
Figure 6-16
PMG ROTOR REMOVAL Figure 6-18

3. Slide the PMG rotor off of the shaft.
1. Remove the exciter armature and PMG (Figure 6-19.)
stator. (Follow instructions found earlier in
this section.)
2. Remove the snap ring that holds the PMG

rotor in place on the shaft. (Figure 6-17 and
6-18.)
Figure 6-19
4. Remove the loading spring. (if the loading

Figure 6-17 spring is not on the shaft, check to see if it is
stuck on the back of the PMG rotor.).
5. On 430 frame generators a second snap

ring is used inboard of the PMG rotor.
(Larger generators have a step on the shaft.)
32
This snap ring must be removed before the
generator main rotor can be removed.
(Figure 6-20.)
Figure 6-21
Figure 6-20
MAIN ROTOR REMOVAL
1. Remove the exciter armature and PMG.

four cap screws holding the bearing caps to Figure 6-22
the front-end bracket. (Figure 6-21.)
Remove the outer cap. (Figure 6-22.)
For two-bearing generators, remove the

drive coupling or sheave and key from the
shaft extension. Remove the four cap screws
holding the bearing lock to the drive end
bracket. (Figure 6-23.) Remove the four cap
screws holding the bearing caps to the front-
end bracket. (Figure 6-21.) Remove the
outer cap. (Figure 6-22.)
Figure 6-23
33
3. If the screen assembly is still mounted,
remove bolts securing the screen assembly
to the drive end bracket or the SAE adapter
and remove the screen assembly. (Figure 6-
24.) (NOTE: Do not remove the drip cover
from the screen assembly if so equipped.)
Figure 6-26
Figure 6-24
Figure 6-27
cap screws and hardened washers holding CAUTION: ON LARGE GENERATORS, A
the drive discs to the drive hub. (Figure 6- HOIST AND LIFTING STRAP SHOULD
25.) Remove all drive discs (and spacers if BE USED TO ASSIST IN DRIVE END
any). BRACKET OR SAE ADAPTOR REMOVAL
For two bearing generators remove the cap

screws holding the drive end bracket to the
generator and remove the bracket
(Figures 6-26 and figure 6-28)
Figure 6-25

cap screws holding the SAE adapter to the
generator and remove the adapter. (Figure 6-
26 and 6-27.)
Figure 6-28
34
6. Using a rotor lifting fixture and a suitable
hoist, carefully remove the rotor assembly
from the main stator and frame assembly
through the drive end. (Figure 6-29.)
CAUTION:
SPECIAL CARE SHOULD BE TAKEN
WHEN REMOVING THE MAIN ROTOR,
WINDING DAMAGE COULD RESULT IF
THE ROTOR IS ALLOWED TO HIT THE
MAIN STATOR.
Figure 6-30
Figure 6-29 Figure 6-31
WARNING
DO NOT APPLY ANY FORCE TO THE EXCITER INSPECTION
ROTOR. DISREGARDING THESE EXCITER STATOR
INSTRUCTIONS MAY CAUSE PER-
SONAL INJURY OR EQUIPMENT 1. Clean dust and dirt from the exciter stator
DAMAGE. winding. (Figure 6-32.) (See section 5.)
FRONT END BRACKET REMOVAL

1. Remove front bracket mounting
screws. (Figure 6-30.)
2. Remove the front-end bracket from the

main stator assembly. (Figure 6-31.)
CAUTION: ON LARGE GENERATORS,

A HOIST AND LIFTING STRAP SHOULD
BE USED TO ASSIST IN THE FRONT END
BRACKET REMOVAL Figure 6-32
35
2. Check the exciter stator for a loose, CAUTION: THREE FORWARD AND
frayed, or burnt winding. Measure winding THREE REVERSE POLARITY DIODES ARE
resistance and insulation resistance. (See USED. BE SURE THE CORRECT PART IS
section 8.) INSTALLED IN THE CORRECT LOCATION.
THE SURGE SUPRESSOR IS POLARIZED.
OBSERVE POLARITY MARKINGS WHEN
Repair or replace as necessary. If field repair
CHANGING THE SURGE SUPRESSOR
of the winding is necessary, contact
Marathon Electric for special winding
procedures and materials.
3. Look for score marks in the bore of the

exciter core caused by rubbing. (This could
indicate bearing or assembly problems and
should be investigated.)
EXCITER (ROTOR) ARMATURE
1. Clean dust and dirt from and rectifier Figure 6-34

assembly. (Figure 6-33) (See Section 5)
Torque mounting nuts to 80 in-lb. Torque
lead terminal nuts to 25 in-lb. Never torque
against the diode terminal - use a 7/16-in.
wrench to support the terminal.
Figure 6-35
4. Check the exciter armature and rectifier

Figure 6-33 assembly for loose, frayed, or burnt winding
or loose connections. Measure winding
2. Check the exciter armature for burrs on resistance and insulation resistance. DO
the mating surfaces. NOT megger diodes or surge suppressor.
Repair or replace as necessary. If field repair
3. Check the rectifiers and surge protector of the winding is necessary, contact
for proper operation. Replace defective Marathon Electric for special winding
parts. procedures and materials.
36
5. Look for score marks on the outside
diameter of the armature core caused by
rubbing. (This could indicate bearing or
assembly problems and should be
investigated.) Figure 6-37
1. Clean dust and dirt from the PMG rotor.

PMG INSPECTION
2.Check to be sure all magnets are tightly
PMG STATOR bonded to the PMG rotor.
1. Clean dust and dirt from the PMG stator
winding. 3.Check the bore and keyway of the PMG
rotor for burrs or corrosion.
4.Look for score marks on the outside

diameter caused by rubbing. (This could
indicate bearing or assembly problems and
should be investigated.)
5. Inspect snap rings and loading spring,

replace as required.
Figure 6-36
MAIN ROTOR INSPECTION
2. Check PMG stator for a loose, frayed, or
burnt winding. Measure winding resistance
BEARING
and insulation resistance. (See section 8.)
Repair or replace as necessary. Contact
Marathon Electric for special winding 1. Check the bearing for damage or wear.
procedures and materials. Clean old grease from the bearing cap, and
fill bearing cap grease cavity 1/3 to 1/2 full
3. Look for score marks in the bore caused of r Chevron SRI (or equivalent).
by rubbing.
CAUTION: If the bearing needs to be
removed any reason, always install a new
PMG ROTOR bearing.
WARNING 2. If the bearing is to be replaced, remove

THE PMG ROTOR USES VERY STRONG with suitable puller. (Figure 6-38.)
MAGNETS. KEEP AWAY FROM IRON
AND STEEL PARTS THAT COULD BE
DRAWN TO THE MAGNETS AS WELL AS
OTHER COMPONENTS THAT CAN BE
DAMAGED BY MAGNETIC FIELDS.
37
Figure 6-38
Figure 6-39
3.Be sure the inner bearing cap is on the
shaft before installing the new bearing. Allow the bearing to cool for one
hour before attempting to assemble the
4. Heat the new bearing in an oven to a generator.
maximum temperature of 212°F (100°C).
Apply a thin coat of clean lubricating oil to
the press-fit area of rotor shaft. Install the
bearing over the end of the shaft until it
seats against the shaft shoulder as shown in
Figure 6-39. The bearing should slide on the FAN
shaft and seated without excessive force. If
the bearing binds on the shaft before being 1. Check the fan for cracks or broken blades.
fully seated a piece of tubing, slightly larger Replace the fan if defective.
than the press area, can be used to drive the
bearing into place. Using light taps with a 2. Mark the hub and fan for alignment, this
soft mallet, apply pressure to the inner race is necessary to be sure the balance weights
only. will be in the same position when the fan is
reinstalled.
CAUTION:
UNDER NO CIRCUMSTANCES SHOULD 3. For single bearing generators. Remove the
PRESSURE BE APPLI ED TO THE OUTER fan mounting cap screws (Figure 6-40) and
RACE OF THE BEARING, AS slide the fan off the shaft. (Figure 6-41.)
PERMANENT BEARING DAMAGE
For two-bearing generators, remove the
COULD RESULT.
drive end bearing and bearing cap. (See
bearing removal instructions.) Remove the
fan mounting cap screws and slide fan off
the shaft. (Figure 6-40 and 6-41.)
38
5. NOTE: Balance weights on the fan are for
balance of the complete rotor assembly. The
rotor assembly should be rebalance if a new
fan has been installed.
6. On two-bearing generators, install bearing

cap and new bearing according to the
bearing assembly instructions. (Item A.)
Drive Hub (Single Bearing Generators)
Figure 6-40 1. Check the drive hub for cracks or stripped

drive disc mounting holes. Replace the hub
if defective.
2. If the hub is to be replaced, remove the

fan (See Item B) and install a suitable puller
to the hub. Remove the two set screws in the
hub over the key. Using a torch, rapidly heat
the hub at the outer diameter while
tightening the puller. (This must be done
rapidly before the heat can expand the
shaft.) Remove the hub. (Figure 6-43)
Figure 6-41
4. To reinstall, slide the fan on the shaft

making sure the fan-mounting surface is
toward the drive hub. Align reference marks
(this is important for assembly balance) and
mount the fan to the drive hub with the cap
screws and Belleville washers. (Figure 6-
42.) Torque the cap screws to 60 ft-lb. (81
N-m).
Figure 6-43
3. To insure proper fan location, mark the

new hub in the same place as the old hub
relative to the keyway. Install key in shaft.
Heat the new hub in an oven to 500°-600°F
(260°-316°C). Use suitable heat resistant
Figure 6-42 gloves, slide the hub over the key in the
shaft until it seats against the shaft
shoulder. (Figure 6-44.)
39
resistance an insulation resistance. Test for
shorted turns using an A-C impedance test A
defective rotor winding must be rewound
The rotor assembly must be rebalanced after
any rework or repair has been completed.
DRIVE DISCS (SINGLE BEARING

GENERATORS ONLY)
1. Inspect the drive discs for distorted or

bent edges. (Figure 6-46) Inspect for worn
mounting holes. Replace all defective discs
as necessary.
Figure 6-44
4. Allow the hub to cool for one hour. After

the hub has cooled, tighten the set screws in
the hub to 50 ft-lbs. (68 N.M.) torque. Match
the alignment marks on the fan and hub and
mount the fan. (See item B.)
5. Rebalancing the rotor assembly is not

necessary if only the hub is replaced and the Figure 6-46
fan is mounted in the same location relative
to the hub and shaft. 2. Inspect the drive disc mounting cap
screws for damaged threads. Replace cap
screws if damaged.
MAIN ROTOR CORE AND WINDINGS
FRONT (EXCITER) END
1. Clean all parts. Remove dust and dirt BRACKET INSPECTION
from the rotor winding air passages with
low-pressure, moisture-free air. 1. Remove the filler and drain grease pipes
and the grease plugs from outer bearing cap.
(Figure 6-47.)
Figure 6-45
Figure 6-47
2. Check the rotor for loose, frayed, or
burned windings. Measure winding
40
2. Clean the end bracket, outer bearing cap, 2. Clean the bracket or adapter, cap screws
grease pipes, and cap screws to remove all and screen assembly to remove all dust, dirt,
dust, dirt, and grease. and grease.
3. Inspect the cap screws for stripped threads 3. Inspect the cap screws for stripped threads
and replace if defective. and replace if defective.
4. Inspect the end bracket for stripped 4. Inspect the bracket or adapter for stripped
threads, cracks, and burred or rough mating threads, cracks, and burred or rough mating
surfaces. Inspect the bearing bore for burrs surfaces. (Figure 6-49 and 6-50.)
or wear. If the bracket shows excessive
bearing bore wear, it should be repaired or
replaced. (Figure 6-48.)
Figure 6-49
Figure 6-48
5. Inspect the mounting pads for the PMG

stator and exciter stator. Be sure they are
smooth, clean, and free of any burrs or rust.
That could interfere with proper alignment.
(Figure 6-47 and 6-48.)
6. Re-assemble the grease pipes and fittings

to the bearing cap. Figure 6-50
5. For two-bearing generators, inspect the

DRIVE END BRACKET OR SAE bearing bore for burrs or wear. If the drive
ADAPTER INSPECTION end bracket shows excessive bearing bore
wear, it should be repaired or replaced.
1. For two-bearing generators, remove the
grease plugs from the bracket.
41
MAIN STATOR INSPECTION
1. Clean dust and dirt from the stator frame

and winding. (Figure 6-51.) (See section 5.)
Figure 6-52
CAUTION: ON LARGE GENERATORS, A

HOIST AND LIFTING STRAP SHOULD
BE USED TO ASSIST IN THE FRONT END
Figure 6-51 BRACKET INSTALLATION.
2. Inspect the frame for stripped threads,

cracks, burred mating surfaces, or other
damage.
3. Inspect the stator for a loose, frayed, or

burnt winding. Measure winding resistance
and insulation resistance. (See section 8.)
Repair or replace as necessary.
FRONT END BRACKET

INSTALLATION
Figure 6-53
1.Install two guide pins (threaded rod can be
used) into the generator side of the end 2. Remove the two guide pins and insert the
bracket mounting holes. Align the guide remaining cap screws and torque to
pins with the holes in the generator frame specifications given in section 12.
and slide the bracket onto the frame. (Figure
6-52.) Install bracket mounting cap screws. MAIN ROTOR INSTALLATION
(Figure 6-53.)
1. Grease bearing cavity and bearing with
Chevron SRI (or equivalent) grease.
2. Using a rotor lifting fixture and a suitable

hoist, carefully install the rotor assembly
into the main stator assembly through the
drive end. (Figure 6-54.) Carefully feed the
rotor leads through the front-end bracket
shaft hole as the rotor is installed.
42
Figure 6-55
Figure 6-54
CAUTION:
SPECIAL CARE SHOULD BE TAKEN
WHEN INSTALLINGTHE ROTOR
ASSEMBLY. WINDING DAMAGE
COULD RESULT IF THE ROTOR
IS ALLOWED TO HIT THE MAIN
STATOR.
WARNING
DO NOT APPLY ANY FORCE TO THE
GENERATOR FAN FOR LIFTING OR Figure 6-56
ROTOR. DISREGARDING THESE
INSTRUCTIONS MAY CAUSE PER-
SONAL INJURY OR EQUIPMENT
DAMAGE.
3. For single bearing generators, slide the

SAE adapter over the fan and secure to the Figure 6-57
main stator and frame assembly with cap For two-bearing generators, insert two
screws torqued per section 12. (Figure 6-55 guide pins in the rear bearing lock holes.
and 6-56.) It may be necessary to raise the (Figure 6-57.) Fill the grease cavity of the
rotor assembly slightly to allow the drive end bracket 1/3 to 1/2 full of Chevron
mounting of the SAE adapter. SRI (or equivalent) grease. Assemble all
grease plugs in the bracket. Mount the
bracket on the bearing and guide the bearing
lock pins through the bracket holes. (Figure
6-58.)
43
spacers (if any), then all drive discs, one at a
time until all discs are installed. (Figure 6-
61.)
Figure 6-58
Figure 6-61
Align the drive end bracket and mount with
the cap screws. (Figure 6-59.) Insert two cap Make sure that all disc mounting holes at
screws with lock washers into the bearing the inner and outer diameter are properly
lock and tighten. Remove the guide pins and aligned. Secure the discs with the grade
replace with the remaining two cap screws eight 5/8-18 cap screws and hardened
with lock washers. Torque bearing cap washers. Torque to 192 ft-lb. (260 N-m).
screws to 25 lb.-ft (34 NM). Torque bracket Torque the bolts in sequence according to
mounting cap screws per specifications Figure 6-62.
given in section 12.
Figure 6-59
Figure 6-62
CAUTION: 5. Install the outer bearing cap on the exciter
ON LARGE GENERATORS, A HOIST end. (Figure 6-63.) Align holes in inner and
AND LIFTING STRAP SHOULD BE outer bearing cap and install cap screws.
USED TOASSIST IN THE DRIVE END Torque to 25 lb.-ft (34 N-M) (Figure 6-64.)
BRACKET OR THE SAE ADAPTER
ASSEMBLY.
4. For single bearing generators, insert a

guide stud into the drive hub. Position all
44
Figure 6-63
Figure 6-66
3. Install snap ring. (Figure 6-67.) Use a

piece of pipe slightly larger than the shaft
(2-3/4 inches) to push the rotor back against
the loading spring until the snap ring seats in
the slot. (Figure 6-68.)
Figure 6-64
PMG INSTALLATION
1. Install inboard snap ring, where supplied,
and loading spring on shaft. (Figure 6-65.)
Figure 6-67
Figure 6-65
2. Slide PMG rotor onto shaft. (Figure 6-66.) Figure 6-68
4. Install the PMG stator on its mounting

pads, with the leads in the left (9:00 o’clock)
inboard position, and secure with the four
45
mounting cap screws and Belleville washers. through the lead hole in the aluminum
(Figure 6-69 and 6-72.) standoff plate. (Figure 6-71.)
Torque to 4 ft-lb. (5 N-M).
Figure 6-69 Figure 6-71
5. Route and secure PMG moving parts. Insert the cap screw and Belleville washer
(Figure 6-72.) through the mounting hole in
the aluminum standoff plate and secure to
EXCITER INSTALLATION the shaft (Figure 6-73). Tighten the cap
screw until the armature seats on the shaft.
Torque to 84 lb.-ft (114 N-M).
1. Attach a wire to the main rotor leads and
feed the wire through the armature bore and
the lead hole in the aluminum standoff plate.
On larger exciters, it will be helpful to
install a guide pin in the end of the shaft to
support the armature while fishing the rotor
leads through. (Figure 6-70.)
Figure 6-72
Figure 6-70
Align the key in the armature bore to the

Figure 6-73
keyway in the shaft. Slide the armature on
2. Observe the polarity markings and
the shaft while feeding the main rotor leads
connect the main rotor leads to the rectifier
46
assembly. (Figure 6-74.) Torque the nuts to CONDUIT BOX INSTALLATION
4 ft-lb. (5.4 N-M). 1. Install the conduit box over the main
stator leads (be sure the leads are in the
upper compartment and secure with bolts
and lock washers. (Fig 6-76 and 6-77.)
Figure 6-74
Figure 6-76
3. Position the exciter field leads at the left
(9:o’clock) inboard position. Using a
suitable lifting device, mount the exciter
stator on the front e bracket mounting pads
and align the mounting holes. (Figure 6-75.)
Mount the cap screws with Belleville
washers. (Figure 6-72.) Torque t cap screws
to 60 ft-lb. (81 N-M). Route and secure the
exciter stator leads away from any moving
parts.
Figure 6-77
2. On generators with bus bar assemblies,

reassemble main stator leads and insulating
blocks to bus bars. (Figure 6-78.)
Figure 6-75
Figure 6-78
47
3. Reconnect exciter leads, PMG leads and
other accessories according to the
connection prints and markings installed WARNING
before disassembly. DO NOT APPLY ANY FORCE TO THE
ASSEMBLY TO PRIME MOVER ROTATING THE GENERATOR
1. Attach a suitable hoist to the generator ROTOR. DISREGARDING THESE
lifting lugs, and move the generator until the INSTRUCTIONS MAY CAUSE PER-
generator foot mounting holes are aligned SONAL INJUY OR EQUIPMENT
with the base and slightly above. DAMAGE.
2. For single bearing generators, if the CAUTION:

screen assembly is mounted on the adapter, DO NOT FORCE THE ALIGNMENT
remove the mounting bolts and remove the OFTHE UNITS. SHIFT THE
screen. (Figure 6-79.) GENERATOR FROM SIDE TO SIDE
OR RAISE OR LOWER WITH A
LIFTING DEVICE AS NECESSARY.
It may be necessary to use shims under the

mounting feet of either the generator or the
prime mover to obtain proper alignment.
Use the same shims as removed under dis-
assembly or proceed as follows: Using the
extreme bottom four cap screws, mount the
SAE adapter to the flywheel housing.
With a .0015 to .002 inch feeler gauge at the

extreme top of the adapter to flywheel
Figure 6-79 housing fit, raise the generator or lower the
prime mover until the gauge is snug. Relieve
(NOTE: Do not remove the drip cover from just enough to release the feeler gauge and
the screen assembly if so equipped.) torque the remaining SAE adapter cap
Insert two guide pins in the flywheel and screws to the flywheel housing.
two in the flywheel housing. Adjust the
generator position until the drive discs are Mount the screen assembly and tighten the
piloted in the flywheel. Remove the guide mounting bolts.
pins and secure the discs with Grade 8 place
bolts and hardened washers or Grade 8 cap For two-bearing generators, align the coup-
screws and heavy series lockwashers. ling halves or sheaves between the generator
and the prime mover by adding shims under
Torque per specifications given in section the feet.
12.
3. Shim under the generator feet for proper
Position the generator so that the SAE support, ensuring that the generator
adapter mates with the flywheel housing. mounting surfaces are level.
48
4. Install the mounting bolts that secure the
generator to the base.
5. For two bearing generators, assemble the

coupling halves or sheave belts between the
generator and the prime mover. (Follow the
coupling manufacturer’s instructions for
assembly and alignment.)
6. Connect all conduits and ducting to the Figure 6-80

conduit box.
NOTE: On single bearing units, the exciter
7. Connect all external wiring to the air gap cannot be checked properly until the
generator inside the conduit box. generator is mounted to the prime mover.
8. Check the exciter air gap (the gap 9. Install the conduit box covers.
between exciter armature and stator) by
inserting a .010 inch feeler gauge in the gap
and rotating around the armature diameter to
ensure the minimum air gap is available.
(See Figure 80.) If the feeler gauge cannot
be rotated full revolution, then check for a
“cocked" exciter stator or loose stator
mounting screws.
49
TROUBLESHOOTING WARNING
HIGH VOLTAGES CAN BE PRESENT
AT THE GENERATOR AND
INTRODUCTION REGULATOR TERMINALS. HIGH
RESIDUAL VOLTAGES CAN BE
This section is intended to suggest a PRESENT EVEN WITH THE
systematic approach to locating and REGULATORDISCONNECTED OR
correcting generator or regulator ITS FUSES REMOVED. SOME
malfunctions. The sections are arranged EQUIPMENT (SUCH AS
according to the symptoms of the problem. SPACEHEATERS) MAY BE
The steps in each section have been ENERGIZED WHEN THE
arranged in an attempt to do the easy checks GENERATOR IS OFF. TOOLS,
first then to prevent further damage when EQUIPMENT, CLOTHING, AND
troubleshooting a disabled machine. YOUR BODY MUST BE KEPT CLEAR
OF ROTATING PARTS AND
The first and perhaps most important step of ELECTRICAL CONNECTIONS.
troubleshooting should be to gather as much
information as possible from personnel who SPECIAL CAUTION MUST BE TAKEN
may have been present during the failure. DURING TROUBLESHOOTING SINCE
Information on how long the generator had PROTECTIVE COVERS AND SAFETY
been running, what loads were on the line, DEVICES MAY BE DISABLED TO
weather conditions, what protective equip- GAIN ACCESS AND MAKE TESTS.
ment operated, etc., can help isolate the
problem. BE CAREFUL. SERIOUS PERSONAL
INJURY OR DEATH CAN RESULT
Always make a thorough visual inspection FROM THESE HAZARDS. CONSULT
to check for any obvious problems before QUALIFIED PERSONNEL WITH ANY
attempting to run the generator. QUESTIONS.
50
SYMPTOM:
Regulator Fuse Blown Replace bad fuse.

Check fuse with ohmmeter.
NO VOLTAGE OR
RESIDUAL VOLTAGE Voltmeter Off Check to be sure meter phase
selector switch is not in the off
position.
Defective Voltmeter Verify proper operation of panel

meter with another meter that is
known to be accurate.
Incorrect Connections Verify generator connections.
Defective Inspect all wiring for grounds, open

Connections/Wiring circuits & short circuits.
No Regulator Input Measure voltage at regulator input

(PMG output)
Defective Diodes, Surge Test generator with constant

Suppressor excitation (12 volt battery test) refer
or Generator Windings
Voltage Regulator Correct problem and adjust

Protective Shutdown regulator. Refer to regulator
Circuits are Operating manual.
Voltage Regulator Adjust or replace regulator. Refer to

Inoperative regulator manual.
51
Under speed Operation Check speed using tachometers
and/or frequency meters.
Defective Voltmeter Verify operation of panel meter

with another meter that is known to
be accurate.
LOW VOLTAGE -
Residual Voltage Disconnect Fl and F2 leads at the
NO LOAD voltage regulator. If voltage goes
down continue on to next step, if
voltage does not change refer to
troubleshooting for symptoms of
“No Voltage - No Residual
Voltage”.
Incorrect Generator Verify generator connections refer

Connections to drawings supplied V generator
set and section 3.
Defective Connections / Inspect all wiring for grounds, open

Wiring circuits, short circuits, and loose
and dirty connections.
Regulator Adjustments Adjust regulator. Refer to regulator

manual. Check exciter field volts.

Suppressor, Generator excitation (12 volt battery test)
Windings
Voltage Regulator not Adjust or replace regulator. Refer to

Operating regulator manual. Properly
52
Overload Measure amps and verify that the
LOW VOLTAGE WHEN load does not exceed nameplate
LOAD IS APPLIED rating of the generator
Defective Ammeter Verify operation of ammeter by

using a separate meter known to be
accurate
Droop Circuit If the generator set is equipped for

paralleling, some voltage droop is
normal as load increases. Refer to
the regulator instruction manual
Continue troubleshooting Continue troubleshooting for

for symptoms “Generator symptoms “Generator Produces
Produces Low Voltage - Low Voltage - No Load”.
No Load”.
Defective Voltmeter Verify operation of panel meter

HIGH VOLTAGE with another meter that is known to
be accurate
Incorrect Operating Speed Verify speed with tachometer or

frequency meter.
Incorrect Connections Verify generator connections

Refer to drawings supplied with
generator set
Defective Connections / Inspect all wiring for grounds, open

Wiring circuits, and short circuits.
Regulator Adjustments Adjust regulator. Refer to regulator

manual
Diode Polarity Incorrect Check diodes, verify proper diodes

are installed and polarity is correct.
Voltage Regulator not Adjust or replace regulator. Refer to

Operating regulator instruction manual.
53
Incorrect Speed Verify speed with tachometer or
VOLTAGE IS frequency meter.
FLUCTUATING
Unstable Speed Verify governor stability.
Voltage Regulator Stability Adjust regulator stability.

Refer to regulator manual.
Defective / Loose Inspect all wiring for loose or dirty

Connections connections.

Suppressor or Generator excitation (12-volt battery test).
Windings
Remote Voltage Adjust Check operation. Refer to regulator

manual.
Defective Regulator Replace regulator. Refer to

regulator manual.
OPERATES Regulator Shutdown on Correct cooling problems. Refer to

SATISFACTORILY Over Temperature regulator manual.
WHEN COLD, BUT
SHUTS DOWN WHEN
WARM
BUILDS VOLTAGE Regulator Protective Check indicators on regulator.

FROM STARTUP,THEN Circuit is Operating Correct problems and adjust as
GOES TO LOW required. Refer to regulator manual.
(RESIDUAL) VOLTAGE
EQUIPMENT RUNS Voltage Waveform is Analyze load. Excessive SCR

NORMALLY ON UTILITY Distorted (Thyristor) loading will cause
POWER, BUT WILL NOT distortion. Some equipment may be
RUN ON GENERATOR sensitive to distorted waveforms.
SET Refer to Marathon Electric.
54
GENERATOR TESTING
VISUAL INSPECTION Problems can be isolated to either the gen-

erator or regulator system by using this test.
Whenever testing and troubleshooting a
generator set, it is always a good practice to TEST PROCEDURE:
make a thorough visual inspection. Remove
covers and look for any obvious problems. 1. Shut the generator set down.
Burnt windings, broken connectors, leads,
mounting brackets, etc., can usually be 2. Connect a voltmeter to the generator
identified. Look for any loose or frayed output.
insulation, loose or dirty connections,
broken wires. Be sure all wiring is clear of 3. Disconnect the Fl and F2 leads at the
rotating parts. regulator.
Verify that the generator is connected for the 4. Connect a 12-volt battery capable of
voltage required this is especially important supplying 1 amp to the Fl and F2 leads. Fl is
on new installations. plus (+), F2 is minus (—).
Check for any foreign objects, loose nuts, CAUTION: Beware of arcing when
bolts, and electrical connectors. Clear paper, connecting leads. Stay clear of battery vents.
leaves, building materials, etc., that could be Escaping hydrogen gas can explode. If
sucked into the generator. (Generators are hazardous conditions exist - use a suitable
air-cooled. Air enters the lower portion of switch to connect or disconnect the battery.
the conduit box.) Check the air gap for
clearance or obstructions (main generator 5. With no load on the generator, (main
and exciter). breakers open) run generator at rated speed.
If possible, rotate the generator rotor by

hand to be sure it turns freely. 6. Measure the generator output voltage.
If serious problems can be identified before 7. Shut generator down.

attempting to operate the machine,
additional damage can be avoided. 8. Disconnect battery (see Caution - Step 3).
9. Compare voltage reading with value

CONSTANT EXCITATION shown in section 12.
(12V BATTERY) TEST
Conclusion: If voltage readings are normal,
THEORY: The generator output voltage is the main generator and exciter are operating
dependent on generator speed, generator properly. Troubleshooting should continue
design, load, and exciter input current. If the with the regulator. If readings are not normal
generator speed and exciter input are known, the problem is in the generator. Continue
the output voltage at no load can be testing diodes, surge suppressor, windings.
measured and compared to the design value.
55
MEASURING VOLTAGES
When testing the generator and regulator,

the most frequent (and usually easiest)
measurement will be a voltage. The
generator will need to be running at rated
speed and may have some of the protective
guards and covers removed. BE CAREFUL.
Keep yourself and your test leads out of the
way. It is best to shut the unit down when
connecting meters. When using alligator
clips or push on terminals, be sure the leads
re supported so vibration does not shake
them loose when running the generator set.
See figure 8-1 for measurement points and Figure 8-1

expected meter range settings.
When in doubt, start with a higher range and
work down.
Consult meter instruction manual to verify
its operation and limitations.
56
TYPICAL VOLTAGE MEASUREMENTS
Voltage Measurement Test Point Meter/Range Selection
Requirement
Output “T” leads or bus bars, System voltage - volts AC See
Generator Output Voltage also main circuit breaker generator nameplate and
“line” side. connection diagram.
Fl and F2 terminals at the 200 volts D.C. range. Fl is
Regulator Output (Exciter regulator. plus (+), F2 if minus (—
Stator Input)
El, E2, E3 terminals at the Usually the same as the
Regulator Sensing Voltage the regulator. system voltage (generator
output volts). However, in
some cases, sensing taken
from winding center taps or
instrument potential
transformers. Maximum 600
volts AC
Example: Center tap of 480-
volt system would give 240
volts El, E2, or E3.
Example:
A 4160-volt system must use a
transformer to step voltage
down below 600 volts.
See the connection diagram
supplied with generator set.
“PMG” leads at the regulator 200-240 VAC 300 Hz

Regulator Input Volts or capacitor. @ 1800 rpm
(PMG Output Volts) 180-220 VAC 250 Hz
@ 1500 rpm
each phase. If the physical size of the

CURRENT (AMP) MEASUREMENTS conductors or the capacity of the meters will
Current measurement (AC) can be easily not permit all cables to be measured at once,
taken with a clamp on type meter. Each one can be measured individually. Add
NOTE: Most clamp type ammeters will not the individual readings together to get the
measure D.C. total. Compare readings to the generator
nameplate (nameplate ratings are always
When measuring generator output current, given per phase).
be sure the clamp is around all cables for
57
Amperage should never exceed the Note markings and disconnect the main
nameplate rating when running the intended rotor leads (Fl leads and F2 leads) from the
load. (Amperage may go above nameplate rectifier assembly. Measure the resistance of
momentarily when starting large motors.) the main rotor winding. Compare reading to
When measuring exciter field amps (Fl and value shown in service specification section
F2 leads) a D.C. meter is required. The 12. Measure from the leads to the exciter-
maximum field current under full regulator mounting bolt to check for grounds.
forcing is 6.5 amps D.C.
Exciter Rotor
MEASURING RESISTANCE
Disconnect the exciter rotor leads at the
The generator windings can be measured diodes (leave leads disconnected if
and compared to the values shown in the proceeding to check diodes). Measure
service specifications. resistance between phases. Compare value
to service specification section 12. Measure
from the leads to the exciter-mounting bolt
Main Stator to check for grounds.
The main stator winding resistance is very

low. A meter capable of readings in the TESTING DIODES (RECTIFIERS)
milliohm range would be required.
However, a standard V.O.M. can be used to Diodes perform the function of an “electrical
check for continuity, shorts, or grounds. check valve”. They conduct in one direction
only and are used to “rectify” ac current into
Example: With leads disconnected, a dc current. To test, measure the resistance
measurement from T1 to T4 should be very first in one direction and then reverse the
low (continuity most V.O.M’s). Measured leads and test in the other direction. The
from T1 orT4 to any other lead should be reading should be high in the reverse
infinite. Measure from the ‘T’ lead the direction and low in the forward direction. A
generator frame to check for grounds shorted diode will read low in both
(reading should be infinite). directions. An open diode will read high in
both directions.
Normal full load reading is approximately 3
amps. NOTES:
1. Two different polarities of diodes are
The exciter stator resistance is measured by used. The only difference is in the way the
disconnecting the Fl and F2 leads at the device is mechanically placed in the case.
regulator. Measure the resistance between When changing diode, be sure the correct
the leads (this value is 22-24 ohms on polarity is used.
standard generators). Measure from the Refer to section 6 figure 6-34.
leads to the frame to check for grounds.
2. Some meters do not have enough voltage
output from their internal batteries to turn
the diode on (about 0.6 volts is required),
and the voltage can change with different
58
range settings. Consult the instruction grounded, it must be disconnected.) Take
manual for your meter. megger reading (refer to the manual for the
3. Polarities supplied by the meters internal megger).
battery may or may not correspond to the
(+) (—) markings on the meter.
INSULATION RESISTANCE -
GENERAL INSULATION RESISTANCE - MAIN
STATOR
Insulation resistance is a measurement of the CAUTION: Be sure the regulator, and any
integrity of the insulating materials that other electronic components, metering,
separate the electrical windings from the protective relays, etc., are disconnected
generators steel core. This resistance can before meggering. High megger voltages
degrade over time or due to contaminants will destroy these parts. All stator leads must
(dust, dirt, oil, grease, and especially be isolated from ground and connected
moisture). Most winding failures are due to together (on most systems with grounded
a breakdown in the insulation system. In neutrals - the neutral can be isolated from
many cases, low insulation resistance is ground and used as a test point). Connect the
caused by moisture collected when the positive megger lead to the main stator
generator is shut down. The problem can be leads. Connect the negative megger lead to
corrected simply by drying out the windings. the generator grounding stud. Take the
Section 5. megohm reading (refer to instructions for
the megger).
Normally the resistance of the insulation
system is on the order of millions of ohms. It
is measured with a device called a “megger” GENERATOR TESTING
which is a megohm meter (Meg is for The minimum acceptable value can be
million) and a power supply. The power calculated using the following formula.
supply voltage varies, but the most common Minimum Insulation Resistance = Gen.
is 500 volts. A megger voltage over 500 is Voltage + 1 (Megohms) / 1000
not recommended except for measuring Example:
medium voltage (2400/4160) stators only. For a 480 volt generator
480 + 1 = 1.48 Megohms
CAUTION: First disconnect any electronic If the reading is below the recommended
components, regulators, diodes, surge value, the winding must be dried out or
protectors, protective relays, etc., will be repaired.
destroyed if subjected to the high megger
voltages. INSULATION RESISTANCE - MAIN
ROTOR
To measure insulation resistance, connect
the red or positive megger lead to the leads Disconnect the main rotor leads from the
for the winding to be tested, connect the diode bridge on the exciter rotor. Connect
back or negative megger lead to the the leads together with the positive megger
generator frame. Be sure the leads of the lead. Connect the negative megger lead to a
part being tested are not touching any metal good ground on the rotor assembly such as
parts of the generator. (If the neutral is the exciter mounting bolt. Take the megohm
59
reading (refer to instructions for the MAIN ROTOR FIELD AC IMPEDANCE
megger). TEST
The minimum acceptable value is 1.5
megohms. THEORY: The main rotor resistance can be
measured with a very accurate meter that is
If the reading is low, the winding must be able to measure low (1 ohm) resistance but it
dried out or repaired. is difficult to determine if there are turn to
turn shorts in the field pole windings. One
shorted turn would only change a resistance
INSULATION RESISTANCE - reading on the order of one half of one
EXCITER STATOR percent.
Disconnect the exciter leads Fl and F2 from The ac impedance test measures the
the regulator. Never subject the regulator to impedance (inductance and resistance) of
a megger. Connect Fl and F2 together with the field pole coils. Shorted turns in the field
the positive megger lead. Connect the pole windings change the coil inductance to
negative megger lead to the ground stud. a much greater degree than the resistance.
Take the megohm reading (refer to
instructions for the megger). PROCEDURE:
The minimum value is 1.5 megohms. Step 1: The rotor must be supported on a
non-magnetic surface such as a wooden
If the reading is low, the winding must be skid. Do not use a steel table that would
dried out or repaired. create a magnetic “short circuit” between the
poles.
INSULATION RESISTANCE - Step 2: Apply 120 volts ac to disconnected

EXCITER ROTOR main rotor leads Fl and F2.
Disconnect the exciter rotor windings (6 Step 3: Measure and record voltages pole.
leads from the diodes). Connect all leads Between points “A” and “C”, “C” and “D”,
together with the positive megger lead. “D” and “E” across each “B”, “B” and
Connect he negative megger lead to a good (Figure 8-1).
ground on the rotor assembly such as the
mounting bolt. Take the megohm reading Step 4: The voltage readings should balance
(refer to the instructions for the megger). within one volt.
The minimum acceptable value is 1.5 RESULTS: If the ac voltages are not
megohms. balanced (30v ± lv ac with 120v ac input)
across each pole, the winding has shorted
If the reading is low, the winding must be turns and should be rewound.
dried out or repaired.
Refer to Marathon Electric for further
information.
60
MAGNAMAX EXPLODED VIEW
61
TABLE 9-1 PARTS LIST
NOTE: The parts in this list are subject to change, model number and serial number must
accompany any parts order or inquiry.

Item Part Description 430 Frame Series 570 Frame Series 740 Frame Series
Part Number Qty. Part Number Qty. Part Number Qty.
1 Screen Assembly
Screen B-525565-1 1 B-525565-2 1 B-525565-3 1
Screen Mounting Bolt Screen A-9646-200 2 A-9646-200 2 A-9646-200 2
Mounting Nut A-7551-18 2 A-7551-18 2 A-7551-18 2
2 Drip Cover assembly B-525566-1 1 B-525566-2 2 B-525566-3 1
3 Adapter
#3Adapter B-525512A 1
#2Adapter B-525512B 1
#1 Adapter B-525513A 1 B-525618A 1
#1/2 Adapter B-525514B 1 B-525616A 1
#0 Adapter B-525514A 1 B-525603A 1 B-525720A 1
#00 Adapter (#18 Disc) B-525617A 1 B-525721A 1
#00 Adapter (#21 Disc) B-526228A 1 B-52572 1A 1
4 Disc Mounting Fasteners
Cap screw for #11-1/2 A-9674-200 6
Cap screw for #14 A-9674-150 6 A-9674-150 9
Cap screw for #18 A-9674-150 6 A-9674-150 9 A-9674-200 18
Cap screw for #21 A-9674-150 18
Cap screw for Delco A-9674-150 6 A-9674-150 9 A-9674-200 18
Hardened Washer A-9667-1 6 A-9667-1 9 A-9667-1 18
5 Drive Discs
#11-1/2 Disc A-525506 5 — — — —
#14 Disc A-525508 5 A-525508 5 — —
#18 Disc B-525975 4 A-525579 5 A-525579 10
#21 Disc — — A-525580 5 A-525580 10
Delco Disc (17.75” 0.0.) A-525507 5 A-525507 5 A-525507 10
6 Spacers
For #11-1/2 Disc A-525567 14 — — — —
For #14 Disc A-525567 5 A-525503 6 — —
For#18 Disc — — — — A-525503 10
For #21 Disc — — — — — —
For Delco Disc — — A-525503 1 A-525503 12
7 Fan Mounting Fasteners
Cap screw A-9626-150 4 A-9626-150 8 A-9626-1 50 8
Cap screw (2 Brg. Only) A-9626-150 4 A-9626-200 8 A-9626-200 8
Belleville Washer A-9682-1 4 A-9682-1 8 A-9682-1 8
8 Fan B-525510A 1 B-525604A 1 B-525719A 1
62
9 Hub
Drive Hub [Sgl Brg. Only) B-525509A 1 B-525606A 1 B-525726A 1
Fan Hub (2 Brg. Only) A-525568A 1 B-525694A 1 B-525750A 1
10 Drive Hub Set Screws — A-9675-50 2 A-9675-50 2
11 Drive Hub Key A-25658-30 1 A-25658-30 1 A-25658-46 1
12 Main Rotor Assembly with REFER TO FACTORY
Windings
13 Front Bearing Cap B-525519A 1 B-525613A 1 B-525743A 1
14 Front Ball Bearing A-7812R-70 1 A-7812R-80 1 A-7812R-110 1
15 Main Body Assembly REFER TO FACTORY
16 Adapter Mounting Fasteners -
Cap screw A-9680-125 12 A-9680-125 16 A-9626-150 16
Lock Washer A-7653-3 12 A-7653-3 16 A-7653-4 16
Flat Washer A-7656-8 16 A-7656-8 16 A-9667-1 16
17 Bracket Mounting Fasteners - - - - -
Cap screw A-9680-1 25 8 A-9680-125 8 A-9626-150 8
Lock Washer A-7653-3 8 A-7653-3 8 A-7653-4 8
Flat Washer A-7656-8 8 A-7656-8 8 A-9667-1 8
18 Front Bracket B-525518A 1 B-525605A 1 B-525739A 1
19 PMG Bearing Cap B-525520A 1 B-525612A 1 B-525742A 1
20 Bearing Cap Fasteners - - - - - -
Cap screw A-9680-350 4 A-9680-400 4 A-9680-450 4
Lock Washer A-7653-3 4 A-7653-3 4 A-7653-3 4
21 Conduit Box D-525673 1 D-525680 1 D-525771 1
22 Conduit Box Mtg. Fasteners
Cap screw A-9680-75 8 A-9680-75 8 A-9626-75 8
Lock Washer A-7675-2 8 A-7675-2 8 A-7675-4 8
23 Snap Ring - Inner A-7610-275 1 — —
24 Loading Spring A-7661-45 1 A-7661-45 1 A-7661-45 1
25 PMG Rotor A-526816 1 A-526816 1 A-526816 1
26 Snap Ring-Outer A-7610-275 1 A-7610-275 1 A-7610-275 1
27 PMG Stator A-525548-1 1 A-525548-1 1 A-525548A-1 1
28 PMG Stator Mtg. Fasteners
Cap screw A-9812-200 4 A-9812-200 4 A-9812-200 4
29 Exciter Stator A-400N-200A I A-400N-300A I See Table 9-2 1
30 Exciter Stator Fasteners - - - - - -
Cap Screw A-9626-300 4 A-9626-400 4 See Table 9-2 4
31 Exciter Rotor Assy. (IncI. 42) - - - - See Table 9-2
430 Frame - All B-526483-2 I — —
570 Frame - Low Voltage — — B-526483-3 1
570 Frame - Med. Voltage — — B-526483-10 1
63
32 Exciter Rotor Fastener - - - - - -
Cap screw A-9670A-200 1 A-9670A-200 1 A-9670A-200 1
33 Grounding Stud Assembly - - - - - -
Stud A-26937-300 1 A-26937-300 1 A-525574-400 I
Washer A-9787-1 2 A-9787-1 2 A-9787-3 2
Nut A-9786-1 1 A-9786-1 2 A-9786-3 2
34 Bus Bar Assembly REFER TO FACTORY
35 DVR2000 AVR D-526352 1 D-526352 1 D-526352 1
36 Capacitor (DVR2000) A-66377-45 1 A-66377-45 1 A-66377-45 1
37 Side Panels Blank B-525679A 1 B-525686A 1 B-525707A 1
Machined for (DVR2000) B-525679AE I B-525686AN 1 B-525707W 1
38 Fuse A-525698-1 1 A-525698-1 1 A-525698-1 1
39 Fuse Holder Cap A-525893 1 A-525893 1 A-525893 1
40 Solid Cover B-525676 1 B-525687 1 B-525706 1
41 Louvered Cover C-525562 1 C-525647 1 C-525670 1
42 Exciter Rectifier Assy. B-525528A 1 B-525528A 1 B-525528B 1
(Includes 43,44,45)
43 Diode Standard Polarity B-525570-1 3 B-525570-1 3 B-525570-2 3
44 Diode Reverse Polarity B-525571-1 3 B-525571-1 3 B525571-2 3
45 Surge Suppressor B-526482-1 1 B-526482-1 1 B-526482-2 1
46 Cover Mtg. Screws A-9646-75 33 A-9646-75 33 A-9646-75 33
TABLE 9-2 : EXCITER ASSEMBLIES

Frame Type Insulation Exciter Stator Exciter Stator Exciter Rotor
Mtg. Cap screws
572 RSL Standard A-400N-250A A-9626-350 B-526483-24
573.574 RSL Standard A-400N-300A A-9626-400 B-526483-3
572 RSL VPI A-400N-250AA A-9626-350 B-526483-25
573.574 RSL VPI A-400N-300AA A-9626-400 B-526483-9
573,574 FSM VPI A-400N-300AA A-9626-400 B-526483-10
741, 742 RSL Standard A-400N-500A A-9626-600 B-526483-5
741, 742, 743 RSL VPI A-400N-500A A-9626-600 B-526483-11
741, 742 FSM VPI A-400N-500A A-9626-600 B-526483-11
743 FSM VPI A-400N-600A A-9626-700 B-526483-12
744 RSL VPI A-400N-600A A-9626-700 B-526483-12
744 FSL VPI A-400N-650A A-9626-750 B-526483-13
64
STANDARD TOOLS
The MagnaMAX generator is assembled In cases where the exciter stator is to be

with American standard SAE hardware. serviced without removing the generator
All fasteners should be properly torqued. conduit box this fixture can be used with
(See section 12). Torque wrenches ranging overhead rigging to remove and reinstall the
from 25 in-lb. through 200 ft-lb. should be exciter stator.
available.
Exciter rotor puller bolt (Figure 10-2). The
Electrical test equipment should include a exciter rotor has a built in pulling system.
voltmeter or multimeter (VOM), clamp on With the use of this bolt, the rotor can be
ammeter, accurate frequency meter or easily removed from the shaft without
tachometer, and a megohmmeter. See damage to the winding.
section Generator Testing for more informa-
tion.
SPECIAL TOOLS
In addition to the standard tools mentioned
above, the following special tools would
facilitate removal and installation of large Figure 10-2
and/or special parts. These tools can be
obtained from the Marathon Electric parts
department. The PMG rotor is installed to the generator
shaft with a snap ring.
Exciter stator lifting fixture (Figure 10-1).
The nominal shaft diameter is 2-3/4 inches

and the ring must be spread approximately
3/4 inches for removal. To install the snap
ring, use a piece of pipe with a 2-3/4 inch
I.D. (Figure 10-4). Push the PMG rotor and
snap ring onto the shaft until the ring snaps
into the groove.
Figure 10-1
Figure 10-4
65
Rotor lifting fixture (Figure 10-5). The main Overseas shipping may require special
generator rotor is heavy (approximately 1/2 export crating. Check with your freight
the weight of the generator) and difficult to carrier.
handle. The proper fixture should be used
whenever removing or installing the main When installed, single bearing generator
rotor into the main stator. Without proper rotors are supported on the drive end by the
care and equipment, the windings can be drive discs bolted to the engine flywheel.
easily damaged. When the engine is removed, the rotor must
be supported by an appropriate fixture to
prevent main rotor, main stator or exciter
damage (Figure 11-1). Before shipping any
single bearing generator, the main rotor
must be supported by the adapter using an
appropriate fixture.
Figure 10-5
MISCELLANEOUS
A selection of wiring devices such as
electric connectors, tape, cable ties,
crimping and stripping tools, etc., should
also be a part of the generator service tool Figure 11-1
kit. The standard regulator uses flat 1/4 inch
female insulated terminals for AWG #14 STORAGE INSTRUCTIONS
wire.
If the generator is placed in storage, the
PREPARATION FOR SHIPMENT following precautions should be taken to
OR EXTENDED STORAGE protect it:
SHIPPING INSTRUCTIONS A. Equipment must be kept clean.
Shipping and handling will be much easier if 1. Store indoors.

the generator is fastened to a suitable
shipping skid that will allow handling by a 2. Keep covered to eliminate airborne dust
forklift. The skid should extend beyond the and dirt.
generator in all directions. If the original
skid is available it should be used. Marathon 3. Cover openings for ventilation, conduit
Electric will supply shipping skid drawings connections, etc. to prevent entry of rodents,
upon request. snakes, birds, and insects, etc.
66
C. Keep bearings lubricated.
B. Equipment must be kept dry. 1. Every six months rotate shaft

several turns to distribute grease in bearings.
1. Store in a dry area indoor.
2. If unit has been stored more than
2. Temperature swings should be minimal to one year, add grease before start-up.
prevent condensation.
D. Review and follow instructions in
3. If stored in an unheated or damp building, Sections 3 and 4 before putting the gen-set
space heaters will be required to prevent into service.
internal condensation.
CAUTION
4. Treat unpainted flanges, shafts, drive DO NOT ATTEMPT TO TRANSPORT
discs, and fittings with a rust inhibitor. ANYGENERATOR WITHOUT
PROPER ROTOR
5. Check insulation resistance of all SUPPORT, EXTENSIVE
windings before starting the generator. If EQUIPMENTDAMAGE CAN OCCUR.
readings are low, the windings must be
dried.
67
TABLE 12-1: MAGNA MAX - FASTENER AND TORQUE SPECIFICATIONS
Part Fastener Spec.® 430-570 Frames 740 Frames
Description
Size Dia.- Torque Ft-Lb. Size Dia.- Torque
Thread Thread Ft-Lb.
Front Bracket Grade 5 cap screws with 3/8 - 16 25 1/2 - 13 60
flat and lock washers
Bearing Caps Grade 5 cap screws with 3/8 - 16 25 3/8 - 16 25
lock washers
Drive Disc Grade 8 cap screws with 5/8 - 18 192 5/8 - 18 192
hardened washers
Adapter Grade 5 cap screws with 3/8 - 16 25 1/2-13 60
(or rear flat and lock washers
bracket)
Conduit Box Grade 5 cap screw with 3/8 - 16 25 1/2-13 60

star type lock washer
PMG Stator Grade 5 cap screws with 1/2-13 4 1/2-13 4
Belleville washers
Exciter Stator Grade 5 cap screws with 1/2-13 60 1/2-13 60
Belleville washers
Exciter Grade 8 cap screw with 1/2-13 84 1/2-13 84

Armature Belleville washer
(rotor)
Cooling Fan Grade 5 cap screws with 1/2-13 60 1/2-13 60
Belleville washers
Main Rotor Grade 8 cap screws with 5/16-18 19 3/8 - 16 35
Coil Supports Belleville washers
Rectifier Grade 5 cap screws 1/4-20 4 1/4-20 4
Assembly
Mounting
Drive Hub Set Socket head set screw 1/4 1/2-13 50 1/2-13 50
Screw in. hex key
NOTES: For table 12-1

All fasteners are SAE (American) standard.
All torque values are for plated hardware that is standard on the MagnaMAX.
If hardware is replaced with non-plated, refer to Table 12-2.
Always use quality hardware of the grade specified.
Main Rotor Coil Supports 570 and 740 frame only. Not used on 430 frames.
68
TABLE 12-2: CAPSCREW TORQUE VALUES
NOTES: Cap screws threaded into aluminum may require reductions in torque of 3O% or more.
Cap screw Diameter and Ultimate Tensile Strength (PSI)
To 1/2 - 69,000 PSI To 3/4 - 120,000 PSI 150,000 PSI
To 3/4 - 64,000 PSI To 1 - 115,000 PSI
To l - 55,000 PSI
SAE 1 OR 2 5 8
Grade
Size Torque Ft-LB (N-M) Torque Ft-Lb. (N-M) Torque Ft-LB (N-M)
(Inches) -
(Thread)
Dry Oiled Plated Dry Oiled Plated Dry Oiled Plated
1/4-20 5(7) 4.5 (6) 4(5) 8 (11) 7 (9) 6 (8) 12 (16) 11 (15) 10 (14 )
1/4-28 6(8) 5.4 (7) 4.8 (6) 10 (14) 9 (12) 8 (11) 14 (19) 13 (18) 11 (15)
5/16-18 11 (15) 10 (14) 9 (12) 17 (23) 15 (20) 14 (19) 24 (33) 22 (30) 19 (26)
5/16-24 13 (18) 12 (16) 10 (14) 19 (26) 17 (23) 15 (20) 27 (37) 24 (33) 22 (30)
3/8-16 18 (24) 16 (22) 14 (19) 31 (42) 28 (38) 25 (34) 44 (60) 40 (54) 35 (47)
3/8- 24 20 (27) 18 (24) 16 (22) 35 (47) 32 (43) 28 (38) 49 (66) 44 (60) 39 (53)
7/16 - 14 28 (38) 25 (34) 22 (30) 49 (66) 44 (60) 39 (53) 70 (95) 63 (85) 56 (76)
7/16-20 30 (41) 27 (37) 24 (33) 55 (75) 50 (68) 44 (60) 78 (106) 70 (95) 62 (84)
1/2-13 39 (53) 35 (47) 31 (42) 75 (102) 68 (92) 60 (81) 105 (142) 95 (129) 84 (114)
1/2-20 41 (56) 37 (50) 33 (45) 85 (115) 77 (104) 68 (92) 120 (163) 108 (146) 96 (130)
9/16-12 51 (69) 46 (62) 41 (56) 110 (149) 99(134) 88(119) 155 (210) 140 (190) 124 (168)
9/16-18 55 (75) 50 (68) 44 (60) 120 (163) 108 (146) 96 (130) 170 (230) 153 (207) 136 (184)
5/8-11 83 (113) 75 (102) 66 (89) 150 (203) 135 (183) 120 (163) 210 (285) 189 (256) 168 (228)
5/8-18 95 (129) 86 (117) 76 (103) 170 (230) 153 (207) 136 (184) 240 (325) 216 (293) 192 (260)
3/4-10 105 (142) 95 (130) 84 (114) 270 (366) 243 (329) 216 (293) 375 (508) 338 (458) 300 (407)
3/4-16 115 (156) 104 (141) 92 (125) 295 (400) 266 (361) 236 (320) 420 (569) 378 (513) 336 (456)
7/8-9 160 (217) 144 (195) 128 (174) 395 (535) 356 (483) 316 (428) 605 (820) 545 (739) 484 (656)
1-14 175 (237) 158 (214) 140 (190) 435 (590) 392 (531) 348 (472) 675 (915) 608 (824) 540 (732)
1 -8 235 (319) 212 (287) 188 (255) 590 (800) 531 (720) 472 (640) 910 (1234) 819 (1110) 728 (987)
1- 14 250 (339) 225 (305) 200 (271) 660 (895) 594 (805) 528 (716) 990 (1342) 891 (1208) 792 (1074)
69
TABLE 12-3:EXCITATION DATA -60 HZ - 1800 RPM
Model Number Exciter Field Exciter Field Volts Fl No Load Output Voltage With Fixed
Low Volts Resistance-Ohms and F2 at regulator No Excitation
@25°C Load 240/480 Volts High Wye Connection®
12V DC 24V DC
431RSL4005 22.5 13.3 460 550
431RSL4007 22.5 14.2 450 545
432RSL4009 22.5 15.3 445 535
432RSL4011 22.5 13.5 460 550
432RSL4013 22.5 11.3 490 580
432RSL4015 22.5 13.1 440 530
432RSL4017 22.5 14.4 450 545
433RSL4019 22.5 16.9 430 525
433RSL4021 22.5 13.7 450 550
572RSL4024 23.0 16.1 440 520
572RSL4027 23.0 16.1 440 520
572RSL4028 23.0 17.5 425 510
572RSL4030 23.0 15.2 440 530
573RSL4032 23.0 15.0 445 530
573RSL4034 23.0 17.0 430 520
574RSL4036 23.0 18.2 420 510
574RSL4038 23.0 15.0 440 540
741RSL4042 22.0 14.8 445 540
741RSL4044 22.0 15.2 440 540
741RSL4046 22.0 15.6 430 540
742RSL4048 22.0 17.4 410 525
743RSL4050 22.0 13.7 460 565
743RSL4052 22.0 19.4 400 510
744RSL4054 22.1 18.6 400 510
744FSL4060 22.1 15.1 420 570
744FSL4062 22.1 16.6 410 535
Model Number Exciter Field Exciter Field Volts Fl No Load Output Voltage With Fixed
Medium Volts Resistance-Ohms and F2 at Regulator Excitation Wye Connection
@25°C No Load 4160 Volts
12V DC 24V DC
573FSM4352 23.0 23.5 3100 4200
573FSM4354 23.0 20.3 3300 4400
574FSM4356 23.0 20.7 3200 4300
574FSM4358 23.0 17.3 3500 4600
741FSM4360 22.0 16.7 3600 4600
742FSM4364 22.0 15.4 3700 4700
742FSM4366 22.0 16.3 3600 4600
743FSM4368 22.1 17.7 3200 4600
743FSM4370 22.1 17.0 3500 4600
For rated load exciter field volts - see generator nameplate.
For low wye connection: divide value shown in table by 2.
For high delta connection: divide value shown in table by 1 .732.
For delta connection: divide value shown in table by 1 .732.
70
TABLE 12-4:EXCITATION DATA -50 HZ - 1500 RPM
Model Number Exciter Field Exciter Field Volts No Load Output Voltage
Medium Volts Resistance-Ohms Fl and F2 at Regulator With Fixed Excitation
@25°C No load @ 415 Volts High Wye Connection
1 2V DC 24V DC
431RSL4005 22.5 15.6 380 460
431RSL4007 22.5 17.1 370 450
432RSL4009 22.5 18.0 360 445
432RSL4011 22.5 16.0 380 455
432RSL4013 22.5 13.1 400 480
432RSL4015 22.5 18.7 360 440
432RSL4017 22.5 17.4 370 450
433RSL4019 22.5 20.7 340 430
433RSL4021 22.5 16.7 360 450
572RSL4024 23.0 19.8 360 430
572RSL4027 23.0 20.0 355 430
572RSL4028 23.0 21.2 370 430
572RSL4030 23.0 18.4 360 440
573RSL4032 23.0 18.9 360 440
573RSL4034 23.0 20.7 350 430
574RSL4036 23.0 21.6 345 425
574RSL4038 23.0 17.7 365 450
741RSL4042 22.0 17.8 360 450
741RSL4044 22.0 18.1 360 450
741RSL4046 22.0 18.7 350 445
742RSL4048 22.0 20 340 440
743RSL4050 22.0 16.1 370 470
743RSL4052 22.0 22.9 330 420
744RSL4054 22.1 22.6 320 420
744FSL4060 22.1 17.0 350 470
744FSL4062 22.1 19.5 330 440
Model Number Exciter Field Exciter Field Volts No Load Output Voltage
Medium Volts Resistance-Ohms Fl and F2 at Regulator With Fixed Excitation
@25°C No load®3300 Volts High Wye Connection
1 2V DC 24V DC
573FSM4352 23.0 21.2 2600 3400
573FSM4354 23.0 18.2 2700 3600
574FSM4356 23.0 18.4 2700 3600
574FSM4358 23.0 15.7 2800 3800
741FSM4360 22.0 15.4 3000 3800
742FSM4364 22.0 14.5 3000 3900
742FSM4366 22.0 15.6 2800 3800
743FSM4368 22.1 15.5 2800 3900
743FSM4370 22.1 15.5 2900 3800
For rated load exciter field volts - see generator nameplate.
For low wye connection: divide value shown in table by 2.
For high delta connection: divide value shown in table by 1 .732.For delta connection: divide
value shown in table by 1 .732.
71
TABLE 12-5: RESISTANCE VALUES - MAIN WINDINGS
NOMINAL COLD (25°C) RESISTANCE IN OHMS
Base Model Winding Main Main
Low Voltage H-SG- Stator Rotor
431RSL4005 430049 .0855 .153
431RSL4007 430048 .0648 .173
432RSL4009 430046 .0418 .190
432RSL4011 430018 .0410 .186
432RSL4013 430015 .0370 .189
432RSL4015 430017 .0260 .225
432RSL4017 430016 .0240 .226
433RSL4019 430042 .0140 .286
433RSL4021 430039 .0137 .297
572RSL4024 570078 .0132 .376
572RSL4027 570072 .0126 .398
572RSL4028 570080 .0092 .423
572RSL4030 570074 .0089 .426
573RSL4032 570075 .0074 .472
573RSL4034 570076 .0059 .507
574RSL4036 570077 .0049 .584
574RSL4038 570069 .0048 .601
741 RSL4042 740040 .0045 .677
741 RSL4044 740041 .0039 .708
742RSL4046 740042 .0036 .748
742RSL4048 740043 .0030 .776
743RSL4050 740051 .0023 .889
743RSL4052 740045 .0018 .979
744RSL4054 740046 .0015 1.100
744FSL4060 740306 .0026 .892
744FSL4062 740307 .0018 1.044
Base Model Winding Main Main
Medium Voltage H-SG- Stator® Rotor
573FSM4352 570213 1.030 .383
573FSM4354 570214 .854 .411
574FSM4356 570215 .568 .508
741FSM4360 740230 .277 .667
742FSM4364 740204 .233 .768
742FSM4366 740206 .151 .888
743FSM4368 740207 .127 .954
743FSM4370 740208 .101 1.053
Main stator values shown are line to line on the high wye connection. For low wye connection
divide value shown in table by 4.
72
TABLE 12-6: RESISTANCE VALUES - EXCITER WINDINGS
NOMINAL COLD (25°C) RESISTANCE IN OHMS
Low Voltage Exciter Stator Exciter Rotor PMG
(Field) (Armature) Stator
430 Frames 22.5 0.022 2.1
570 Frames 23.0 0.045 2.1
741 Frames 22.0 0.043 2.1
742 Frames 22.0 0.043 2.1
743 Frames 22.0 0.043 2.1
744 Frames 22.1 0.048 2.1
Medium Exciter Stator Exciter Rotor PMG
Voltage (Field) (Armature) Stator
570 Frames 23.0 0.070 2.1
741 Frames 22.0 0.043 2.1
742 Frames 22.0 0.043 2.1
743 Frames 22.1 0.048 2.1
73

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General MagnaMAXDVR UnirotorTM

Standby Generator Ratings Power Factor

Premium Insulation System The standard voltage regulator is a fully

Character Category Description

Arrangement Adapter SAE Size Drive Disc SAE Size

The generator conduit box construction

Be sure the generator frame is grounded to

12 LEAD LOW WYE CONNECTION

12 LEAD LOW DELTA CONNECTION

10 LEAD LOW WYE CONNECTION

6 LEAD DELTA CONNECTION

4 LEAD WYE CONNECTION

LOW ZIG ZAG -- SINGLE PHASE CONNECTION

HIGH ZIG ZAG -- SINGLE PHASE CONNECTION

The prime mover provides the speed and PARALLELING BASICS

1. Reactive droop compensation. (Formerly PARALLELING CIRCUITRY

3.Follow the manufacturer's instructions and

4. Replace the regulator fuse and adjust the

5. Close the main circuit breaker and apply the

6. Monitor the generator output current to

Dirt and dust will conduct electricity between

Insulation resistance should be checked when

6. Using a low-pressure grease gun, add grease

Use Chevron SRI or equivalent anti-friction

741, 742, 322 2.4 4.2 14.0 3000 4500

1. Remove conduit box covers

(NOTE: Do not remove the drip cover from

4. Remove conduit box. (Figure 6-7).

2. On generators equipped with bus bars,

2. Remove the cap screw and Belleville

Remove the exciter stator. Using a lifting

3.Use a six inch, 3/4-16NF, cap screw for a

1. Remove exciter armature. (Follow

2. Remove the PMG output leads from the

Carefully feed the main rotor leads through

3. Note the position of the PMG stator leads

4. Remove the four mounting cap screws.

PMG ROTOR REMOVAL Figure 6-18

2. Remove the snap ring that holds the PMG

4. Remove the loading spring. (if the loading

5. On 430 frame generators a second snap

MAIN ROTOR REMOVAL

1. Remove the exciter armature and PMG.

2. For single bearing generators, remove the

For two-bearing generators, remove the

For two bearing generators remove the cap

5. For single bearing generators, remove the

Figure 6-29 Figure 6-31

FRONT END BRACKET REMOVAL

2. Remove the front-end bracket from the

CAUTION: ON LARGE GENERATORS,

3. Look for score marks in the bore of the

EXCITER (ROTOR) ARMATURE

1. Clean dust and dirt from and rectifier Figure 6-34

4. Check the exciter armature and rectifier

1. Clean dust and dirt from the PMG rotor.

4.Look for score marks on the outside

5. Inspect snap rings and loading spring,