Synchronous Generators BG 132 and BG 160

Synchronous Generators 

Series DGG, DWG and WG 

Size BG 132 and BG 160 

Operating and Installation Instructions 

English 08/2002

Synchronous Generators BG 132 / BG 160 

Copyright, general information, manufacturer's address 

Copyright 

No part of this Operation Manual may be reproduced, published or transmitted in 

any form or by any means without the express permission of Generator-Technik 

Schwäbisch Gmünd GmbH &Co. KG. 

© 2002 Generator-Technik Schwäbisch Gmünd GmbH & Co. KG. All rights 

reserved. 

General information 

Technical modifications after date of printing are not considered. Subject to 

change without notice. 

Issue date: August 2002 

Validity of the manual 

This manual applies to all synchronous generators of the types DGG (three-phase 

DC generators), DWG (three-phase AC generators) and WG (single-phase AC 

generators). However, for reasons of clarity only three-phase AC generators are 

represented and mentioned in the manual. In their general sense the given 

explanations are however also applicable for single-phase AC generators of the 

series WG and appropriate generators with special voltages and frequencies. 

Further information about the designation system for the various generator types 

can be found in chapter 1 on page 11. 

Manufacturer's address 

For any information and support concerning technical problems, services and 

orders please contact us. 

Generator-Technik Schwäbisch Gmünd GmbH & Co. KG 

Ziegelfeldstraße 18 

D-73563 Mögglingen, Germany 

Phone +49 7174 89 80 0 0 

Fax +49 7174 89 80 0 25 

2 Issue date: August 2002


Table of contents 


Some important and valuable information .................................................. 5 

Warranty ............................................................................................... 5 

Proper use ............................................................................................ 6 

Preconditions and requirements to be met by the place of installation ........... 6 

Safety precautions ................................................................................. 7 

1 Designation system for generator types .............................................. 11 

1.1 Type codes .............................................................................. 11 

1.2 Examples for designations .......................................................... 12 

2 Description .................................................................................... 13 

2.1 Use of different sizes (BG 132 and BG 160) .................................. 13 

2.2 Overview of features and options for different sizes and designs ...... 13 

2.3 General functionality ................................................................ 15 

2.4 Generator governor ................................................................... 17 

2.5 Mechanical designs ................................................................... 19 

2.6 Drive types .............................................................................. 21 

2.7 Terminal box (standard version) .................................................. 22 

2.8 Control box (optional, only for 8 kVA and 13 kVA generators) .......... 23 

3 Technical data ................................................................................ 25 

3.1 Generators ............................................................................... 25 

3.2 Control box (optional, only for 8 kVA and 13 kVA generators) .......... 25 

3.3 Generator governor ................................................................... 25 

4 Installation .................................................................................... 27 

4.1 Safety precautions for installation ............................................... 27 

4.2 Requirements to be met by the place of installation and use ........... 29 

4.3 General regulations for installation ............................................. 29 

4.4 Permissible mounting positions and drain holes for cond. water ....... 31 

4.5 Installation for single-bearing generators ..................................... 35 

Issue date: August 2002 3



4.6 Installation of two-bearing generators (BG 132) ........................... 49 

4.7 Installation of two-bearing generators (BG 160) ........................... 62 

4.8 Electrical connection of the generators ........................................ 70 

5 Operation ...................................................................................... 73 

5.1 Safety information for operation ................................................. 73 

5.2 Permissible operating conditions ................................................ 75 

5.3 Electric protection equipment, protective measures and grounding ... 75 

5.4 Connection to an existing power distribution network 

(e.g. house wiring) ................................................................... 77 

5.5 Operating information for safe working with electric devices ........... 78 

5.6 Operation of the generator ......................................................... 80 

6 Maintenance .................................................................................. 85 

6.1 Maintenance overview ............................................................... 86 

6.2 Safety precautions .................................................................... 87 

6.3 Visual inspections and cleaning to be performed by the user ........... 88 

6.4 Maintenance to be performed by authorized qualified personnel ...... 89 

7 Reconditioning ............................................................................... 92 

8 Removal ........................................................................................ 93 

8.1 Safety precautions .................................................................... 93 

8.2 Removal of two-bearing generators (BG132 and BG160) ................. 93 

8.3 Removal of single-bearing generators .......................................... 93 

9 Transport and storage .....................................................................103 

10 Putting out of operation, storage after dismantling, disposal ................104 

10.1 Waste disposal information .......................................................104 

11 Spare parts ...................................................................................105 



Some important and valuable information 

Some important and valuable information 

Dear customer, 

Generator-Technik Schwäbisch Gmünd GmbH & Co. KG is a technically leading 

manufacturer of power generators in the best tradition and manufactures 

generators with ratings of 4 to 30 kVA as well as its own design of electronic 

control units for those generators. What makes GTS generators stand out is their 

excellent fitness for practical use and superior quality. They are maintenancefree, 

durable, precise and robust. 

Choosing a synchronous generator of this series was a decision for a technically 

superior product. This product has been manufactured using only high-quality 

components which meet the requirements of VDE testing and comply with 

appropriate German (DIN) and European (EN) standards. 

All information contained in these operating instructions has been carefully 

compiled and checked by us to the best of our knowledge and belief. Please be 

sure to read and understand the operating instructions before installing, 

commissioning and using the generator. 

Generator-Technik Schwäbisch Gmünd GmbH & Co. KG does not assume any 

liability for any applications which are contrary to the descriptions given in 

these operating instructions, and for any loss or damage which has been caused 

by incorrect operation and handling, faulty installation, improper use, abuse, 

non-approved technical modifications or by any repairs performed by 

unauthorized personnel. 

If you have any questions, please contact Generator-Technik Schwäbisch Gmünd 

GmbH & Co. KG. 

Warranty 

Yours sincerely, 

Generator-Technik Schwäbisch Gmünd GmbH & Co. KG 

For the generators of the series described in this manual, we issue warranty 

according to the latest version of the "Allgemeine Lieferbedingungen für 

Erzeugnisse und Leistungen der Elektroindustrie (general conditions for the 

supply of products and services of the electrical industry)" of the ZVEI. 



Proper use 

Proper use 

The generators described in this manual are intended for the generation of 

electrical energy within the context of emergency standby operation for feeding 

in mobile distribution systems. The generators must only be used according to 

the voltage and power specifications listed on the type plate. Reverse feeding 

operation (e.g. connection of four-quadrant converters) is not planned and only 

conditionally possible after consulting the manufacturer. 

The generators have to be driven with the specified rated speed. The generator 

outputs have to be protected against overcurrent and short-circuit by adequate 

fuse equipment according to the specifications on the type plate. 

The generators must not be connected to other power distribution or electricity 

generation systems (such as other generators or the public electricity supply 

network, for example). 

The use of the generators is only allowed for applications described here and in 

conformity with the specifications given in this manual. Any other application is 

considered to be improper use and is not permitted. 

In case of improper use, misuse or abuse of the generators or of parts of them, 

Generator-Technik Schwäbisch Gmünd GmbH & Co. KG will not assume any 

liability. 

Preconditions and requirements to be met by the place of 

installation 

Single-bearing generators are mounted directly to the engine. These generators 

may only be mounted to engines which comply with the applicable regulations, 

rules and requirements. 

Two-bearing generators are usually installed right next to the engine. The 

generator has to be firmly and securely mounted on an absolutely flat base with 

a bearing capacity adequate to the weight class of the generator. When using a 

belt drive, it is advisable to mount the generator adjustable. For that purpose 

e.g. mounting rails can be used, providing the possibility of adjusting the belt 

tension. 

All generators are splash-proof according to IP54 specifications and can thus 

also be mounted and used outdoor. The generators are not explosion-protected 

and thus must no be used in explosive atmospheres. Further regulations on this 

have to be observed! 



Safety precautions 

When selecting the place of installation and use, the required minimum 

clearances have to be observed, adequate ventilation has to be ensured at any 

time, and the temperature of the cooling air must not exceed 40 °C. Further 

information can be found in chapter 4 on page 27. 

The generators and the parts mounted to them must not be sprayed with highpressure 

cleaners. Therefore, the generators should preferably be installed in a 

way and place which makes it impossible to even inadvertently spray the 

generator with high-pressure cleaners. 


This section summarizes the safety precautions of relevance. Read and 

understand the safety precautions before installing, commissioning and 

operating the generator and observe the precautions. You will find the safety 

precautions in the relevant passages through the manual as well. 

Work on electrical installations and equipment may only be 

 

performed by adequately trained qualified personnel and in 

conformity with the applicable national rules and regulations 

(in Germany: VDE regulations, among others). 

DANGER 

Risk of 

personal injury 

or death 

and 

destruction 

hazard 


performed in the off and de-energized state. Mortal danger by 

electric shock! Engines that have been turned off must be 

secured against accidental restarting (e.g. by removing the 

ignition key and keeping it safe)! 

Installation and commissioning of the generator as well as any 

maintenance, service and replacement work may only be 

performed by authorized and qualified personnel. 

Do not operate the generator in explosive environments. 

Further regulations on this have to be observed! 

Do not perform any visual inspections for maintenance 

purposes and cleaning work on the generator during operation. 

Always turn off the engine first and make sure that it cannot be 

restarted accidentally (e.g. by removing the ignition key and 

keeping it safe). Mortal danger by electric shock! 




DANGER 

Risk of 


or death 


destruction 

hazard 

Never connect the generator to the public electricity supply 

network or to any other systems for power generation. Risk of 

death, fire and destruction hazard! 

Never connect several generators to each other. Risk of death, 

fire and destruction hazard! 

If the generator shall be connected to an existing power 

distribution network (e.g. a house wiring), it has to be 

ensured, that the system is completely and reliably 

disconnected from the public electricity supply network of the 

energy supply company. Reverse feeding into the public 

electricity supply network or network interconnection is not 

allowed. Reverse feeding involves mortal danger by electric 

shock for persons possibly working at the de-energized public 

electricity supply network. Due to network interconnection 

with the public electricity supply network, the generator can be 

damaged, burn or cause fire in electrical cables of the system. 

Grounding the neutral conductor of the generator (N, midpoint 

conductor) supersedes the protective measure "protection 

separation" and should therefore be avoided. If the neutral 

conductor N shall be grounded anyway, this may only be 

performed by an electrically qualified person. In this case, a 

current-operated earth-leakage circuit breaker has to be 

connected on the load side of the generator output. The 

efficiency of the electrical protective measure has to be 

confirmed by an appropriate measurement. 

The generator supplies highly dangerous voltages during 

operation! Never touch the generator or the devices connected 

to the generator with wet hands during operation. Mortal 

danger by electric shock! 

Generator components may be very hot, not just during but also 

after operation. Burning hazard! 

The generator may only be operated with the protective covers 

for the drive mounted as specified. Risk of personal injury! 




Be sure to read and understand the operating instructions 

 

completely before using the generator. The generator may only 

be used for applications described in section "Proper use" 

above and in conformity with the specifications in this manual. 

DANGER 

Risk of 


or death 


destruction 

hazard 

Before connecting devices to the generator, ensure that the 

devices are switched off. Accident hazard! Unsupervised 

starting devices can endanger or injure persons as well as cause 

damages or damage themselves. 

Infants and animals must never have admittance to the 

generator, not just during but also after operation. Make 

appropriate precautions. Mortal danger by electric shock, injury 

and burning hazard! 

The generator or its components must never be 

exposed to the jet of high-pressure cleaners. 

Mortal danger by electric shock and 

destruction hazard! 

CAUTION 

Destruction 

hazard 

or 

damage 

Be sure to observe the permissible operating conditions given in 

section 5.2 on page 75. The generator may only be operated in 

conformity with the operating conditions and data specified there. 

This particularly applies to the ambient and cooling conditions and 

the permissible current load. 

For installation and repair only genuine components or external 

components expressly approved by the manufacturer may be used. 

It is not permitted to perform any modifications on the generator 

or on individual components or the control box. Any modification, 

improper repair or use of unsuitable external components will 

terminate all and any claims under a warranty as well as the type 

approval according to the German Equipment Safety Law and the 

certification to EU / EEC directives. In this case the manufacturer 

will not assume any liability. 






Chapter 1, Designation system for generator types 

1 Designation system for generator types 

This chapter provides information about the designation system for the 

individual generator types as well as examples of generator designations. 

1.1 Type codes 

DWG (BL) 17 / 7,0 - 2ZE 

E: Electronic generator governor 

Z: Two-bearing design 

E: Single-bearing design 

Number of poles: 

2 poles (rated speed 3000 rpm) 

or 

4 poles (rated speed 1500 rpm) 

Single-phase output power in kVA, e.g. 7 kVA 

Three-phase output power in kVA, e.g. 17 kVA. 

Power determines size: 

• 2-pole generator: up to 17 kVA = BG 132, 

20 kVA and higher = BG 160 

• 4-pole generator: 10 kVA and higher = BG 160 

With specification (BL): Brushless generator 

Without specification (BL): Brush-type generator 

DWG: Three-phase AC generator 

WG: Single-phase AC generator 

DGG: Three-phase DC generator 



Chapter 1, Designation system for generator types 

1.2 Examples for designations 

Type 

DWG 8,0/5,0-2EE 

Features 

Three-phase AC generator, brush-type machine, 8 kVA 

three-phase power, 5 kVA single-phase power, 2-pole 

machine, single-bearing design, electronic governor, size 

BG 132 (2-pole generator < 17 kVA). 

DWG (BL) 10/6-4ZE Three-phase AC generator, brushless, 10 kVA three-phase 

power, 6 kVA single-phase power, 4-pole machine, twobearing 

design, electronic governor, size BG 160 (10 kVA, 

4-pole generator). 



Chapter 2, Description 

2 Description 

2.1 Use of different sizes (BG 132 and BG 160) 

Depending on the rated output power and the number of poles the generators 

are produced in two different sizes: BG 132 or BG 160. 

BG 132 

Size BG 132 is used for 

• 2-pole generators (driving speed 3000 rpm) with rated power outputs smaller 

than 17 kVA. 



• 2-pole generators (driving speed 3000 rpm) with rated power outputs greater 

than and including 20 kVA or 

• 4-pole generators (driving speed 1500 rpm) with rated power outputs greater 

than and including 10 kVA. 

2.2 Overview of features and options for different sizes and 

designs 

The following table shows an overview of features and possible options for the 

different generator sizes and types. 

Key for the table: 

x = possible or "yes" 

- = not possible or "no" 




Version / Option BG 132 

2-pole up to 

17 kVA 

Generator directly mounted to 

engine 

Engine-/manufacturer-depending 

sealing betw. engine and generator 


2-pole ≥ 20 kVA 

4-pole ≥ 10 kVA 

1-bear. 2-bear. 2-bearing 

x - - 

x - - 

Direct coupling via flange - x x 

Belt or hydraulic drive - x x 

Brushless Generator x x x 

Brush-type generator x x - 

Supply without terminal box, 

cable directly lead out in a hose 

Terminal box mounted, 

no governor/filter functions 


governor/filter functions partly 

implemented 


governor/filter functions completely 

implemented 

Option "Expanded generator 

governor with no-load automatic" 

Control box mounted, 

aluminum cast or sheet metal 

x x x 

x x x 

x x x 

x x x 

x x x 

x 1 x 1 - 

Option hour meter in control box x 1 x 1 - 

Option insulation monitoring in 

control box 

x 1 x 1 - 

1. Only available for versions with rated power output of 8 kVA or 13 kVA. 




2.3 General functionality 

All generators of these series are self-excited synchronous inner-pole generators. 

The generator consists of the functional groups main machine, exciter and 

rotating rectifier mounted in a common housing. The electronic generator 

governor can be placed in a terminal box mounted on the generator, an external 

control box or in the optional control box mounted on the generator instead of 

the terminal box. 

Due to various constructional measures, an amortisseur and a balancing control 

the generators have an extreme asymmetric load capability. 

Cooling of the generators is performed by a rotating direction-independent selfventilation. 

For this purpose, the cooling air is sucked on the rear side by a fan 

impeller and then blown to the front outside along the generator. 

The supplied generator voltage is regulated by the electronic generator governor, 

so that the output voltage fulfills the requirements of IEC 38 for the entire range 

between no-load and rated load condition. This corresponds to the quality 

standard of the public electricity supply network. The output frequency 

constancy depends on the speed constancy of the engine. 

In case of short generator overload conditions (below the reaction time of the 

circuit breakers) or if devices with a too high power consumption or a too high 

starting power are connected to the generator, the generator governor 

automatically limits the output power (by limiting the exciter field current) and 

reduces the output voltage. 

Optionally an expanded generator governor with no-load automatic is available. 

Further information about the generator governor can be found in section 2.4 on 

page 17. 

If the generator is not equipped with the option "Insulation monitoring with 

switching-off", it fulfills the protective measure "Protection separation with 

equipotential bonding" according to VDE 0100 part 728. The used power system 

is the IT system with neutral conductor N and equipotential bonding conductor 

PE (see Figure 1). 

If the generator is equipped with the option "Insulation monitoring with 

switching-off", it fulfills the better protective measure "Protection separation 

with insulation monitoring" according to VDE 0100, part 728. 

The generators of this series comply with the EMC regulations EN ISO 14982, ISO 

TC 127 / ISO FDIS 13766 / DIN EN 13909 and further EMC regulations referenced 

in these regulations. 




Generator 

L1 

L2 

L3 

N 

PE 

Load 

Figure 1 

Power system of the generator: Principle diagram for protection 

separation 




2.4 Generator governor 

Figure 2 

Generator governor LCAR3LIM for brush-type generators 

(simplified schematic representation) 




Figure 3 

Generator governor LCAR3LIM for brushless generators 

(simplified schematic representation) 




2.5 Mechanical designs 

Depending on the rated power output and the number of poles the generators 

are produced in two different sizes: BG 132 or BG 160. 

Size BG 132 is used for 2-pole generators with rated power outputs up to 17 

kVA. These generators are available as brushless type or with carbon brushes. 

Depending on the kind of use, generators of the size BG 132 can either be built 

as single-bearing generators or as two-bearing generators. Single-bearing 

generators are directly mounted to the engine. In this case the engine bearing is 

used as second bearing. 


• 2-pole generators with rated power outputs starting from 20 kVA or for 

• 4-pole generators with rated power outputs starting from 10 kVA. 

Generators of the size BG 160 are exclusively available as brushless generators 

and are only produced as two-bearing generators. 

Two-bearing generators are usually installed right next to the engine. Regarding 

the generator drive, there are various options to choose from (refer to section 

2.6 on page 21). 

To cover a wide range of applications, the generators can be delivered in 

different versions regarding the electrical connection. 

• Generator with terminal box mounted (standard type): 

The terminal box mounted on the generator contains a connection terminal 

plate for the connecting cables as well as the generator governor. 

Furthermore, a suppression filter can be installed in the terminal box. 

However, the suppression filter can also be located in an external control 

cabinet, if desired. Further information about the terminal box can be found 

in section 2.7 on page 22. 

• Cable directly lead out of the generator in a hose without a terminal box 

mounted: 

For this version, all connecting cables of the generator as well as the cables 

for the generator governor are led out of the generator housing using a hose. 

This version offers the special advantage, that the generator can also be used 

in relatively hot environments. In this case, the generator governor as well as 

the complete current distribution and the electrical fuse protection has to be 

installed in an external control cabinet. 




• Generator with a control box mounted (only applicable for 8 kVA and 13 kVA 

versions): 

In the standard version the control box optionally mounted on the generator 

contains the generator governor, a suppression filter, the sockets for 

connecting the loads as well as an all-pole circuit breaker for protecting the 

installed sockets against overcurrent and short-circuit. As additional options 

an hour meter and an insulation monitoring can be installed. Further 

information about the optional control box can be found in section 2.8 on 

page 23. 

Terminal box 

Drive shaft 

Mounting profile 

(all around with 45° 

spacing) 

Drain hole for 

condensation water 

(if available) 

Angle brackets 

(fitted on both sides) 

Cooling 

profiles 

Cooling air intake 

Fan impeller shroud 

Drain hole for condensation water 

(if available) 

Figure 4 

Two-bearing generator, size BG 132 with terminal box 




2.6 Drive types 

2.6.1 Single-bearing generators (only BG 132) 

Single-bearing generators are exclusively intended for direct mounting to the 

engine. The shafts of the generator and the engine are directly connected to 

each other and the bearing of the engine is used as second bearing for the 

generator. Therefore, the generator always runs at the same speed as the engine. 

With this type of drive, it has to be ensured that the engine has an appropriate 

speed rating. Otherwise the generator is operated at underspeed or overspeed 

which can restrict the functionality of the generator. 

For information regarding the installation of the generator please refer to 

chapter 4 on page 27. 

2.6.2 Two-bearing generators 

Two-bearing generators can be driven in different ways as described below. For 

information regarding the installation of components necessary for the 

corresponding type of driving, please refer to chapter 4 on page 27. 

Belt pulley drive 

The generator is mechanically connected to the engine via a belt pulley and a 

belt. The belt drive is a particularly simple and inexpensive type of drive. 

Moreover it offers the advantage that the speeds of the engine and the generator 

can be optimally balanced by selecting the transmission ratio. 

Direct coupling of the generator via flange 

Using direct flange mounting, the shafts of the generator and the engine are 

connected by a flange. Therefore, the generator always runs at the same speed as 

the engine. With this type of drive, it has to be ensured that the engine has an 

appropriate speed rating. Otherwise the generator is operated at underspeed or 

overspeed which can restrict the functionality of the generator. 

Hydraulic motor drive 

In this case, the generator is driven by a hydraulic motor supplied from a 

hydraulic system. When using this type of drive, attention must be particularly 

drawn to the fact that the generator is not operated at overspeed. This may have 

adverse effects on the functionality of the generator as well. 




2.7 Terminal box (standard version) 

The terminal box mounted to the generator contains a connection terminal plate 

for the connecting cables. Inside the terminal box cover the completely sealedin 

generator governor is installed. The terminal box can furthermore contain a 

suppression filter which, however, can also be placed in an external control 

cabinet, if desired. 

The generator governor in the terminal box cover can also be replaced by an 

optionally available expanded generator governor with a no-load automatic 

function. Further information about this can be found in section 2.4 on page 17. 

Generator governor 

Connection terminal plate 

Terminal box 

Suppression filter (optional) 

Figure 5 

Terminal box with connection terminal plate, generator governor 

and suppression filter 




2.8 Control box (optional, only for 8 kVA and 13 kVA generators) 

2.8.1 General 

The control box mounted on the generator is only available for generators with 

rated power outputs of 8 kVA and 13 kVA. In the standard version it contains the 

generator governor, a suppression filter, the sockets for connecting the loads as 

well as an all-pole circuit breaker for protecting the installed sockets against 

overcurrent and short-circuit. As additional options an hour meter and an 

insulation monitoring with switching-off can be installed. 

The generator governor in the control box can also be replaced by an optional 

expanded generator governor with no-load automatic function. Further 

information about this can be found in section 2.4 on page 17. 

Hour meter 

(optional) 

Insulation monitoring unit 

(optional) 

Circuit breaker 

(4-pole) 

Socket 400 V 

Sockets 230 V 

Figure 6 

Control box with installed options hour meter and insulation 

monitoring 




2.8.2 Option insulation monitoring with switching-off 



insulation monitoring" according to VDE 0100, part 728. 

The insulation monitoring unit (see Figure 6) monitors the insulation of the 

devices connected to the sockets. If it detects a defective insulation of a 

connected device or extension cord, the insulation monitoring unit immediately 

switches off all sockets and the red signal lamp "FAULTY INSULATION" lights up 

to indicate the fault. In this case the defective device has to be disconnected 

and taken out of operation and the insulation monitoring unit has to be reset. 

Generators which are equipped with an insulation monitoring unit 

must not be connected to further insulation monitoring units, 

since the insulation monitoring units can mutually interact. 

CAUTION 



Chapter 3, Technical data 

3 Technical data 

3.1 Generators 

The technical data of the generator can be found on the type plate mounted on 

the generator. 

3.2 Control box (optional, only for 8 kVA and 13 kVA generators) 

Type of enclosure 

Connectors 

Features 

Optional features 

Permissible length of 

connected cables 

IP54 (all covers closed and locked) 

1 CEE socket 5 x 16 A (3P + N + PE) 

3 protective contact sockets 16 A (1P + N + PE) 

4-pole circuit breaker B 16 A 

Governor, filter and noise suppression installed 

Hour meter 

Insulation monitoring unit with signal lamp 

Fulfills protective measure "Protection separation 

with insulation monitoring" according to DVGW 308 

Total length of all connected cables: 

250 m max. at conductor cross section 2.5 mm 2 

100 m max. at conductor cross section 1.5 mm 2 

3.3 Generator governor 

Governor type 

LCAR3 

Pin assignment Pin Color Function 

1 

2 

3 

4 

5 

6 

red 

gray 

yellow 

yellow 

yellow 

F1 

F2 

1/2 U 

1/2 V 

1/2 W 



Chapter 3, Technical data 



Chapter 4: 4.1 Safety precautions for installation 

4 Installation 

The installation procedures may differ depending on the generator version and 

type. Where applicable, such differences are mentioned in the concerning texts. 

Prior to installation of the generator, read and understand the safety precautions 

in section 4.1 as well as all other applicable sections of this chapter and observe 

the instructions and information given therein. 

CAUTION 

The installation work described in this chapter 

may only be performed by authorized and 

qualified personnel. 

Do not open or disassemble the generator and/or 

the control box mounted on the generator 

(depending on the version)! The generator may 

only be opened by the manufacturer or an agency 

authorized by the manufacturer. It is not allowed 

to perform any work or operations not described 

in this manual. 

4.1 Safety precautions for installation 


 




DANGER 



electric shock! 

Engines that have been turned off have to be secured against 

accidental restarting (e.g. by removing the ignition key and 

keeping it safe)! 

Installation of the generator as well as any maintenance, 

service and replacement work may only be performed by 

authorized and qualified personnel. 






Chapter 4: 4.1 Safety precautions for installation 

DANGER 

CAUTION 














Be sure to completely read and understand the operating 

instructions before installing and using the generator. The 

generator may only be used for applications described in 

section "Proper use" and in conformity with the specifications 

given in this manual. 

For installation only genuine components or external components 

expressly approved by the manufacturer may be used. 

It is not permitted to perform any modifications on the generator 

or on individual components or the control box. Any modification, 

improper repair or use of unsuitable external components will 

terminate all and any claims under a warranty as well as the type 

approval according to the German Equipment Safety Law and the 

certification to EU / EEC directives. In this case the manufacturer 

will not assume any liability. 



Chapter 4: 4.2 Requirements to be met by the place of installation and use 

4.2 Requirements to be met by the place of installation and use 

Single-bearing generators are mounted directly to the engine. These generators 

may only be mounted to engines which comply with the applicable regulations, 

rules and requirements. 

Two-bearing generators are usually installed right next to the engine. The 

generator has to be firmly and securely mounted on an absolutely flat base with 

a bearing capacity adequate to the weight class of the generator. When using a 

belt drive, it is advisable to mount the generator adjustable. For that purpose 

e.g. mounting rails can be used, providing the possibility of adjusting the belt 

tension. 

All generators are splash-proof according to IP54 specifications and can thus 

also be mounted and used outdoor. The generators are not explosion-protected 

and thus must no be used in explosive atmospheres. Further regulations on this 

have to be observed! 

When selecting the place of installation and use, the required minimum 

clearances have to be observed, adequate ventilation has to be ensured at any 

time, and the temperature of the cooling air must not exceed 40 °C. 

The generators and the parts mounted to them must not be sprayed with highpressure 

cleaners. Therefore, the generators should preferably be installed in a 

way and place which makes it impossible to even inadvertently spray the 

generator with high-pressure cleaners. 

4.3 General regulations for installation 

A correct and proper installation of the generator is a prerequisite for a safe, 

reliable and error-free operation as well as the electrical and mechanical safety. 

Usually the generators are operated with a counterclockwise direction of 

rotation. In this case the output voltage has a "clockwise rotating field". 

However, the generators can also be operated with a clockwise direction of 

rotation. Then the output voltage has a "counterclockwise rotating field". 

Due to the dynamic processes during the switching of electric loads, the engine 

must have adequate power reserves and its governor system must be able to deal 

with such processes. 

The constructional form and design of the generator must not be changed. 

Mounting surfaces must be precisely flat. Misalignments during installation have 

to be avoided. 



Chapter 4: 4.3 General regulations for installation 

After installation, a test finger according to EN 60034, part 5, or a foreign part 

with a diameter greater than 12 mm (e.g. a sphere) must not come in contact 

with rotating parts, if a risk could result from this. Especially the protective 

covers of the power transmission have to be constructed stable and mounted 

firmly. It must not be possible to remove protective covers without using tools. 

The cooling air must be supplied and eliminated in a way, that the accumulating 

dissipation heat is eliminated definitively. Only harmless amounts of dust and 

water may be sucked with the cooling air. Short-circuits of the air have to be 

avoided. 

Generators with a second shaft end must not be operated without a machine or 

protective cover correctly installed to this end. 

If the generator is not already equipped ex works with a control box containing 

electric protection equipment and sockets, adequate fuse equipment has to be 

installed in an external control cabinet to protect the circuits (sockets) against 

overcurrent and short-circuit. Observe that the neutral conductor N has to be 

fused as well. Consult the generator manufacturer GTS for the correct types and 

nominal currents of the circuit breakers to be used. Further information about 

this can be found in section 4.8 on page 70. 

If the generator is not already equipped ex works with a control box containing 

electric protection equipment and sockets, the generator, the control cabinet 

and the complete electric installation have to be checked by visual inspection, 

testing and measurement according to DIN VDE 0100, part 610, before bringing 

the generator into operation for the first time. 

Observe the specific installation rules and instructions for the individual 

generator types listed in the following sections of this manual. There you 

can also find particular installation notes for the different drive types of the 

generators. 

• Refer to section 4.5 on page 35 for single-bearing generators of the size 

BG 132. 

• Refer to section 4.6 on page 49 for two-bearing generators of the size 


• Refer to section 4.7 on page 62 for two-bearing generators of the size 


• Refer to section 4.8 on page 70 for notes and instructions concerning the 

electrical connection of the generators. 



Chapter 4: 4.4 Permissible mounting positions and drain holes for cond. water 

4.4 Permissible mounting positions and drain holes for cond. water 

4.4.1 Permissible mounting positions for single-bearing 

generators 

Single-bearing generators are mounted directly to the 

engine. Thus, a horizontal mounting position is 

predetermined by the engine. 

When ordering the generator, the position of the 

terminal box has to be specified (or the position of 

the cable lead-out or the control box, depending on 

the version). 

The following mounting positions are possible: 

• Terminal box on top 

• Terminal box turned by 45° or 90° to the left or 

to the right 

No other mounting positions are permitted! 

ok 

ok 

ok 




4.4.2 Permissible mounting positions for two-bearing generators 

(BG 132 and BG 160) 

The generator has to be mounted on a horizontal flat 

base standing on its angle brackets, as shown in 

the accompanying figure. 

When mounted in normal position, the terminal box 

is positioned on the top of the generator (or the 

cable lead-out or the control box, depending on the 

version). 

It is also possible to install the generator turned by 

45° or 90° to the left or to the right, as shown in the 

accompanying figure. For this purpose, the angle 

brackets have to be removed and mounted again to 

the corresponding mounting profiles. 

ok 

ok 

ok 

No other mounting position is permitted! 

no 

no 

no 




4.4.3 Drain holes for condensation water (BG 132 and BG 160) 

NOTE 

This section is only applicable, if drain holes are available in the 

generator housing. 

The drain holes for condensation water are not available at all 

generators. Depending on the intended field of application of the 

generator, these holes can also be missing. In case of doubt, please 

check the generator. 

Under unfortunate circumstances, possibly 

condensation water can occur inside the 

generator. To provide an outlet for this 

condensation water, the generator housing 

possibly has several drain holes (4 holes 

each on the front and on the rear, 90° 

spacing). 

If these drain holes are available in the 

housing, the holes at the lowest point in 

mounting position has always to be 

opened. 

All other holes (on both sides and on the 

top) have to be closed by screws. 

NOTE: The holes on the rear side are 

covered by the fan impeller shroud. The 

holes are only accessible after removing 

the shroud. 

Max. thread length 8 mm! 

Make sure that the two drain holes located 

on the bottom are opened. If necessary, 

remove the screws to open the 

condensation water drain holes. 




Make sure that the holes on both sides and 

on the top are closed with screws. 

If you are installing the generator turned 

from the mid position, remove the screws 

from the holes located at the bottom side 

in order to open the condensation water 

drain holes and then use these screws to 

close the open holes which are now 

located on the side. 



Chapter 4: 4.5 Installation for single-bearing generators 

4.5 Installation for single-bearing generators 

For installing the generator proceed according to the descriptions in this section 

4.5. Prior to installation, read and understand the safety precautions in section 

4.1 as well as the sections 4.2 to 4.4 and observe the instructions and 

information given there. 

Optionally, lifting eye bolts are provided on the top or on both sides of the 

generator (45° from the vertical) for attaching lifting equipment. Lifting 

equipment may only be attached to the generator using these lifting eye bolts. 

Only appropriate lifting equipment may be used. 

4.5.1 Scope of delivery (single-bearing generators) 

The scope of delivery may differ depending on the generator version and the 

engine type. The type of sealing against the engine depends on the engine/ 

manufacturer. For this reason, the appropriate sealings have to be ordered 

together with the generator. 

4.5.2 Dimensions (single-bearing generators) 

The dimensions of the generator can be found in the drawing sheet included in 

the annex. 

No other parts may be mounted to the mounting 

profiles of the generator housing. 

CAUTION 

4.5.3 Minimum clearances and regulations for cooling (singlebearing 

generators) 

In order to provide sufficient cooling the generator needs adequate ventilation. 

The cooling air is sucked on the rear side by the fan impeller and then blown to 

the front side through the cooling profiles along the housing. If necessary, 

adequate openings for cooling air inlet and outlet have to be provided. 

It is absolutely important to observe the following regulations for minimum 

clearances and cooling. 




Minimum clearances (single-bearing) 

The following minimum clearances towards 

parts or walls have to be observed for 

installation (see also the accompanying 

figures on the right): 

• All sides: a = 100 mm 

• Rear side: b = 170 mm 

Cooling (single-bearing) 

It is absolutely important to observe the 

following regulations for cooling. Danger 

of overheating! 

The temperature of the supplied cooling air 

must not exceed 40 °C. 

In the cooling air intake area on the rear 

side of the generator a maximum partial 

vacuum of P max =4Pa may arise. 

Otherwise the fan impeller cannot suck 

enough cooling air. 

In the cooling air blow out area on the 

front side of the generator a maximum 

overpressure of P max = 7 Pa may arise. 

Otherwise the circulation of the cooling air 

is not sufficient. 

Cooling air circulation must not be 

impaired by other air flows (e.g. 

directed from the side or from the front 

to the generator). 

a 

a 

b 

P max = 7 Pa 

a 

b 

P max = 4 Pa 




4.5.4 Installation to the engine (single-bearing generators) 

The minimum clearances and regulations for cooling given in the section above 

have to be met for installation. 

4.5.4.1 Sealing of the generator against the engine 

During installation a sealing has to be attached between the generator and the 

engine. The type of sealing depends on the used engine. The sealings prescribed 

for the different engines are listed in the following table. 

Engine Type of sealing Installation instructions 

B&S 12.5 HP / 14 HP VE1/877 or VE1/977 Press the sealing into the 

shaft opening in the end 

shield. 

Honda GX 390 K1V VE1/871 Bond the sealing into the 

Yamaha MZ 360 K 

corresponding clearance in the 

end shield. 

Yanmar L90 / L100 Fluid sealing Apply liquid sealant into the 

corresponding clearance in the 

end shield. 

Hatz 1D 60C 

No sealing required. 




4.5.4.2 Installation of brush-type generators 

Removal prior to installation and removal of the carbon brushes holder 

1. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 7/2) and 

detach the sleeve (1). 

2. Remove both connection cables from the connection lugs of the carbon 

brushes holder (4). The connection cables are coded by the width of the 

connection lugs and therefore secured against interchanging. 

3. Unscrew the fastening screw of the carbon brushes holder and detach the 

carbon brushes holder (4). 

4. Pull out the transport locking (wooden chock). 

5. Remove the fan impeller shroud (3) from the generator. 

1 

2 

3 

4 

Flange represented 

turned by 45° 

Figure 7 

Removal prior to installation of single-bearing brush-type 

generators 




Installation 

NOTE 

For differing installation instructions for shaft fastening by tension 

bolt (instead of the grub-screw described here), please refer to 

section 4.5.4.4 on page 45. 

1. Screw the supplied grub-screw (Figure 8/1) into the engine shaft as far as it 

will go using an Allen wrench. 

2. Apply the sealing to the front end shield of the generator as described in 


3. Align the generator in front of the engine in a way, that the generator shaft 

lies in one line with the engine shaft. If necessary, support the generator 

accordingly. 

4. Push the generator against the engine flange and align the threaded hole of 

the generator shaft with the grub-screw screwed into the engine shaft. 

5. Screw the generator shaft by turning the fan impeller onto the grub-screw in 

the engine shaft as far as it will go. This pulls the generator against the 

engine flange. 

NOTE 

While screwing the generator shaft onto the grub-screw, align 

the mounting holes in the end shield with the drillings in the 


It is not necessary to tighten the generator shaft on the grubscrew. 

It is sufficient, if the shaft is screwed onto the grubscrew 

as far as it will go, since the screw-connection tightens 

itself when the generator is loaded. 

For installation instructions for shaft fastening by tension bolt, 

please refer to section 4.5.4.4 on page 45. 

6. Fasten the generator's end shield to the engine flange using four fastening 

screws (Figure 8/2). 




1 

Apply appropriate sealing 

depending on the engine 

2 

4x 

Figure 8 

Installation of single-bearing brush-type generators to the 

engine 

7. Insert the carbon brushes holder (Figure 9/4) correctly positioned into the 

generator and press it on to the collector rings on the shaft, so that the 

carbon brushes are pressed into the carbon brushes holder and the carbon 

brushes holder lies on its mounting base. 

8. Continue to press on the carbon brushes holder and screw in the fastening 

screw, but do not tighten it completely. While screwing in the fastening 

screw, the carbon brushes holder is automatically positioned on the 

mounting base. 

9. Check the proper seating of the carbon brushes holder and then tighten the 

fastening screw. 

10. Plug both connection cables onto the connection lugs of the carbon brushes 

holder according to the width of the connectors. 




11. Remount the sleeve (Figure 9/3) and fasten it by tightening the two screws 

(2). 

12. Remount the fan impeller shroud (Figure 9/1). 

Flange represented 

turned by 45° 

1 

4 

2 

3 

Figure 9 

Installing the carbon brushes holder 




4.5.4.3 Installation of brushless generators 

Removal prior to installation 

1. Remove the fan impeller shroud (Figure 10/1) from the generator. 

2. Unscrew the four fastening screws (3) at the generator and detach the front 

end shield (2). 

3 

2 

1 

Figure 10 

Removal prior to installation of brushless single-bearing 

generators 




Installation 

NOTE 

For additional installation instructions for shaft fastening by 

tension bolt (instead of the grub-screw described here), please 

refer to section 4.5.4.4 on page 45. 

1. Screw the supplied grub-screw (Figure 11/1) into the engine shaft as far as it 

will go using an Allen wrench. 

2. Apply the sealing to the removed front end shield of the generator as 

described in section 4.5.4.1 on page 37. 

3. Set the removed front end shield (Figure 11/2) with the sealing applied onto 

the engine flange and fasten it using the four screws (Figure 11/3). 

4. Align the generator in front of the engine in a way, that the generator shaft 

lies in one line with the engine shaft. If necessary, support the generator 

accordingly. 

5. Push the generator against the engine and align the threaded hole of the 

generator shaft to the grub-screw screwed into the engine shaft. 

6. Screw the generator shaft by turning the fan impeller onto the grub-screw in 

the engine shaft as far as it will go. This pulls the generator housing against 

the front end shield already mounted on the engine. 

NOTE 

While screwing the generator shaft onto the grub-screw, align 

the generator with the front end shield mounted on the engine. 

It is not necessary to tighten the generator shaft on the grubscrew. 

It is sufficient, if the shaft is screwed onto the grubscrew 

as far as it will go, since the screw-connection tightens 

itself when the generator is loaded. 

For installation instructions for shaft fastening by tension bolt, 

please refer to section 4.5.4.4 on page 45. 

7. Fasten the end shield to the generator using four fastening screws (Figure 

12/2). 





1 



2 

3 

4x 

Figure 11 

Installation of brushless single-bearing generators to the 

engine (1) 

1 

2 

4x 

Figure 12 

Installation of brushless single-bearing generators to the 

engine (2) 




4.5.4.4 Additional installation instructions for shaft fastening by 

tension bolt 

Instead of the grub-screw described in the sections 4.5.4.2 and 4.5.4.3, 

optionally a tension bolt can be used to connect the shafts. In this case the 

generator shaft is drilled hollow. 

In this case proceed as follows instead of using the particular installation 

instructions. 

When installing single-bearing brush-type generators 

The following descriptions assume that you have already performed the removal 

prior to installation and the removal of the carbon brushes holder according to 


The steps listed here replace the steps 1. to 6. on page 39. 

1. Apply the sealing to the front end shield of the generator as described in 

section 4.5.4.1 on page 37 (see also Figure 13). 

2. As shown in Figure 13, align the generator in front of the engine in a way, 

that the generator shaft lies in one line with the engine shaft. If necessary, 

support the generator accordingly. 

3. Push the generator against the engine flange, so that the shafts hit each 

other. 

4. Insert the tension bolt (Figure 13/1) from the rear side through the generator 

shaft and screw it into the engine shaft, but do not yet tighten it. 

NOTE 

While screwing in the tension bolt, align the mounting holes in 

the end shield of the generator according to the drillings in the 


5. Fasten the end shield of the generator to the engine flange using four 

fastening screws (Figure 13/2). 

6. Secure the engine shaft against twisting and tighten the tension bolt. 

7. Continue with the further steps described in section 4.5.4.2: Start with step 

7. on page 40. 






1 

2 

4x 

Figure 13 

Installation of single-bearing brush-type generators fastened 

with tension bolt 

When installing brushless single-bearing generators 

The following descriptions assume that you have already performed the removal 

prior to installation according to section 4.5.4.3 on page 42. 

The steps listed here replace the steps 1. to 8. on page 43. 

1. Apply the sealing to the removed front end shield of the generator as 

described in section 4.5.4.1 on page 37 (see also Figure 14). 

2. Set the removed front end shield with the sealing applied onto the engine 

flange and fasten it using the four screws (Figure 14/2). 

3. As shown in Figure 14, align the generator in front of the engine in a way, 

that the generator shaft lies in one line with the engine shaft. If necessary, 

support the generator accordingly. 




4. Push the generator against the engine, so that the shafts hit each other. 

5. Insert the tension bolt (Figure 14/1) from the rear side through the generator 

shaft and screw it into the engine shaft, but do not yet tighten it. By 

screwing in the tension bolt, the generator shaft is pushed onto the engine 

shaft. 

NOTE 

While screwing in the tension bolt, align the generator 

according to the front end shield mounted at the engine. 

6. Fasten the end shield to the generator using four fastening screws (Figure 

15/2). 

7. Secure the engine shaft against twisting and tighten the tension bolt. Be 

sure to use the correct torque! Please contact the manufacturer, if you do not 

know the correct torque for the tension bolt. 




2 

4x 

1 

Figure 14 

Installation of brushless single-bearing generators with tension 

bolt (1) 




1 

2 

4x 

Figure 15 

Installation of brushless single-bearing generators with tension 

bolt (2) 



Chapter 4: 4.6 Installation of two-bearing generators (BG 132) 

4.6 Installation of two-bearing generators (BG 132) 

For installing two-bearing generators of the size BG 132 proceed according to 

the descriptions in this section 4.6. Prior to installation, read and understand 

the safety precautions in section 4.1 as well as the sections 4.2 to 4.4 and 

observe the instructions and information given there. 

CAUTION 

On both sides of the generator, a lifting eye bolt is provided for 

attaching lifting equipment. Lifting equipment may only be 

attached to the generator using these lifting eye bolts. Only 

appropriate lifting equipment may be used. 

4.6.1 Dimensions and mounting (two-bearing type, BG 132) 

The minimum clearances and regulations for cooling given in the following 

section 4.6.2 have to be met for installation. 

The dimensions of the generator can be found in the drawing sheet included in 

the annex. 

The generator has to be fastened using four 

screws (min. requirements: M8 or 

comparable, quality 8.8). The fastening must 

be durable as well as shock and vibration 

resistant. The screws must be secured 

against self-acting unscrewing by suitable 

measures, e.g. a clamp collar according to 

4 fastening screws 

DIN 128. 

Tightening torque for fastening screws: 

M = 25 Nm 




Permissible load on the shaft: 

• Standard end shield (shaft ø 28 mm): 

Fr max = 2000 N (measured at an axial 

distance of 50 mm from the shaft outlet 

in the end shield) 

Fa max = 200 N 

Fa max 

Fr max 

• Reinforced end shield (shaft ø 32 mm): 


distance of 50 mm from the shaft outlet 

in the end shield) 




CAUTION 

4.6.2 Minimum clearances and regulations for cooling (twobearing 

types, BG 132) 










Minimum clearances (BG 132, twobearing 

types) 





• Both sides and top: a = 100 mm 

• Front side: b = 200 mm 

• Rear side: c = 170 mm 

Cooling (BG 132, two-bearing types) 








vacuum of P max = 4 Pa may arise. 












a 

a 

b 

b 

P max = 7 Pa 

c 

a 

P max = 4 Pa 




4.6.3 Installation instructions for belt drive (two-bearing 


Belt pulleys and belts must be covered by a 

 

protective cover. Never operate the generator 

without the protective covers correctly 

mounted. Risk of personal injury! 

DANGER 

Never touch a running belt. Risk of personal 

injury! 

Do not knock the belt pulley onto the shaft. 

Taper bushes must be preferred for fastening. 

CAUTION 

To prevent the belt pulley against twisting, 

it is protected on the shaft by a feathered 

key. The belt pulley is fastened by a screw to 

the front end of the shaft. This screw has to 

be protected against accidental loosening 

using a suitable lock washer. 

• Threaded hole in the shaft: 

M10 x 22 mm 

• Tightening torque: M = 50 Nm 

The axis of the driving shaft must be 

absolutely parallel to the shaft of the 

generator. 

The belt pulleys on both shafts must be 

flush to each other so that the belt runs 

absolutely straight. 




The belt must not sag loosely. 

When using slim SPA-type V-belts, the 

distance between the shafts must not 

exceed 600 mm. Permissible shaft distances 

for other belts can be obtained from the 

manufacturer. 

Maximum tractive force (tension) of the 

drive belt on the shaft: 

• F max = 2000 N for standard end shield 

(shaft ø28mm) 

• F max = 3800 N for reinforced end shield 

(shaftø32mm) 

The specified maximum tractive force is 

applicable at an axial distance of max. 50 

mm from the shaft outlet in the end shield. 

If the belt is to be mounted with a greater 

distance to the end shield, the belt tension 

must be reduced in order to compensate the 

higher leverage to the shaft. 

Type and number of used belts 

The type and number of used belts have to 

be adapted to the power of the generator. 

The maximum belt tension force has to be 

observed! 

F max 

l max 




4.6.4 Installation instructions for flange mounting (two-bearing 


4.6.4.1 Flange mounting for BG 132 with standard end shield 




2. Unscrew the four screws M12 x 12 (3) and detach them together with the 

washers. 

1 

2 

3 

4x 

Figure 16 

Removal prior to installation for flange mounting (two-bearing 

types, BG 132 with standard end shield) 




Installation 

1. Set the flange (Figure 17/1) onto the generator and fasten it using the four 

screws (4a) with nuts (3a). Underlay the screw head with a blocking disk 

(4b) and apply threadlocking adhesive to the thread of the screw. Underlay 

the nuts with toothed disks (3b). 

2. Remount the sleeve (Figure 17/2) and fasten it by tightening the two screws. 

3. Plug the clutch-plate (5) onto the generator shaft and protect it against 

twisting on the shaft by means of a feathered key. 

4. Fasten the driving side of the clutch (6) to the engine and insert it into the 

clutch-plate. When inserting, twist the clutch a little bit until the gearing 

locks, if necessary. 

5. Fasten the flange (1) to the engine. 

1 

4x 

6 

5 

4a 

4b 

2 

3b 

3a 

4x 

Figure 17 Installation for flange mounting (two-bearing types, BG 132 

with standard end shield) 




4.6.4.2 Flange mounting for BG 132 with reinforced end shield 


Unscrew the four headless setscrews M12 x 25 (Figure 18/1). 

1 

Figure 18 

Removal prior to installation for flange mounting (two-bearing 

types, BG 132 with reinforced end shield) 




Installation 


screws (2a). Underlay the screw head with a toothed disk (2b) and apply 

threadlocking adhesive to the thread of the screw. 







1 

4x 

4 

3 

2a 

2b 

Figure 19 Installation for flange mounting (two-bearing types, BG 132 

with reinforced end shield) 




4.6.5 Installation instructions for hydraulic drive (two-bearing 


4.6.5.1 Hydraulic drive for BG 132 with standard end shield 


At the generator perform the removal prior to installation as described on page 

54 (see Figure 16). 

Installation 


screws (4a) with nuts (3a). Underlay the screws with a blocking disk (4b) and 

apply threadlocking adhesive to the thread of the screws. Underlay the nuts 

with a toothed disk (3b). 

2. Remount the sleeve (1) and fasten it by tightening the two screws. 

3. Plug the first part of the clutch (5) onto the generator shaft and protect it 

against twisting on the shaft by means of a feathered key. 

4. Mount the disc (6) to the hydraulic motor (8). 

5. Set the second part of the clutch (5) onto the hydraulic motor. 

6. Set the hydraulic motor (8) together with the disc (6) and the second part of 

the clutch onto the generator. When inserting, twist the clutch a little bit 

until the gearing locks, if necessary. 

7. Underlay the eight screws (7a) with a blocking disc (7b) and use them to 

fasten the disc (6) to the flange (2). 

8. Place the sleeve (9) to the clutch assembly and fasten it by tightening the 

two screws. 




2x 

9 

8x 

1 

8 

7a 

7b 2 

6 

5 

2x 

4x 

4a 

4b 

3b 

3a 

4x 

Figure 20 

Installation of the flange mounting for hydraulic drive (twobearing 

types, BG 132 with standard end shield) 




4.6.5.2 Hydraulic drive for BG 132 with reinforced end shield 




Installation 


screws (2a). Underlay the screws with a blocking disk (2b) and apply 

threadlocking adhesive to the thread of the screws. 











two screws. 




2x 

7 

6 

8x 

5a 

5b 

4 

3 

2a 

2b 

4x 

1 

Figure 21 

Installation of the flange mounting for hydraulic drive (twobearing 

types, BG 132 with reinforced end shield) 




4.7 Installation of two-bearing generators (BG 160) 

For installing generators of the size BG 160 proceed according to the 

descriptions in this section 4.7. Prior to installation, read and understand the 

safety precautions in section 4.1 as well as the sections 4.2 to 4.4 and observe 

the instructions and information given there. 

CAUTION 

On both sides of the generator, a lifting eye bolt is provided for 

attaching lifting equipment. Lifting equipment may only be 

attached to the generator using these lifting eye bolts. Only 

appropriate lifting equipment may be used. 

4.7.1 Dimensions and mounting (BG 160) 

The minimum clearances and regulations for cooling given in section 4.7.2 must 

be met for installation. The dimensions of the generator can be found in the 

drawing sheet included in the annex. 

The generator has to be fastened using 

four screws (min. requirements: M12 or 

comparable, quality 8.8). The fastening 

must be durable as well as shock and 

vibration resistant. The screws must be 

secured against self-acting unscrewing by 

suitable measures, e.g. a clamp collar 

according to DIN 128. 

4 fastening screws 

• Tightening torque for fastening screws: 

M = 87 Nm 

Fr max 

• Permissible load on the shaft: 

Fa max 


distance of 60 mm from the shaft 

outlet in the end shield) 




CAUTION 




4.7.2 Minimum clearances and regulations for cooling (BG 160) 







Minimum clearances (BG 160) 



a 


a 

a 


b 

• Both sides and top: a = 100 mm 

• Front side: b = 300 mm 

• Rear side: c = 200 mm 

Cooling (BG 160) 


b 



P max = 4 Pa 




P max = 7 Pa 


vacuum of P max = 4 Pa may arise. 

c 















4.7.3 Installation instructions for belt drive (BG 160) 

Belt pulleys and belts must be covered by a 

 

protective cover. Never operate the generator 

without the protective covers correctly 

mounted. Risk of personal injury! 

DANGER 

Never touch a running belt. Risk of personal 

injury! 

Do not knock the belt pulley onto the shaft. 

Taper bushes must be preferred for fastening. 

CAUTION 

To prevent the belt pulley against twisting, 

it is protected on the shaft by a feathered 

key. The belt pulley is fastened by a screw to 

the front end of the shaft. This screw has to 

be protected against accidental loosening 

using a suitable lock washer. 

• Threaded hole in the shaft: 

M16 x 36 mm 

• Tightening torque: M = 200 Nm 

The axis of the driving shaft must be 

absolutely parallel to the shaft of the 

generator. 

The belt pulleys on both shafts must be 

flush to each other so that the belt runs 

absolutely straight. 




The belt must not sag loosely. 

When using slim SPA-type V-belts, the 

distance between the shafts must not 

exceed 800 mm. Permissible shaft distances 

for other belts can be obtained from the 

manufacturer. 

Maximum tractive force (tension) of the 

drive belt on the shaft: 

F max. = 5000 N at an axial distance of max. 

60 mm from the shaft outlet in the end 

shield. If the belt is to be mounted with a 

greater distance to the end shield, the belt 

tension must be reduced in order to 

compensate the higher leverage to the 

shaft. 

F max 

l max 

Type and number of used belts 

The type and number of used belts have to 

be adapted to the power of the generator. 

The maximum belt tension force has to be 

observed! 




4.7.4 Installation instructions for flange mounting (BG 160) 


Unscrew the four headless setscrews M12 x 25 (Figure 22/1). 

1 

Figure 22 Removal prior to installation for flange mounting (BG 160) 




Installation 


screws (2a). Underlay the screw head with a toothed disk (2b) and apply 

threadlocking adhesive to the thread of the screw. 







1 

4x 

4 

3 

2a 

2b 

Figure 23 Installation of the flange mounting (BG 160) 




4.7.5 Installation instructions for hydraulic drive (BG 160) 




Installation 


screws (2a). Underlay the screws with a blocking disk (2b) and apply 

threadlocking adhesive to the thread of the screws. 











two screws. 




2x 

7 

6 

8x 

5a 

5b 

4 

3 

4x 

2a 

2b 

1 

Figure 24 Installation of the flange mounting for hydraulic drive (BG 160) 



Chapter 4: 4.8 Electrical connection of the generators 

4.8 Electrical connection of the generators 

Prior to installation, read and understand the safety precautions in section 4.1 

as well as the connection notes in this section 4.8 and observe the instructions 

and information given there. 

This section is only applicable for generators which are not equipped with a 

control box ex works. 


 




DANGER 




Engines that have been turned off must be secured against 












4.8.1 General 

If the generator is not equipped with a control box ex works, adequate fuse 

equipment has to be installed in an external control cabinet to protect the 

connected circuits (sockets): 

• Short-circuit tripping: characteristic "B" 

• Protection against overcurrent: according to nominal current 

• The neutral conductor has also to be fused. 




4.8.2 Version with terminal box 

Observe the following connection notes when connecting generators equipped 

with a terminal box: 

• When opening the terminal box, be careful not to tear-off or damage the 

connecting wires of the generator governor installed in the cover. 

• After opening the terminal box, remove the plug-and-socket connector to the 

generator governor installed in the terminal box cover. The plug-and-socket 

connector is mechanically coded and thus can not be plugged-in twisted. 

Plug-in the connector only immediately before closing the cover. 

• For leading cables into the terminal box only use appropriate waterproof 

IP54 cable glands. 

• Lay the connecting wires inside the terminal box with utmost care. 

• When closing the cover, be careful not to catch or squeeze any connecting 

wires. 

Figure 25 

Pin assignment of the connection terminal plate in the terminal 

box 




4.8.3 Version without terminal box, cables are lead out in a hose 

Optionally the generator can also be delivered without a terminal box equipped. 

In this case, the connecting cables are lead out of the generator in a hose. 

This is a customized version. For this reason, the connection of the cables has to 

be discussed with the generator manufacturer. 



Chapter 5, Operation 

5 Operation 

This chapter provides information about operating the generator. The operation 

can differ depending on the generator version and equipment. Where applicable, 

such differences are mentioned in the concerning texts. 

Prior to operating the generator, read and understand the safety precautions 

listed in section 5.1 as well as the sections 5.2 through 5.6 below and observe 

the instructions and information given there. 

5.1 Safety information for operation 

This section summarizes all relevant safety precautions for operating the 

generator. 

DANGER 

Do not operate the generator in explosive environments. 

Further regulations on this have to be observed! 






The generator supplies highly dangerous voltages during 

operation! Never touch the generator or the devices connected 

to the generator with wet hands during operation. Mortal 

danger by electric shock! 


















 




DANGER 








Be sure to completely read and understand these operating 

instructions before using the generator. The generator may only 

be used for applications described in section "Proper use" and 

in conformity with the specifications given in this manual. 

Before connecting devices to the generator, ensure that the 

devices are switched off. Accident hazard! Unsupervised 

starting devices can endanger or injure persons as well as cause 

damages or damage themselves. 

Infants and animals must have no admittance to the generator, 

not just during but also after operation. Make appropriate 

precautions. Mortal danger by electric shock, injury and 

burning hazard! 





CAUTION 

Be sure to observe the operating conditions given in section 5.2. 

The generator may only be operated in conformity with the 

operating conditions and data specified there. This especially 

applies to the ambient and cooling conditions and the permissible 

current load. 




5.2 Permissible operating conditions 

The generator may only be used, if the operation conditions listed below are 

kept. 

Only those devices may be connected, the voltage and frequency specifications 

of which meet the specifications given on the type plate of the generator. The 

generator may not be overloaded. The total power consumption of all connected 

devices must not exceed the output power specified for the generator. 

The generator must have a free cooling air supply as well as an unimpeded 

cooling air dissipation. The cooling air temperature must not exceed 40 °C. If 

the cooling conditions can not be met, the generator must not be loaded with 

its full rated output power. 

In case of inadequate cooling of the generator or under conditions other than 

permissible operation conditions, the generator output voltage is automatically 

reduced. In this case, the load connected to the generator has to be reduced to 

avoid damage of the connected devices. 

5.3 Electric protection equipment, protective measures and 

grounding 

5.3.1 Electric protection and grounding/equipotential bonding 

If the generator is not equipped with the option "Insulation monitoring with 


equipotential bonding" according to VDE 0100, part 728. 


switching-off", it fulfills the better protective measure "Protection separation 

with insulation monitoring" according to VDE 0100, part 728. 

For a proper function of the mentioned electrical protective measures, it is not 

required to ground the generator (e.g. using a grounding rod). If this is desired 

anyway or required for some special cases, a defined grounding of the generator 

housing can be performed or the generator housing can be included into an 

equipotential bonding with other devices. For this purpose, only the 




corresponding earth connection points marked with the earth symbol 

be used. 

may 

DANGER 










5.3.2 Protection against overcurrent 

If the generator is equipped with a control box ex works, the sockets of the 

control box mounted on the generator are protected against overcurrent and 

short-circuit conditions using automatic circuit breakers. See Figure 26. 

Circuit breaker block 

(protection: 3P + N) 

Figure 26 

Circuit breaker in control box (only applicable for 8 kVA and 

13 kVA generators) 




If the generator is not equipped with a control box ex works, adequate fuse 

equipment has to be installed in an external control cabinet to protect the 

connected circuits (sockets): 

• Short-circuit tripping: characteristic "B" 

• Protection against overcurrent: according to nominal current 

• The neutral conductor has also to be fused. 

5.4 Connection to an existing power distribution network (e.g. 

house wiring) 

The connection of generators to an existing power distribution network (e.g. 

house wiring) may only be performed by a qualified electrically skilled person 

and only after permission of the energy supply company. Observe all relevant 

DIN and VDE regulations, especially DIN VDE 0100, part 728.6, as well as 

possibly existing additional technical connection regulations of the energy 

supply company. 

For this purpose, considerable changes at the generator can be necessary which 

may only be performed by a qualified electrically skilled person and after 

consultation of the generator system manufacturer. 


 




DANGER 











5.5 Operating information for safe working with electric devices 

Observe the following operating information for a safe 

 

operation and handling of electric devices. 

Please also observe the safety precautions for operation given 

DANGER in section 5.1 on page 73. 

• Devices that caused the insulation monitoring unit to switch-off and to 

indicate a "FAULTY INSULATION" must also not be operated at other 

generators without insulation monitoring or in the public electricity supply 

network. Devices with defective insulation have to be immediately taken out 

of operation and replaced or repaired by the device manufacturer or an 

authorized electric company. 

• Only connect devices that are in a faultless and safe condition. The devices 

and connectors have to be clean and dry. 

• Before connecting devices to the generator, ensure that the devices are 

switched off. Accident hazard! Unsupervised starting devices can endanger or 

injure persons as well as cause damages or damage themselves. 

• Depending on the field of operating and application, regulations, 

prescriptions, requirements or recommendations of the professional 

associations and trade associations have to be observed when working with 

generators. Additionally, the Gerätesicherheitsgesetz (GSG, German 

Equipmant Safety Law), the relevant regulations for preventing accidents as 

well as the mine regulations of the countries have also to be considered. 

When using generators outside the scope of requirements of the Federal 

Republic of Germany, the suitability of the generator has to be proofed under 

consideration of the individual national requirements. If you have any 

questions, please contact the system manufacturer. 

• The generator may only be operated under the permissible operating 

conditions given in section 5.2 on page 75. 

• Many portable electric tools comply with protection class II (protective 

insulation, identification ). It is recommended to use such devices as far 

as possible. If devices of protection class I are used (i.e. with metal housing 

parts which are not insulation protected), these must be equipped with a 

connection cable and a connector with PE conductor. 

• When working in "conductive areas with limited freedom of movement", i.e. 

in areas within the scope of DIN VDE 0100 part 706 (e.g. in metal tanks), 

only one single device may be connected to the generator if it is a "hand- 




held electric tool or a mobile measuring instrument". Otherwise for each 

device a separate isolating transformer or an isolating transformer with 

several separate secondary windings must be used. Hand-held luminaires in 

conductive areas with limited freedom of movement may only be operated via 

an isolated transformer with protection low voltage (SELV). 

• Cables for distribution (e.g. extension cords and cord sets) must be 

extensively selected, laid and maintained. Electric cables have to be checked 

in regular intervals. Defective cables and cords have to be exchanged. When 

connecting extension cords, observe the following section 5.6.2 on page 81. 




5.6 Operation of the generator 

CAUTION 

Only take the generator into operation after you have completely 

read and understood all sections of this chapter 5, particularly the 

safety precautions given in section 5.1 on page 73. 

If your generator is equipped with the option "Insulation 

monitoring with switching-off", the correct function of the 

insulation monitoring unit has to be checked every working day. 

The generator may only be taken into operation, if the correct 

function of the insulation monitoring unit has been confirmed. 

5.6.1 Control elements in the control box (if available) 

Figure 27 shows all possible control elements and indicators in the control box 

optionally mounted on the generator (insulation monitoring unit and hour meter 

are also optional). 

Insulation monitoring unit 

with switch and signal lamp 

(optional) 

Circuit breaker block 

(protection: 3P + N) 

Hour meter 

(optional) 

Socket 400 V 

3 sockets 230 V 

Figure 27 

Control elements and indicators in the control box (optional) 




5.6.2 Current distribution and connection of devices 

DANGER 

CAUTION 

NOTE 

The generator must not be used for the supply of assemblies 

for construction sites. 

Generators which are equipped with an insulation monitoring 

unit must not be connected to further insulation monitoring 

units since the insulation monitoring units can mutually 

interact. 

The generator may not be overloaded. The total power consumption 

of all connected devices must not exceed the output power 

specified for the generator. 

Only those devices may be connected the voltage and frequency 

specifications of which meet the specifications listed on the type 

plate of the generator. 

If your generator is equipped with a control box: 

• Do not use the circuit breakers in the control box for switching 

the connected devices on and off. When using several devices 

connected to the single-phase AC voltage sockets at the same 

time (especially when using devices with different power 

consumptions), short-term over- or undervoltages may arise due 

to a turn-on delay of the neutral conductor. 

• The cover of the control box and the hinged lids of unused 

sockets have always to be kept correctly closed in order to 

guarantee IP54 protection (tighten the locking screws by 

hand). 

Current-operated earth-leakage circuit breakers are not functional 

in ungrounded networks (IT systems, as supplied by the generator), 

because there is no grounding. However, since the generator 

supplies the protective measure "protection separation", additional 

protection by means of current-operated earth-leakage circuit 

breakers is not necessary. 




Proceed as follows to take the generator into operation and to connect the 

loads: 

1. If necessary, perform the daily check of the insulation monitoring unit. See 

section 5.6.3 on page 84. 

2. Make sure that no devices are connected to the generator. 

3. Switch off all devices which are to be connected later (switch in position 

"OFF" or "0"). Accident hazard by unsupervised starting devices! 

4. Start the engine. Wait until the engine has reached its rated speed. 

5. If necessary, switch on the circuit breakers in the control box (if equipped, 

see Figure 27) or in the control cabinet (position "ON" or "I"). 

6. Connect (or switch on) the devices one after the other. First switch on the 

powerful devices with high current consumptions or high starting currents 

and then the less powerful devices. 

NOTE 

The total length of all connected extension cables may not 

exceed the following values: 

• 250 m max. at a conductor cross section of 2.5 mm 2 

• 100 m max. at a conductor cross section of 1.5 mm 2 

Devices driven by electric motors possibly require starting 

currents that are many times higher than the specified 

operating currents. In case of doubt, please contact the 

manufacturer. 

To ensure a safe operation of three-phase generators, the load 

currents should be distributed to all three phases as equal as 

possible. 

Take care that the maximum currents specified for each socket 

are not exceeded. 




7. When switching off the connected devices, switch off the devices one after 

the other and unplug their mains plugs. If possible, first switch off the less 

powerful devices and finally the powerful devices with high current 

consumptions. 

NOTE 

Ensure that the hinged lids of the sockets are correctly closed 

again after unplugging the mains plugs. 




5.6.3 Checking the insulation monitoring unit (if available) 

CAUTION 

If your generator is equipped with the option "Insulation 

monitoring with switching-off", the correct function of the 

insulation monitoring unit has to be checked every working day. 

The generator may only be taken into operation, if the correct 

function of the insulation monitoring unit has been confirmed. 

Proceed as follows to check the insulation monitoring unit (refer to Figure 27 for 

the location of the control elements and indicators): 

1. Unplug all devices and cables connected to the generator. 

2. Start the engine. The check must be performed while the generator is 

running. 

3. Open the cover of the control box and switch on the insulation monitoring 

unit (position "ON" or "I"). 

4. Push the red test push-button which is at the same time used as an indicator. 

Now the insulation monitoring unit must trip. 

5. Check whether the insulation monitoring unit has tripped and the red 

indicator "FAULTY INSULATION" is on. 

NOTE 

If the insulation monitoring unit does not trip or if the "FAULTY 

INSULATION" indicator does not light, the generator must not 

be used any longer. In this case, mark the generator as 

defective and have it repaired (refer to section 7 on page 92). 

6. Stop the engine to reset the insulation monitoring unit. 

7. Switch on the insulation monitoring unit again (position "ON" or "I") and 

correctly close the cover of the control box (tighten the locking screws by 

hand). 

8. If the check was successful the generator is now ready for operation. 



Chapter 6, Maintenance 

6 Maintenance 

All components of the generator are maintenance-free in principle (exception: 

changing the carbon brushes holder for brush-type generators, see section 6.4.1 

on page 89). Nevertheless, the maintenance operations listed in section 6.1 

have to be performed regularly and on time to ensure reliable operation of the 

generator. 

CAUTION 

In addition to the work described in this chapter, the driving 

system/engine possibly has to be checked according to the 

guidelines and regulations of the driving system/engine 

manufacturer. This also includes the correct attachment of 

protective covers. Be sure to observe the maintenance instructions 

of the driving system/engine manufacturer. 

Do not open or disassemble the housing of the 

generator or the control box! The generator may 

only be opened by the manufacturer or an agency 

authorized by the manufacturer. It does not 

contain any components which can be replaced or 

repaired by the user. It is not allowed to perform 

any work or operations not described in this 

manual. 

Any damages and defects found on the generator have to be repaired 

immediately by authorized and qualified personnel independent of the 

maintenance intervals. The generator must not be taken into operation until any 

defects have been removed. Any repair work must only be carried out by 

adequately trained qualified personnel. 




6.1 Maintenance overview 

Interval Maintenance operation To be performed by 

Every 

working day 

Monthly 

Every 1.000 

hours of 

operation 

Every 5.000 

hours of 

operation 

Every 20.000 

hours of 

operation 

Check the correct function of the insulation 

monitoring unit (if available). 

See section 5.6.3 on page 84. 

At the generator: 

• Visual inspection for contamination or 

damages. Cleaning if necessary. 

• If necessary, clean the plates and labels 

or replace them. 

• Check the cooling air openings for 

contamination or blocking and clean 

them, if necessary. 

See section 6.3 on page 88. 

At the control box (if mounted): 

• Visual inspection for contamination or 

damages. Cleaning if necessary. 

• Check the cover and the socket lids for 

waterproof locking. 

See section 6.3 on page 88. 

Only for brush-type generators: 

Check the carbon brushes 


Check the ball bearings by "listening". 

Replace, if necessary (rough noises at the 

bearings). 

User 

User 

User 

Qualified 

electrically skilled 

person 

Qualified 

skilled person 

Replace the ball bearings 

Manufacturer 

The standard maintenance interval for 

replacing the ball bearings is 20.000 hours. 

If necessary (see check every 5.000 hours), 

the ball bearings have to be replaced earlier. 





6.2 Safety precautions 

This section summarizes the safety precautions relevant for maintenance 

operations. 


 



(in Germany: e.g. VDE regulations). 

DANGER 




Engines that have been turned off must be secured against 



Any maintenance, service and replacement operations on the 

generator may only be performed by authorized and qualified 

personnel. 












For repair and replacement operations, only genuine components or 

external components expressly approved by the manufacturer may 

be used. 

CAUTION 




6.3 Visual inspections and cleaning to be performed by the user 

In addition to the safety precautions provided below, read and observe the 

safety precautions listed in section 6.2 above. 


 




DANGER 




The following operations have to be performed by the user in monthly intervals. 

1. Check the generator housing for damages visible on the outside as well as for 

excessive contamination which could impair cooling. If necessary, use a wet 

cloth to clean the generator. 

2. If the generator is equipped with a control box, check the housing of the 

control box and the installed sockets for damages and contamination visible 

on the outside. If necessary, use a wet cloth to clean the control box. Check 

the transparent cover of the control box and the hinged lids of the sockets 

for damages and waterproof locking. 

3. Check whether the safety and warning label and the type plate attached to 

the generator are readable. If necessary, clean the plates and labels or 

replace them. 

4. Check the cooling air openings on the rear side of the generator for 

contamination which could obstruct the cooling air flow and use a wet cloth 

to clean the openings, if necessary. 




6.4 Maintenance to be performed by authorized qualified 

personnel 

Any maintenance, service and replacement operations on the 

 

generator may only be performed by authorized and qualified 

personnel. 

DANGER 

In addition to the safety precautions listed below, read and observe the safety 

precautions given in section 6.2. 

6.4.1 Checking and/or replacing the carbon brushes (only brushtype 

generators) 

The carbon brushes of brush-type generators have to be removed and checked 

every 1.000 hours of operation by qualified personnel as described below. If the 

carbon brushes are used up more than half, the complete carbon holder must be 

replaced. It is not possible to replace only one single carbon brush. 

Removing the carbon brushes holder 




brushes holder (Figure 28/3). The connection cables are coded by the width 

of the connection lugs and therefore protected against interchanging (see 

Figure 29). 


carbon brushes holder (Figure 28/3). 

1 

2 

3 

Figure 28 

Removing the carbon brushes holder 




Checking the carbon brushes 

The carbon brushes holder has to be replaced, if the carbon brushes are used up 

more than half, i.e. if they jut out of the carbon brushes holder less than 6 mm 

(see Figure 29). 

red 

gray 

6 mm min. 

Figure 29 

Checking/Replacing the carbon brushes 


1. Insert the carbon brushes holder (Figure 30/3) correctly positioned into the 

generator and press it onto the collector rings on the shaft, so that the 

carbon brushes are pressed into the carbon brushes holder and the carbon 

brushes holder lies on its mounting base. 

2. Continue to press on the carbon brushes holder and screw in the fastening 

screw, but do not tighten it completely. While screwing in the fastening 

screw, the carbon brushes holder is automatically positioned on the 

mounting base. 

3. Check the proper seating of the carbon brushes holder and then tighten the 

fastening screw. 

4. Plug both connection cables onto the connection lugs of the carbon brushes 

holder according to the width of the connectors (see Figure 30). 

5. Remount the sleeve (Figure 30/1) and fasten it by tightening the two screws 

(2). 




1 

2 

red gray 

3 

Figure 30 


6.4.2 Replacing the ball bearings 

The ball bearings of the generator have to be replaced at least every 20.000 

hours of operation. However, if rough noises are detected at the ball bearings 

during the check prescribed every 5.000 hours of operation, the ball bearings 

have to be replaced earlier. 

We strongly recommend for these operations to remove the generator and to 

send it to the manufacturer or to an agency authorized by the manufacturer. 

Removing the generator is described in chapter 8 on page 93. 



Chapter 7, Reconditioning 

7 Reconditioning 

Aside from the work described for maintenance in chapter 6, no other 

reconditioning operations can be carried out for the generators outside the 

manufacturer plant. 

If repair work is necessary, we recommend to remove the generator and to send 

it to the manufacturer or to an agency authorized by the manufacturer. 

Removing the generator is described in chapter 8 on page 93. 



Chapter 8, Removal 

8 Removal 

To remove the generator, proceed according to the descriptions given in this 

chapter. 

8.1 Safety precautions 

DANGER 

Removing of the generator may only be performed by 

authorized and qualified personnel. 



For removing the generator make sure that the switched-off 

engine cannot be restarted accidentally (e.g. by removing the 

ignition key and keeping it safe). Mortal danger by electric 

shock, risk of personal injury! 

8.2 Removal of two-bearing generators (BG132 and BG160) 

The removal of two-bearing generators has to be performed in accordance with 

the descriptions in chapter 4. 

8.3 Removal of single-bearing generators 

NOTE 

For the removal of single-bearing generators the following special 

tools are required: 

• Special tool of the engine manufacturer to hold the engine 

shaft. 

• For shaft fastening by grub-screw: 

Special hexagon nut for turning the generator shaft using a 

spanner as well as special sawing ring pliers for removing and 

mounting the sawing ring which secures the fan impeller on the 

shaft. 

• For shaft fastening by tension bolt: 

Pushing rod and pushing screw. 

• Additionally for brush-type generators: 

Special wooden chock serving as transport locking for the rotor. 




8.3.1 Removal of single-bearing brush-type generators 

Work prior to removal and removal of the carbon brushes holder 

1. Disconnect the electric connection cables of the generator as described in 

section 4.8 on page 70. 




brushes holder (Figure 31/5). The connection cables are coded by the width 

of the connection lugs and therefore secured against interchanging. 


carbon brushes holder (Figure 31/5). 

5. Refer to the following descriptions to continue the removal: 

- For shaft fastening by grub-screw continue on page 95. 

- For shaft fastening by tension bolt continue on page 97. 

1 2 

3 

4 

5 

Figure 31 

Work prior to removal of single-bearing brush-type generators 




Removal for shaft fastening by grub-screw 

1. Remove the fan impeller shroud (Figure 31/4) and the fan impeller (Figure 

31/3) from the generator. The fan impeller is secured against twisting on the 

shaft by means of a feathered key and a sawing ring. 

2. Attach the special hexagon nut (Figure 32/2) onto the generator shaft 

instead of the fan impeller and secure it against twisting by means of the 

feathered key (1). 

3. Hold the engine shaft using the special tool of the engine manufacturer. 

4. Attach the spanner to the special hexagon nut and undo the grub-screw 

connection between engine and generator shaft. 

5. Support the generator if necessary and unscrew the four end shield fastening 

screws (Figure 32/3) at the engine flange. 

6. Unscrew the generator shaft from the grub-screw screwed into the engine 

shaft and detach the generator. 

7. Unscrew the grub-screw (Figure 32/4) from the engine shaft using an Allen 

wrench. 

1 

4 

2 

3 

Figure 32 Removal of single-bearing brush-type generators (1) 




8. Detach the special hexagon nut (Figure 33/1) from the generator shaft. 

9. Remount the carbon brushes holder (Figure 33/4) according to the 

descriptions on page 90 (section 6.4.1) into the generator and reconnect the 

connection cables. 

10. Insert the special wooden chock serving as transport locking for the rotor. 

11. Remount the sleeve (Figure 33/6) and fasten it by tightening the two 

screws (5). 

12. Remount the fan impeller (Figure 33/2) and secure it on the generator shaft 

by means of the feathered key (against twisting) and the sawing ring. 


6 

5 

1 

2 

3 

4 

Figure 33 Removal of single-bearing brush-type generators (2) 




Removal for shaft fastening by tension bolt 

1. Detach the cap (Figure 34/2) at the fan impeller shroud. 


3. Undo the tension bolt (Figure 34/1) and pull it out of the generator shaft. 


screws (Figure 34/3) at the engine flange. 

5. Insert the pushing rod (Figure 34/4) into the generator shaft instead of the 

tension bolt and screw the pushing screw (5) into the generator shaft. By 

screwing in the pushing screw, the generator shaft is detached from the 

engine shaft. 

6. Detach the generator from the engine. 

7. Remove the pushing screw and the pushing rod from the generator shaft. 

Remount the cap onto the fan impeller shroud. 

8. Remount the carbon brushes holder (Figure 33/5) according to the 

descriptions on page 90 (section 6.4.1) into the generator and reconnect the 

connection cables. 

9. Insert the special wooden chock serving as transport locking for the rotor. 

10. Remount the sleeve (Figure 33/7) and fasten it by tightening the two 

screws (6). 

1 

2 

4 

5 

3 

Figure 34 

Removal of single-bearing brush-type generators with tension 

bolt 




8.3.2 Removal of brushless single-bearing generators 

Work prior to removal 

1. Disconnect the electric connection cables of the generator as described in 

section 4.8 on page 70. 

2. Refer to the following descriptions to continue the removal: 

- For shaft fastening by grub-screw continue with the following section on 

this side. 

- For shaft fastening by tension bolt continue on page 101. 

Removal for shaft fastening by grub-screw 

1. Remove the fan impeller shroud (Figure 35/3) and the fan impeller (Figure 

35/2) from the generator. The fan impeller is secured against twisting on the 

shaft by means of a feathered key and a sawing ring. 


screws (Figure 35/4) at the generator. 

3. Attach the special hexagon nut (Figure 36/2) onto the generator shaft 

instead of the fan impeller and secure it against twisting by means of the 

feathered key (Figure 36/1). 


5. Attach the spanner to the special hexagon nut and undo the grub-screw 

connection between engine and generator shaft. 

6. Unscrew the generator shaft from the grub-screw screwed into the engine 

shaft and detach the generator. 

7. Remove the front end shield of the generator which is still mounted on the 

engine. For this purpose, unscrew the four screws (Figure 36/3) and detach 

the end shield (Figure 36/4). 

8. Remount the front end shield (Figure 36/4) to the generator. 




9. Unscrew the grub-screw (Figure 37/1) from the engine shaft using an Allen 

wrench. 

10. Detach the special hexagon nut (Figure 37/2). 

11. Remount the fan impeller (Figure 37/3) and the fan impeller shroud (Figure 

37/4). Secure the fan impeller on the generator shaft by means of the 

feathered key (against twisting) and the sawing ring. 

1 

4 

2 

3 

Figure 35 Removal of brushless single-bearing generators (1) 

1 

4 

2 

3 





1 

2 

3 

4 





Removal for shaft fastening by tension bolt 

1. Detach the cap (Figure 38/2) from the fan impeller shroud. 

2. Detach the front end shield from the generator. For this purpose, unscrew the 

four fastening screws (Figure 38/5) of the front end shield at the generator. 


4. Undo the tension bolt (Figure 38/1) and pull it out of the generator shaft. 

5. Insert the pushing rod (Figure 38/3) into the generator shaft instead of the 

tension bolt and then screw the pushing screw (Figure 38/4) into the 

generator shaft. By screwing in the pushing screw, the generator shaft is 

detached from the engine shaft. 

6. Detach the generator from the engine. 

7. Remove the pushing rod (Figure 38/3) and the pushing screw (Figure 38/4) 

from the generator shaft. Remount the cap (Figure 38/2) onto the fan 

impeller shroud. 

8. Remove the front end shield (Figure 39/1) of the generator which is still 

mounted to the engine. For this purpose, unscrew the four screws (Figure 39/ 

2) and detach the end shield. 

9. Remount the front end shield to the generator. 

5 

1 

2 

3 

4 

Figure 38 

Removal of brushless single-bearing generators with tension bolt 

(1) 




1 

2 

Figure 39 

Removal of brushless single-bearing generators with tension bolt 

(2) 



Chapter 9, Transport and storage 

9 Transport and storage 

The generators are bolted onto a transport pallet and packed accordingly for 

protection against damages and penetrating humidity when leaving the factory. 

Single-bearing generators achieve IP54 protection only when they are mounted 

to the engine. 

The generators have to be transported and stored dry and protected 

against water. Transport and storage may only be performed in 

delivery state with the packaging and protective devices mounted. 

CAUTION 

On both sides of the generator, a lifting eye bolt is provided for attaching lifting 

equipment. Lifting equipment may only be attached to the generator using these 

lifting eye bolts. Only appropriate lifting equipment may be used. 

If no lifting eye bolts are provided at the generator ex works, these must be 

mounted later for lifting the generator. 

Generators BG 132 Generators BG 160 

Weight (mass) approx. 40 - 80 kg approx. 140 -180 kg 

Permissible temperatures: 

transport 

storage 

Permissible rel. humidity: 

transport 

storage 

-25 °C to +60 °C 

-20 °C to +50 °C 

95%, non-condensing 

95%, non-condensing 



Chapter 10, Putting out of operation, storage after dismantling, disposal 

10 Putting out of operation, storage after dismantling, 

disposal 

Dismantling the generators and putting the generators out of operation have to 

be performed according to the descriptions in chapter 8. 

Generators which are still functional have to be packed and stored as described 

in chapter 9. 

Generators which are no longer functional have to be labeled accordingly and 

disposed or supplied for recycling in accordance with the legal requirements. For 

more detailed information refer to the relevant environmental protection 

authority or to the manufacturer. 

10.1 Waste disposal information 

Generator housing 

Fan impeller shroud 

Fan impeller 

Rotor and shaft 

Windings 

Electronic components 

Aluminum 

Iron/steel 

Polypropylene 

Iron/steel 

Copper, impregnated by modified Ester- 

Imide (THEIC) 

Electronics scrap 



Chapter 11, Spare parts 

11 Spare parts 

Companies authorized for repair and replacement work are asked to contact the 

manufacturer for the service manual. 



Chapter 11, Spare parts

Synchronous Generators BG 132 and BG 160

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?