Kato Engineering Standard AC Generator User Manual

Kato Engineering Standard AC Generator

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Copyright © 2012 Kato Engineering, Inc. All rights reserved

Instruction Manual

Installation • Operation • Maintenance

Standard AC generator

Single or two-bearing

Drive-end air discharge

Publication 350-01001-00, 01/19/2016

Please read this manual and all included manuals in its entirety

before unpacking, installing, and operating your generator. If your

manual came on a CD, read all the ﬁ les included on the CD.

Kato EngineeringP.O. Box 8447 Mankato, MN USA 56002-8447Tel: 507-625-4011

Fax: 507-345-2798Email:

KatoEngineering@emerson.com www.kato-eng.com

Copyright © 2015 Kato Engineering, Inc. All rights reserved

Table of Contents

Questions and Answers:

W
William HannaAug 9, 2025
Why is the voltage fluctuating on my Kato Engineering Portable Generator?
- W
  William GrantAug 9, 2025
  To resolve fluctuating voltage in your Kato Engineering Portable Generator: * Check the frequency and voltage of incoming power if the generator set is motor-driven. For engine-driven sets, check the engine governor. * Tighten all loose internal or load connections. * Reduce the load to the rated value if the generator is overloaded. * Trace the DC excitation circuit and correct any defects. * Correct the speed of the prime mover if there is overspeed. * Check, adjust, repair, or replace the voltage regulator if it's not operating properly.
W
williamcrosbyAug 15, 2025
What to do if my Kato Engineering Portable Generator is overheating?
- G
  Gene MckenzieAug 15, 2025
  To resolve overheating in your Kato Engineering Portable Generator: * Clean all clogged ventilating screens and air passages. * Replace any dry or defective bearings. * Align the generator set if there is a coupling misalignment. * Test field coils for shorts and replace the shorted rotor or return it to the factory for repair if generator field coils are shorted or grounded. * Adjust the load to the nameplate rating if there is an unbalanced load, overload, or low power factor.

Kato Engineering Standard AC Generator Specifications

General

Brand	Kato Engineering
Model	Standard AC Generator
Category	Portable Generator
Language	English

Summary

Introduction

Safety Instructions

Details essential safety precautions for installation, operation, and maintenance.

Construction and Operating Principles

Stator Construction

Rotor Assembly

Excitation System Overview

Installation Procedures

Receiving Inspection

Unpacking and Moving

Assemble to Prime Mover and Alignment

Procedures for connecting the generator to the prime mover and performing alignment.

Two-Bearing Close-Coupled Alignment

Detailed steps for aligning two-bearing generators with flywheel housing.

Two-Bearing Alignment

Procedures and tolerances for aligning two-bearing generators using couplings.

Single-Bearing Alignment

Steps for aligning single-bearing generators, including shaft and endbracket measurements.

Foot Deflection Check

Electrical Connections

Guidance on making all electrical connections according to codes and diagrams.

Inspection Before Startup

Final checks to perform after electrical connections are made before starting.

Operation Guide

Initial Startup (Manual & Automatic Control)

Step-by-step guide for starting generators with dual voltage control modes.

Initial Startup (Automatic Control Only)

Step-by-step guide for starting generators with automatic voltage control.

Restoring Residual Magnetism/Field Flashing

Procedure to restore residual magnetism when voltage fails to build up.

Continuous Operation

Parallel Operation

Instructions for operating the generator in parallel with a system.

Maintenance Schedule

Maintenance Schedules

2000 Hours / 6 Months Maintenance

8000 Hours / 1 Year Maintenance

20,000 Hours / 3 Years Maintenance

30,000 Hours / 5 Years Maintenance

Visual Inspection of Windings

Methods for visually inspecting windings to identify signs of wear, damage, or contamination.

Cleaning Procedures

Insulation Resistance Tests

Guidelines and procedures for measuring insulation resistance of generator windings.

Dry Out Procedures

Rectifier Tests

Methods for testing generator rectifiers using an ohmmeter or test lamp.

Disassembly Guide

Overall Disassembly

Exciter Armature and PMG Removal

Bearing Removal

Assembly Guide

Bearing Installation

Overall Assembly

Exciter Armature and PMG Installation

Torque Specifications

ASTM and SAE Torque Values

Metric Torque Values

Troubleshooting Generator Issues

Symptoms, Causes, and Remedies

Guide to identifying and resolving common generator problems.

Overheating Troubleshooting

Specific troubleshooting steps for generator overheating issues.

Vibrations Troubleshooting