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Starlight TFW Generator Description, Installation And Adjustment

Jan. 02, 2020

This article mainly introduces Starlight TFW Series generator safe caution, description, installation and adjustment details. If you are using this type of alternator or want to know about our product, it is necessary to read the related information.

Safe Caution

Please remember safety first. If you are not sure of the instructions or procedures, seek qualified help before continuing.

This service manual emphasizes the safety precautions necessary during the installation, operation, and maintenance of your TFW generator.


1. The lifting eyes on the generator are designed to support the generator only. Do not lift a complete generator set (engine) by means of lifting eyes on the generator. Personal injury or damage to the equipment may result.

2. Do not apply any force to the generator fan. Never "BAR OVER" the engine-generator set by using the fan. Failure to comply with these safety procedures could result in severe injury to personnel or damage to the equipment.

3. Before any service work is done, disconnect all power sources, and lock out all controls to prevent an unexpected start-up of the generator set.

4. Proper grounding in compliance with local and national electrical codes must be provided.

5. Whenever the generator is running, always assume and proceed as if voltage is present. Residual voltage is present at the generator terminals, and at the regulator panel connections, even with the regulator fuse removed. Caution must be exercised, or serious personal injury or death can result.

6. Whenever solvent, cleaners, or flammable liquids are present, adequate ventilation must be available to avoid fire, explosion, and health hazards. Always avoid breathing vapors and suitable personal protective equipment to prevent personal injuries (head, eyes, face, feet, hand, respirator, etc.)

7. Special caution must be taken during trouble shooting since protective covers and safety devices may be removed or disabled to gain access and make tests.


II. Description.

TFW series three phase AC synchronous brushless generator is a new generation brushless generator, which based on the MAGNA PLUS generator of Marathon electric co. USA.

TFW generator may be combined with diesel engine (internal-combustion engine) to make fixed or movable electrical power. It is suited for commercial buildings, hospitals, factories, farms, fields, etc. as power and lighting. The generating set may be used for the prime power or stand by.

TFW series alternators are of unique design, advanced construction, excellent performances, reliable operation, easy use, small volume and light weight.



1. TFW series generator are manufactured in accordance with NEMA ODP type. It consists of main generator, AC brushless exciter, rotating rectifiers, AVR, conduit box, etc.

2. Class H or Class F insulation system.

3. The frame is made by steel plate. The design of stator lamination is unique. If necessary, 12 lead wires may be supplied.

4. Main rotor apply the single piece 4-pole salient lamination, coupled with die cast or welding damping winding, field winding to form a unique rotor construction. The field winding is layer wound with thermo setting epoxy for high mechanical and electrical integrity.




1. TFW series generator may be operated continuously at rated load under following Conditions:

a. Ambient. Air temperature ≤40°C,well ventilation, marine use, ≤45°C

b. Elevation.≤1,000 m over sea level

2. Electrical performances.

a. Steady voltage regulation≤1.0%

b.Transient voltage regulation≤+20%, -15%

c. Adjustable voltage range 95-105%Un

d. Waveform distortion at no-load,≤ 5%(line voltage)


Starlight alternator production

UP. Storage.


In the event that the generator is not to be installed on its prime mover immediately, it is recommended that the unit be stored in a cleaned, dry area which is not subject to rapid changes in temperature and humidity.

In the event of long term storage, the generator should be tested cleaned and dried as required, before being put into service. See the maintenance section of this manual for further information.


IV. Installation and adjustment.


1. Generator must be mounted at the clean, dry and well ventilation place. The prime mover and generator should be installed on a public frame, never put them on the cement floor, and ensure the public frame under formed.

2. Single bearing generators.

Single bearing units are provided a SAE flywheel housing adapter and flexible drive discs to match the engine. Close tolerances are maintained in the manufacture of the generator to promote ease to alignment.

Special steel drive discs are bolted the shaft. In some case spacer are used to achieve the proper "XG" dimension. Holes are provided in the periphery of the coupling discs which correspond to tapped holes in the engine flywheel. The outside diameter of the drive discs fit in a rabbet in the flywheel so that concentricity is assured.


CAUTION: Grade 8.8 place to the flywheel. Do not use split type lock washers, they will cause stress risers, and may result in disc failure.


The SAE flywheel housing adapter and the engine flywheel housing are designed to match each other, with no further alignment necessary.

Shims may be necessary under the generator feet to insure a solid mounting. Do not force the feet to an uneven mounting surface, serious problems could result.


After, the generator has been assembled to the engine, check for end-play of the assembled set. Using a suitable lever, force the engine flywheel forward so that the crankshaft is pressed against its thrust bearing. When force is removed, the engine crankshaft should remain in position. Apply force in the opposite direction forcing the crankshaft towards the generator, and observe if the crankshaft remains in this position after force has been removed. Refer to the engine manual for proper or recommended end-play. If the crankshaft springs away in either direction after force has been removed, it is an indication that the generator shaft is not moving freely, and normal life of the thrust bearing could be impaired. Probable course of this problem are:


a. Improper "XG" dimension of either the generator or the engine flywheel, or both. Generator bearing may be bottoming out in its bearing bracket,

b. Misalignment:

a) Improper seating of generator drive discs in the engine flywheel.

b) Improper mating of the generator frame to the engine flywheel housing.

c) Set sub-base is not true. Generator and or engine feet require shims. See mounting instructions.

3. Two bearing generators.

If generator couples with engine by flange rabbet, it is easy to mount. If it coupled by other way, should pay more attention to installation, it may be necessary to shim the generator feel for proper support and alignment. Aligning the generator and engine as accurately as possible will reduce vibration, increase bearing life, and minimize coupling wear.

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