On Wed, 15 Nov 2017 10:56:56 -0800, wrote:

The voltage from my generator drooped so much that a 3500 watt
generator would no longer start a 1/4 hp motor.

I wonder what caused the capacitor to bulge? Mostly, I find that it's
the ripple current, where a small amount of AC voltage ripple is
impressed across a filter capacitor. This causes a high current to
flow through the capacitor, which causes heating, which causes the
electrolyte to boil, which eventually blows the lid off the capacitor.

So, what would cause AC to flow through the capacitor? Well, the
generator will do that if the output from each of the presumably two
phases is different. That could be caused by having a radically
different load on each of the two phases. A two phase 3500 watt
generator is really a dual 1750 watt generator, where each phase can
only supply 1750 watts. If you try to load all 3500 watts across one
phase, bad things will happen. Another possibility is a shorted turn
on one winding. I have a few other guesses, but can offer much
without a clue as to how its wired, which might be available once you
disclose the maker and model number.


--
Jeff Liebermann
150 Felker St #D http://www.LearnByDestroying.com
Santa Cruz CA 95060 http://802.11junk.com
Skype: JeffLiebermann AE6KS 831-336-2558