Baldor DG3E Portable Generator User Manual
Contents
1. 3 1 Receiving amp Inspection lt er reme anata dad eee Movida at 3 1 Lifting the Generator seen en ae tee 3 1 Storage a a nia gene Sabet a aaa ean alec ana 3 1 Physical Location etapa acti oe Re he tan a a ae eee aaa ae Yao aS 3 2 Installations eee oe ee Oe eh Gee ee cd 3 2 Electrical Connections histo a Be ead ea ag 3 2 Fraime Ground Connection eee ak 3 3 Engine Qil tee ene einer 3 4 Battery Connections dock eatin oon ah rae St so i es 3 4 Use of Electric Motor Loads erorian riaan AN eed ee Daa dee 3 5 Optional Wheel Kit tone eee one eaten ate 3 6 Recommended Engine and Battery 3 6 Section 4 garnet ee dee Ud gee ke 4 1 Operator ControliP ane ewatontancd and ne Mera ane de eS 4 1 Pre Staitt ee ee2. a Sak A 4 2 Start Up Procedure ee aa Ad learn aS Pa Bee aa as 4 2 ENG CHIC suo aha Bite 4 2 Stopping Procedure arenema aa best rs na erp ha 4 2 Section 5 Troubleshooting and Maintenance 5 1 Setar bch Beaman race Parakey ae hare 5 1 Problems and Solutions si sete ti Ad pA Sak gid ha eae 5 2 Appendix A DG Series a daa 1 Operator Panel 1 2 Wiring Diagrams dd A 3 MN2414 Table of Contents i ii Table of Contents MN2414 Section 1 Product Safety Information Safety Notice Responsibility Be sure that you are completely familiar with the safe operation of this equipment This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment Improper use can cau
3. td NMOGLAHS AWVA Z M 19 INIYVENOT LI YILIN 3NU 03SdV73 6 10 JSIMYSHLO 5531 0 91 53 TONLNOO KET OO 91919 MN2414 Figure 7 DG6E Wiring Diagram NOLLOSNNOO Hd ZLWH 3990 Un 00910 48 33 120000 9 23114 02 21 819 2 0 62 NGL lt 002 82 10 81 66 lt 1 G3SIAZYN gay 9 2417 AJY NOWdINOS30 SSIAZY 2530 Bw0160D 112 492 awvas 01 1009 4009 aaawnr 8 a U 9109 Gang H f ath wy 002 amp s 2 621 om zoz 5 2 Seis goot 8 S mito pte one 6 3 e 05 L Z s243 R S 0682 _ 8 u 25700 TOOT 9 H g TL gt 22 5007 2001 H o gt gt H OK 21 gt gt EL gt 4 gt gt T Toa gt gt 2005 gt 2000
4. BY REB REVISED 08 38 25 05 20 2002 TDR 262964 REV DESC MOVE WIRE 5520 TO ANOTHER TERMINAL REV LTR A FILE 00001572 MTL A 4 Premier K Series MN2414 00850 Figure 6 Wiring Diagram with Low Oil amp Remote Start 4 A3 S90 WYNOVIC lt 2810000 22 314 195752 01 1002 01 21 22 16 51 4 gay YLT o 206 0164 OMG GYVO YMOd 183 02 2530 15 25 440 NO LUVLS SONG 509 504 001 AOZ Lf Te O O Sols soron AIKIN USLUVLS X9 OL ONIGNNOYS Tv ALAVIS 5 OL 5 5 8 w w 8 2 D lt 6 lt andy xz lt 8 lt lt lt lt 9ST aaa mar 94 wa ot lt 1 Heat ae an 91 lt er lt lt a Geo lt a 91 e E N JLYW HOLIMS ansa 26 1 Premier Series 5
5. Keep non qualified personnel at a safe distance from this equipment Only qualified personnel familiar with the safe installation operation and maintenance of this device should attempt start up or operating procedures Always stop engine before making or removing any connections Always stop engine and allow it to cool before refueling When your generator is delivered it becomes the responsibility of the owner operator of the generator set to prevent unsafe conditions and operation of the equipment Some responsibilities include but are not limited to the following 1 It is the responsibility of the owner operator of this generator to ensure that this equipment is correctly and safely installed 2 It is the responsibility of the owner operator of this generator to ensure that this equipment when installed fully complies with all federal state and local codes 3 It is the responsibility of the owner operator of this generator to ensure that any person operating this equipment has been properly trained 4 It is the responsibility of the owner operator of this generator to ensure that any person operating this equipment has access to all manuals and information required for the safe use and operation of this equipment 5 It is the responsibility of the owner operator of this generator to ensure that it is properly maintained and safety inspected at regular scheduled intervals 6 Itis the responsibility of the owner operator o
6. PITTSBURGH 616H BEATTY ROAD MONROEVILLE PA 15146 PHONE 412 380 7244 FAX 412 380 7250 TENNESSEE MEMPHIS 4000 WINCHESTER ROAD MEMPHIS TN 38118 PHONE 901 365 2020 FAX 901 365 3914 TEXAS HOUSTON 4647 PINE TIMBERS SUITE 135 HOUSTON TX 77041 PHONE 713 895 7062 FAX 713 690 4540 DALLAS 3040 QUEBEC DALLAS TX 75247 PHONE 214 634 7271 FAX 214 634 8874 UTAH SALT LAKE CITY 2230 SOUTH MAIN STREET SALT LAKE CITY UT 84115 PHONE 801 832 0127 FAX 801 832 8911 WISCONSIN MILWAUKEE 2725 SOUTH 163RD STREET NEW BERLIN WI 53151 PHONE 262 784 5940 FAX 262 784 1215 INTERNATIONAL SALES FORT SMITH AR P O BOX 2400 FORT SMITH AR 72902 PHONE 479 646 4711 FAX 479 648 5895 CANADA EDMONTON ALBERTA 4053 92 STREET EDMONTON ALBERTA T6E 6R8 PHONE 780 434 4900 FAX 780 438 2600 OAKVILLE ONTARIO 2750 COVENTRY ROAD OAKVILLE ONTARIO L6H 6R1 PHONE 905 829 3301 FAX 905 829 3302 MONTREAL QUEBEC 1844 WILLIAM STREET MONTREAL QUEBEC H3J 1R5 PHONE 514 933 2711 FAX 514 933 8639 VANCOUVER BRITISH COLUMBIA 1538 KEBET WAY PORT COQUITLAM BC V3C 5M5 PHONE 604 421 2822 FAX 604 421 3113 WINNIPEG MANITOBA 54 PRINCESS STREET WINNIPEG MANITOBA R3B 1 2 PHONE 204 942 5205 FAX 204 956 4251 AUSTRALIA UNIT 3 6 STANTON ROAD SEVEN HILLS NSW 2147 AUSTRALIA PHONE 61 2 9674 5455 FAX 61 2 9674 2495 UNIT 8 5 KELLETTS ROAD ROWVILLE VICTORIA 3178 AUSTRALIA PHONE 61
7. components 4 Inspect and replace any control panel components that are broken or not working properly receptacles circuit breakers switches etc Troubleshooting and Maintenance 5 1 Problems and Solutions Some of the more common problems are listed in Table 5 1 This information is intended to be a check or verification that simple causes can be located and fixed It is not an exhaustive how to for all types of problems Procedures that require in depth knowledge or skills like flashing the field should be referred to the Baldor Generator Service Department by calling 920 236 4200 Table 5 1 Troubleshooting Guide Problem Possible Cause Remedy Engine wil not start No Tuel Check that fuel valves are ON Check fuel level in fuel tank Restricted air flow Check replace air filter Check that engine switch is in Start position Engine will not crank electric start Dead battery Remove battery and trickle charge or replace with new battery Never Jump Start Engine starts but will not run smoothly Fuel or ignition problem Refer to engine manual Engine overheats Excessive load Debris or dirt buildup on engine Remove one or more electrical loads Remove debris Clean engine surfaces to allow cooling No output voltage Breaker tripped or defective Loss of residual magnetism in exciter field poles Open in stator windings Defective exciter circuit Rese
8. gt gt 5 5 14 S005 8 lg D 009 a 335 5 Z 8 JIN XILIW BWIL 1354913 5 O00 OLOO _ O00 000 SOON 2999 E00N 1003 W ANAINMA MN2414 A 6 Premier K Series UNITED STATES ARIZONA PHOENIX 4211 S 43RD PLACE PHOENIX AZ 85040 PHONE 602 470 0407 FAX 602 470 0464 CALIFORNIA LOS ANGELES 6480 FLOTILLA COMMERCE CA 90040 PHONE 323 724 6771 FAX 323 721 5859 HAYWARD 21056 FORBES STREET HAYWARD CA 94545 PHONE 510 785 9900 FAX 510 785 9910 COLORADO DENVER 2520 W BARBERRY PLACE DENVER CO 80204 PHONE 303 623 0127 FAX 303 595 3772 CONNECTICUT WALLINGFORD 65 SOUTH TURNPIKE ROAD WALLINGFORD CT 06492 PHONE 203 269 1354 FAX 203 269 5485 FLORIDA TAMPA PUERTO RICO VIRGIN ISLANDS 3906 EAST 11TH AVENUE TAMPA FL 33605 PHONE 813 248 5078 FAX 813 247 2984 GEORGIA ATLANTA 62 TECHNOLOGY DR ALPHARETTA GA 30005 PHONE 770 772 7000 FAX 770 772 7200 ILLINOIS CHICAGO 1601 FRONTENAC ROAD NAPERVILLE IL 60563 PHONE 630 848 5100 FAX 630 848 5110 INDIANA INDIANAPOLIS 5525 W MINNESOTA STREET INDIANAPOLIS IN 46241 PHONE 317 246 5100 FAX 317 246 5110 800 428 4141 IOWA DES MOINES 1800 DIXON STREET SUITE C DES MOINES IA 50316 PHONE 515 263 6929 FAX 515 263 6515 MARYLAND BALTIMORE 6660 SANTA BARBARA RD SUITE 22 24 ELKRIDGE MD 21075 PHONE 410 579 2135 FAX 410 579 26
9. 3 9753 4355 FAX 61 3 9753 4366 BALDOR CENTROAMERICA RESIDENCIAL PINARES DE SUIZA POL 15 44 NVA SAN SALVADOR EL SALVADOR CENTRO AMERICA PHONE 503 288 1519 FAX 503 288 1518 BALDOR SUDAMERICA CALLE F EL CANGREJO CONDOMINIO CONDADO PLAZA APT 11D BELLA VISTA PANAMA CITY REP DE PANAMA PHONE 507 265 6041 CHINA SHANGHAI JIAHUA BUSINESS CENTER ROOM NO A 8421 808 HONG QIAO ROAD SHANGHAI 200030 PHONE 86 21 64473060 FAX 86 21 64078620 GERMANY DIESELSTRASSE 22 D 85551 KIRCHHEIM MUNICH GERMANY PHONE 49 89 90508 0 FAX 49 89 90508 492 INDIA 14 COMMERCE AVENUE MAHAGANESH COLONY PAUD ROAD PUNE 411 038 MAHARASHTRA INDIA PHONE 91 20 25 45 95 31 32 FAX 91 20 24 55 95 30 ITALY BALDOR ASR AG SUCCURSALE DI MENDRISIO VIA BORROMINI 20A CH 6850 MENDRISIO SWITZERLAND PHONE 41 91 640 9952 FAX 41 91 630 2633 JAPAN DIA BLDG 802 2 21 1 TSURUYA CHO KANAGAWA KU YOKOHAMA 221 0835 JAPAN PHONE 81 45 412 4506 FAX 81 45 412 4507 KOREA ROOM 210 BUPYEONG INDUSTRIAL COMMERCIAL COOPERATIVE 396 16 CHEONGCHEON 2 DONG BUPYEONG GU INCHEON KOREA 403 858 PHONE 82 32 508 3252 FAX 82 32 508 3253 MEXICO 2 0 BLVD AL AEROPUERTO LEON 37545 GUANAJUATO MEXICO PHONE 52 477 761 2030 FAX 52 477 761 2010 MIDDLE EAST amp NORTH AFRICA VSE INTERNATIONAL CORP 3233 NORTH ARLINGTON HEIGHTS SUITE 100W ARLINGTON HEIGHTS IL 60004 PHONE 847 590 5547 SINGAPORE 51 KAK
10. 4 FEMALE MALE FEMALE MALE BULLET 2 M1 00O 000 MATE N LOC CONNECTOR PINOUTS 900 wo wo a 8 31 18 U uU Go amp S 1 YSIS DEN PFU 2 vot 0061 IO YOLIOWdVO 0091 o 16 3 m8 8 CHN oze 0700 CEST 9 88 a gt amp 0999 OZEL 2 83 15 a eA al a 0 AS 5 9 S 2 5 2 621 7 m 9 yr pe S orgs 2 aos J R D 0 0011 aozi gt k oret cost grer 21 gt Bll 7 gt gt 21 D TRI Ne 48 Pligg ana PH gt gt 56 gt ort 1 Oni lt TN 85 one 91 BALDOR ELECTRIC CONNECTION DIAGRAM DG3E REF BWO067D
11. 8 operating hours Maintain the proper oil evel 3 Change the oil as is recommended the engine manufacturer s owner s manual 4 Clean the cooling fins on the engine to keep the engine s heat dissipation potential at its maximum 5 Inspect and clean all governor linkages so they operate properly Alternator also called Generator End This generator set must be run at its proper speed to obtain the correct electrical power at its output All engines have a tendency to slow down when a load is applied to it The engine governor is designed to hold the operating speed as nearly constant as possible When the electrical load is increased the engine is more heavily loaded and engine speed drops slightly This slight decrease in engine speed results in a slight decrease in generator voltage and frequency output This voltage and frequency variation has no appreciable effect in the operation of motors lights and most appliances and tools However timing devices and clocks will not keep perfect time when used on this generator 1 Clean the generator set and remove any and all dust dirt or other foreign material 2 Inspect and clean the cooling air intake and exhaust louvers of the generator end Make sure they are clean Remove dirt or any buildup that may restrict the cooling air flow 3 Clean the generator set and its components with a damp cloth or sponge Never use a water hose or pressure washer as this may damage electrical
12. WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING MN2414 Before servicing the generator set be sure to disconnect the battery terminals to prevent accidental engine rotation or starting Before cleaning inspecting repairing refueling or performing any maintenance to the generator set always be sure the engine has stopped and that all rotating parts have also stopped After stopping certain components are still extremely hot so be careful not to get burned Inspect all wiring frequently and replace any damaged broken or frayed wiring or wires with damaged insulation immediately Electrical shock can cause serious or fatal injury Disconnect all electrical wires and load devices from generator power outlets before servicing the generator Electrical shock can cause serious or fatal injury Always treat electrical circuits as if they are energized Check all fuel tanks supply piping and their connections monthly for fuel leaks Diesel fuel is flammable and can cause fire explosions injury or death If a leak is found replace only with approved pipe or components A battery presents a risk of fire and explosion because they generate hydrogen gas Hydrogen gas is extremely explosive Never jump start a battery smoke in the area around the battery or cause any spark to occur in the area around the battery Do not mutilate the battery or dispose of a ba
13. X Not Shown TA0000A00 Fuel Tank X Not Shown TA0002A02 Fuel Cap with Gauge X Not Shown TA0000A03 Fuel Tank X Not Shown TA0002A04 Fuel Cap with Gauge X Not Shown TA0001A00 Fuel Valve X X 20 BA204A02L2B Base Frame X 20 BA205A02L Base Frame 20 BA0217A00L2B Base Frame X 21 HB7025A00 Engine Mounting Foot 21 HB7025A00Z Engine Mounting Foot X X 21 HB7025A02 Alternator Mounting Foot X X 21 HB7025A6 Engine Mounting Foot Left HATZ X X 21 HB7025A07 Engine Mounting Foot Right HATZ X X 22 HB7002A11 Engine end frame cross member X 23 HB7025A01 Alternator end frame cross member X X Not Shown RM1088A07 Vibration Isolator X Not Shown RM1088A36 Vibration Isolator X Not Shown HB6116A00 Battery Tie Down X X Not Shown HA3187A11 Battery Tie Down Bolt X X Not Shown LB0094C02 Decal Warning X Not Shown LB0094A35 Decal Warning X X Not Shown LB0094A90 Decal Starting X Not Shown LB0094A91 Decal Fuel Valve X Not Shown LB9606A04 Decal Baldor Logo 5 65 X X Not Shown LB9606A06 Decal Baldor Logo 9 Not Shown LB9630A00 Decal DG3E X Not Shown LB9639A00 Decal DG6E X Not Shown RE5031A01 Relay Not Shown RE5031A10 Relay Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix MN2414 Premier K Series A 3 Figure 5 Wiring Diagram 00670 lt le MATE N LOC CONNECTION 1
14. battery is discharged the electronic governor will not operate and the generator set will not run Procedure The correct type battery must be purchased and installed in the battery compartment provided 1 Remove the bag containing the battery box components 2 Set the battery on the battery tray 3 Install the battery hold down rods as shown in Figure 3 4 a Place the bent end of the battery hold down rod through the hole in the battery tray b Place the threaded end of the battery hold down rod through the hole in the battery hold down bar and secure with flat washer lock washer and nut c Repeat steps a and b for the other battery hold down rod 4 Connect the battery cables to the battery be sure the Positive lead is connected to the positive battery terminal and the negative lead is connected to the positive battery terminal Figure 3 4 Battery Installation The and terminals of your battery may be different than shown Be sure that the Positive lead is connected to the positive terminal of your battery Washers amp Nut Battery Tie Down Battery Battery Tie Down Bolt Battery Rack Use of Electric Motor Loads Electric motors require much more current amperes to start them than to keep them running Some motors particularly split phase motors are very difficult to start and require 5 to 7 times more current to start them Repulsion induction type motors are the easiest to start and normally onl
15. displays the voltage level being produced by the generator set AC Circuit Breakers Provide overload protection for the generator set 120 Volts NEMA 5 15R GFCI Receptacle This ground fault circuit interrupter duplex receptacle is rated at 125VAC 15 Amps 120 Volts NEMA L5 30R Receptacle Twist lock style receptacle rated for 125VAC 30 Amps 120 240 Volts NEMA L14 30R Receptacle Twist lock style receptacle rated for 125 250VAC 30 Amps Premier K Series A 1 Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure A 3 and A 4 Parts information is provided in Table A 1 Parts information for the engine is provided in the engine manual that was provided with your generator set Please refer to the engine manual for replacement parts information 20 Figure A 3 Alternator Assembly 21 la 7 ona OR Table A 1 Generator Set Parts List CON E RM1088A15 31 18x0 56 RM1088A36 31 18x0 75 Ref No Part No Description DG3E DG6E 1 HA9139A01 Adaptor X X 1 HB6178A00 Adaptor 2 HA1037A00 Washer X X 3 61FN3000 Fan X X 4 61RA0017A00 Rotor Assembly includes bearing X 4 61RA0015A00 Rotor Assembly includes bearing X 4 61RA0015A02 Rotor Assembly includes bearing 5 61SA0016A07 Stator Assembly X 5 61SA0021A04 Stator Asse
16. for malfunction Electrical shock when frame is touched Static charge Grounded armature or field coil Ground generator frame at local reference ground see Section 3 Return to factory for repair Mechanical noise Defective bearing Rotor rubbing on stator Loose or misaligned coupling Replace bearing Bad bearing replace Bent shaft return to factory Loose end bell tighten Loose drive Discs tighten Tighten align coupling and alternator shaft to engine shaft Service Service for your generator can be obtained from Baldor Generators Please have the following information available prior to contacting the factory The model number and serial number of the generator set complete and accurate description of the problem Parts Parts for your generator can be obtained from Baldor Generators Please have the following information available prior to contacting the factory The model number and serial number of the generator set complete and accurate description of the part part number if known Note Engine parts can usually be obtained from a local distributor by using the information in the engine manufacturer s owner s manual 5 2 Troubleshooting and Maintenance MN2414 DG Series Information in this Appendix applies to the following Baldor Generators and DG6E Caution The brass connecting tab on some 120VAC duplex receptacles have been removed Each re
17. generator set that is running Loads should be connected and position secure before starting the engine Hazards are caused by moving a generator set that is running Continued on next page 1 2 Product Safety Information MN2414 Operation Warning Statements Continued WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING MN2414 Be sure that you understand how to stop the engine quickly in case of an emergency situation Become familiar with the controls and safety systems provided with this generator set Always wear safety glasses with side shields and hearing protection when working near the generator Improper operation may cause violent motion of connected equipment Be certain that unexpected movement will not cause injury to personnel or damage to equipment Never operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave Exhaust fumes are extremely dangerous to all personnel that are in or in contact with that area Never permit anyone to operate the generator without proper instructions Be sure to keep a copy of this manual with the generator so that all users can be properly informed of its safe operation Never allow children or pets to be in the area where the generator is running The gen
18. shipping container and report any damage immediately to the commercial carrier that delivered your system 2 Verify that the part number of the system you received is the same as the part number listed on your purchase order 3 Ifthe system is to be stored for several weeks before use be sure that it is stored in a location that conforms to published storage temperature and humidity specifications Lifting the Generator When lift or hoist equipment is used to lift the generator and move it to position be careful not to contact overhead wires or other obstacles The generator weighs between 100 and 350 165 Use proper lift equipment and methods to avoid injury Lift only by the tubular metal frame Figure 3 1 DG Series Generators atA DIESEL DG6E 6000W Storage If you will not be using the generator set for a significant amount of time 8 months or longer you should store the generator to prevent any problems that could arise from sitting idle Please fully read the following guidelines prior to storing the unit 1 Close all the fuel valves Note Do not let the fuel tank run completely empty Unlike gas engines diesel engines must be primed to remove air from the fuel lines 2 Disconnect and remove the battery if your generator set is so equipped 3 Drain the used oil from the engine s crankcase and refill it with clean oil 4 Provide maintenance to the engine and generator set as described in the engine
19. utility must be connected by means of approved transfer switch equipment so as to isolate the electrical circuit from the utility distribution system when the generator is operating Failure to isolate the electrical circuits by such means may result in injury or death to utility power workers due to backfeed of electrical energy onto the utility lines WARNING Circuit overload protection must be provided in accordance with the National Electrical Code and local regulations WARNING Check Ground Fault Circuit Interrupt receptacles monthly by using the Test and Reset buttons WARNING Only a professional experienced technician should install a fuel supply system Gasoline and diesel fuel are flammable and can cause fire explosions injury or death Fuel supply lines should be kept away from sharp objects to prevent rupture Comply with all NFPA regulations and local codes for shut off valves regulators fuel line type etc WARNING Have electrical circuits and wiring installed and checked by licensed electrician or qualified technician Electrical shock can cause serious or fatal injury WARNING Incorrect installation of this generator set could result in property damage injury or death Connection of the generator to its fuel source must be done by a qualified professional technician or contractor Continued on next page 1 4 Product Safety Information MN2414 Warning Statements Continued Maintenance
20. 77 MASSACHUSETTS BOSTON 6 PULLMAN STREET WORCESTER MA 01606 PHONE 508 854 0708 FAX 508 854 0291 MICHIGAN DETROIT 33782 STERLING PONDS BLVD STERLING HEIGHTS MI 48312 PHONE 586 978 9800 Baldor District Offices FAX 586 978 9969 MICHIGAN Continued GAND RAPIDS 668 3 MILE ROAD NW GRAND RAPIDS MI 49504 PHONE 616 785 1784 FAX 616 785 1788 MINNESOTA MINNEAPOLIS 21080 134TH AVE NORTH ROGERS MN 55374 PHONE 763 428 3633 FAX 763 428 4551 MISSOURI ST LOUIS 422 INDUSTRIAL DRIVE MARYLAND HEIGHTS MO 63043 PHONE 314 298 1800 FAX 314 298 7660 KANSAS CITY 915 N W PLATTE VALLEY DR RIVERSIDE MO 64150 PHONE 816 587 0272 FAX 816 587 3735 NEW YORK AUBURN ONE ELLIS DRIVE AUBURN NY 13021 PHONE 315 255 3403 FAX 315 253 9923 NORTH CAROLINA GREENSBORO 1220 ROTHERWOOD ROAD GREENSBORO NC 27406 P O BOX 16500 GREENSBORO NC 27416 PHONE 336 272 6104 FAX 336 273 6628 OHIO CINCINNATI 2929 CRESCENTVILLE ROAD WEST CHESTER OH 45069 PHONE 513 771 2600 FAX 513 772 2219 CLEVELAND 8929 FREEWAY DRIVE MACEDONIA OH 44056 PHONE 330 468 4777 FAX 330 468 4778 OKLAHOMA TULSA 2 EAST DAWES BIXBY OK 74008 PHONE 918 366 9320 FAX 918 366 9338 OREGON PORTLAND 20393 SW AVERY COURT TUALATIN OR 97062 PHONE 503 691 9010 FAX 503 691 9012 PENNSYLVANIA PHILADELPHIA 1035 THOMAS BUSCH MEMORIAL HIGHWAY PENNSAUKEN NJ 08110 PHONE 856 661 1442 FAX 856 663 6363
21. BALDOR Diesel POW R Products Generator DG3E and DG6E Installation amp Operating Manual 5 05 MN2414 WARNING CALIFORNIA PROPOSITION 65 WARNING Engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects and other reproductive harm WARNING CALIFORNIA PROPOSITION 65 WARNING Battery posts terminals and related accessories are known to the state of California to cause cancer birth defects and other reproductive harm Table of Contents Section 1 Product Safety Information 1 1 Safety Ea A 1 1 RESPONSIDIINY eta bore gates eee eae 1 1 IMPORTANT SAFETY INSTRUCTIONS 2 1 2 Caution Statements ean ed sa ede a a ee ee Glee Ge es 1 6 Section 2 General Information Saeed a Stee ear eG Le eae ee 2 1 Limited Warranty a yaaa hath hein Ge haa Gye aa aan goats 2 1 Owner s Responsibilities 2 2 Limitations taht ea cde el bee de ae a 2 2 Section 3 Receiving amp Installation
22. EC requires that the frame and exposed conductive surfaces metal parts be connected to an approved earth ground Local codes may also require proper grounding of generator systems WARNING Place protective covers over all rotating parts such as drive shaft pulley belt etc Rotating parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury WARNING Unauthorized modification of a generator set may make the unit unsafe for operation or may impair the operation of the unit Never start a generator set that has been modified or tampered with Be sure that all covers and guards are properly installed and that the unit is safe before starting the engine If you are unsure contact Baldor before starting the engine WARNING When moving the generator use reasonable caution Be careful where you place fingers and toes to prevent injury Pinch Points Never try to lift a generator without a hoist or lift means because they are heavy and bodily injury may result WARNING When transporting a generator especially if it has wheel option installed secure the unit to prevent movement during transport WARNING Never connect this generator to any buildings electrical system unless a licensed electrician has installed an approved transfer switch The National Electrical Code NEC requires that connection of a generator to any electrical circuit normally powered by means of an electric
23. I BUKIT ROAD 2 K B WAREHOUSE COMPLEX SINGAPORE 417863 PHONE 65 6 744 2572 FAX 65 6 747 1708 SWITZERLAND POSTFACH 73 SCHUTZENSTRASSE 59 CH 8245 FEUERTHALEN SWITZERLAND PHONE 41 52 6474700 FAX 41 52 6592394 TAIWAN 4F NO 25 SEC 1 TUNHUA 5 ROAD TAIPEI 10557 TAIWAN R O C PHONE 886 2 2577 4352 FAX 886 2 2577 4157 UNITED KINGDOM 6 BRISTOL DISTRIBUTION PARK HAWKLEY DRIVE BRISTOL BS32 OBF U K PHONE 44 1454 850000 FAX 44 1454 859001 WARNING CALIFORNIA PROPOSITION 65 WARNING Engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects and other reproductive harm WARNING CALIFORNIA PROPOSITION 65 WARNING Battery posts terminals and related accessories are known to the state of California to cause cancer birth defects and other reproductive harm 2 1 amp 0505 BALDOR BALDOR ELECTRIC COMPANY P O Box 2400 Ft Smith AR 72901 2400 479 646 4711 Fax 479 648 5792 Printed in USA Baldor Electric Company 5 05 MN2414
24. National Fire Protection Association is appropriate Continued on next page Product Safety Information 1 3 Warning Statements Continued Burn WARNING Parts of this generator are extremely hot during and after operation To prevent severe burns do not touch any part of the generator until you have first determined if the part is hot Wear protective clothing and after use allow sufficient time for parts to cool before touching any part of the generator WARNING Do not touch the hot exhaust parts of the engine In addition to a severe burn the sudden involuntary jerk of the hand or body part caused by contact with high voltage or a hot surface can result in injury to yourself or others Installation WARNING Installation and repair procedures requires specialized skills with electrical generating equipment and small engine systems Any person that installs or performs repairs must have these specialized skills to ensure that the generator set is safe to operate Contact Baldor for installation or repairs WARNING Be sure all wiring complies with the National Electrical Code NEC and all regional and local codes or CE Compliance Improper wiring may cause a hazardous condition and exposure to electrical hazards can cause serious injury or death WARNING Be sure the system is properly grounded before applying power Do not apply AC power before you ensure that grounds are connected Electrical shock can cause serious or fatal injury N
25. POSE AND MERCHANTABILITY NO OTHER WARRANTY EXPRESSED OR IMPLIED WHETHER OR NOT SIMILAR IN NATURE TO ANY OTHER WARRANTY PROVIDED HEREIN SHALL EXIST WITH RESPECT TO THE GOODS SOLD UNDER THE PROVISIONS OF THESE TERMS AND CONDITIONS ALL OTHER SUCH WARRANTIES ARE HEREBY EXPRESSLY WAIVED BY THE BUYER UNDER NO CIRCUMSTANCES SHALL BALDOR GENERATORS BE LIABLE OR RESPONSIBLE IN ANY MANNER WHATSOEVER FOR ANY INCIDENTAL CONSEQUENTIAL OR PUNITIVE DAMAGES OR ANTICIPATED PROFITS RESULTING FROM THE DEFECT REMOVAL REINSTALLATION SHIPMENT OR OTHERWISE This is the sole warranty of Baldor Generators and no other affirmations or promises made by Baldor Generators shall be deemed to create an expressed or implied warranty Baldor Generators has not authorized anyone to make any representations or warranties other than the warranty contained herein Warranty Period Labor Parts Portable Products Premier Powerchief 1 Year 3 Years DG Series K Series Towable Products TS 1 Year or 3 000 Hours Whichever comes first 1 Year or 3 000 Hours Whichever comes first 3 Years or 3 000 Hours Whichever comes first 3 Years or 3 000 Hours Whichever comes first Excluded from any warranty coverage regardless of time period Light Fixture Lamps and Ballasts POW R LITE Light Towers 3600 RPM Standby Systems Some AE Models 1 Year or 1 000 Hours Whichever comes first 3 Years or 1 000 Hours Whichever comes first 1800 RPM Standby Sys
26. aN 1 1 15 308 L14 30R 125 125 250V 4 a eS Ja X w NEMA 5 20R GOLD GOLD SILVER 125V 20A Frame Ground Connection WARNING Be sure the system is properly grounded before applying power Do not apply AC power MN2414 before you ensure that grounds are connected Electrical shock can cause serious or fatal injury NEC requires that the frame and exposed conductive surfaces metal parts be connected to an approved earth ground Local codes may also require proper grounding of generator systems The NEC requires that the frame and exposed metal surfaces be at local ground reference potential to avoid electrical shock hazard A local ground reference may require a driven earth ground conductor at the generator installation site Make the ground connection as shown in Figure 3 3 Use the appropriate size wire normally 6 AWG as required by NEC and local codes The local reference ground is normally a copper clad earth ground rod driven into the earth at least 8 feet Receiving amp Installation 3 3 Frame Ground Connection Continued Figure 3 3 Frame Ground Connection Mut Washer 8 Ground Wire Lug Washer Stud Earth Ground Frame Engine Oil Refer to the engine manual that was provided with your generator Determine the correct type of engine oil and the amount specified by the engine manufacturer Add the required amount of oil
27. and generator maintenance sections of this manual 5 Cover any bare metal spots with paint or another type of rust preventative WARNING Never store an engine with fuel in its tank indoors or in an enclosed poorly ventilated area where diesel fumes could reach an ignition source and cause an explosion MN2414 Receiving amp Installation 3 1 Physical Location The mounting location of the system is important It should be installed in an area that is protected from direct harmful gases or liquids dust metallic particles shock and vibration It can only be installed in an outdoor location so the exhaust fumes are vented to the atmosphere This system must never be installed inside an enclosed building home shop or garage etc Several other factors should be carefully evaluated when selecting a location for installation 1 For effective cooling and maintenance the generator should be mounted on a flat smooth non flammable level surface A concrete pad is ideal and provides a secure installation 2 location for the generator must be dry Never operate a generator in an area that has standing water or puddles 3 Installation should prevent obstructions by buildup of leaves grass sand snow etc It is important that the unit be operated in a reasonably clean environment 4 All engines give off considerable heat when running The engine in your generator set uses air to keep it cool so it is important that the ambient temper
28. ation or while refueling Gasoline and diesel fuel are flammable and can cause fire explosions injury or death Stop engine and allow engine to cool before refueling Gasoline and diesel fuel are flammable and can cause fire explosions injury or death Never store the generator with fuel in the tank Never store the generator indoors or in an enclosed area or in a poorly ventilated enclosure where fumes may reach an open flame electrical spark or pilot light as on a furnace water heater clothes dryer etc Gasoline and diesel fuel are flammable and can cause fire explosions injury or death Allow generator to cool before transporting it or storing it Always drain fuel from tank after generator has cooled When transporting the generator especially over rough roads always drain the fuel tank to prevent leakage or spillage of fuel Gasoline and diesel fuel are flammable and can cause fire explosions injury or death Operate the generator only on a level surface If the generator is tilted during operation fuel spillage may result Gasoline and diesel fuel are flammable and can cause fire explosions injury or death Keep generator at least three feet away from buildings and other structures Keep generator away from flammable or hazardous materials trash rags lubricants explosives paints etc and grass or leaf build up Keep a fire extinguisher near the generator while generator is in use An extinguisher rated ABC by the
29. ature is cool and does not exceed 100 F even while it is running Where natural ventilation is inadequate a fan to boost circulation should be used 5 Exhaust Gases from internal combustion engines are extremely poisonous Never operate an engine indoors WARNING Exhaust fumes gases are extremely dangerous and can cause severe illness or death Never Installation breath exhaust fumes produced by a running engine Only run the engine outdoors where ventilation is plentiful Exhaust gases contain carbon monoxide a colorless odorless and extremely dangerous gas that can cause unconsciousness or death Symptoms of carbon monoxide poisoning include dizziness nausea headaches sleepiness vomiting or incoherence If you or anyone else experiences these symptoms get out into fresh air immediately Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or reinstalled in a well ventilated area 6 electrical equipment should be protected from excessive moisture Failure to do so will result in deterioration of the insulation and may result in short circuits and a possible electrocution hazard The generator is completely assembled tested and adjusted at the factory before it is shipped to you External connections required at the time of installation are Note The generator is shipped dry This means no oil is in the engine crankcase and no battery is installed You must refer to the engine
30. ceptacle is powered by a separate generator winding When replacing a receptacle inspect the brass tab that normally links both receptacles If it is removed be sure to remove the brass tab from the replacement receptacle before it is installed Failure to remove the tab will cause a direct short to the generator windings and cause possible generator damage Operator Panel Configuration Figure A 1 N ACVOLTS ELAPSED 120V 120 240V OIL AC BREAKERS OIL Low Oil pressure indicator Illuminates when oil pressure is low DG3E Operator Panel 120 Volts NEMA 5 15R GFCI Receptacle This ground fault circuit interrupter duplex receptacle is rated at 125VAC 15 Amps 120 Volts NEMA L5 30R Receptacle Twist lock style receptacle rated for 125VAC 30 Amps 120 240 Volts NEMA L14 30R Receptacle Twist lock style receptacle rated for 125 250VAC 30 Amps AC Voltmeter This voltmeter displays the voltage level being produced by the generator set Elapsed Time Displays the total run time hours of the generator set AC Circuit Breakers Provide overload protection for the generator set Figure A 2 DG6E Operator Panel 2 120 VOLTS ELAPSED 120 VOLTS AC VOLTMETER 120 240 VOLTS AC CIRCUIT BREAKERS 120 VOLTS s MN2414 Elapsed Time Displays the total run time hours of the generator set AC Voltmeter This voltmeter
31. ection for the generator output When tripped the plunger in center of breaker will extend out about 3 8 inch Remove the loads push the plunger into the breaker to reset the breaker the restore the loads WARNING Never connect this generator to any buildings electrical system unless a licensed electrician has installed an approved transfer switch The National Electrical Code NEC requires that connection of a generator to any elastical circuit normally powered by means of an electric utility must be connected by means of approved transfer switch equipment so as to isolate the electrical circuit from the utility distribution system when the generator is operating Failure to isolate the electrical circuits by such means may result in injury or death to utility power workers due to backfeed of electrical energy onto the utility lines Receptacles Receptacles are provided to allow easy connection of electrical loads Never connect this generator to any buildings electrical system unless a licensed electrician has installed an approved transfer switch Multiple receptacles may be used at the same time provided the total electrical load does not exceed the generators rated output 120Volts NEMA 5 20R GDCI Duplex receptacle provides ground fault protection Rated 125VAC at 20 Amperes 30 Amps 120 Volts Twist lock NEMA L5 30R receptacle rated 125 Volts at 30 Amperes 30 Amps 120 240 Volts Twist lock NEMA L14 30R receptacle rated 250Volts a
32. enerator to the load The gauge of the wire will depend on the distance to the load the permissible voltage drop at the load and the current required by the load If you are not sure of the gauge wire needed for your application consult a competent electrician Using wire that is too small can result in fire hazard Also be sure the wire has the appropriate ratings for insulation and environment conditions The correct mating connector must be used to fit the connectors provided on the operator panel of your generator Table 3 1 describes the connector types provided receptacles and the load characteristics to help you choose the correct size wire Figure 3 2 shows the receptacles 3 2 Receiving amp Installation MN2414 Electrical Connections Continued Table 3 1 Single Phase Power Receptacle Description Model Electrical Connection Information Receptacle Provided at Panel Straight 120VAC Twist Lock 120VAC Twist Lock 120 240VAC Twist Lock 120 240VAC Rated Watts 20Amp 30Amp 30Amp 50 Full load Amps 120 240 DG3E 2 5 20R GFCI 120VAC 1 L5 30R 120VAC 1 L14 30R 120 240VAC 3300 25 0 12 5 DG6E 4 5 20R 120VAC 1 L5 30R 120VAC 1 L14 30R 120 240VAC 6000 50 0 25 0 Note GFCI is Ground Fault Protected power Class 1 wiring methods must be used for field wiring connections to terminals of a Class 2 circuit Figure 3 2 Receptacle Connections GOLD 0 x
33. erator and the equipment being powered by the generator may cause injury or death Never operate the generator unless all guards covers shields and other safety items are properly installed Do not put hands feet tools clothing or other objects near rotating parts such as drive shaft pulley belt etc Rotating parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury When operating this generator remain alert at all times Never operate machinery when physically or mentally fatigued or while under the influence of alcohol drugs or medication Never operate the engine when the air cleaner is removed An engine backfire can cause serious burns Never jump start a generator to start the engine If the battery charge is insufficient to start the engine charge or replace the battery and try to restart Jump starting a battery can cause the battery to explode and cause severe injury or death to anyone in the area High voltage is present whenever engine is running Electrical shock can cause serious or fatal injury Never operate electrical equipment while standing in water on wet ground or with wet hands feet or shoes or while barefoot High voltage is present whenever the engine is running Electrical shock can cause serious or fatal injury Always stop engine before connecting or disconnecting power cords or external devices Do not smoke near generator during oper
34. eries DG MODEL SUMMER WINTER OIL DG3E 15 70130 OIL OIL CAPACITY RECOMMENDED BATTERY AMPS COLD CRANKING 20W 50 5W 20 1 55 PTS Interstate SP 40 340 DG6E 15 71520 3 6 Receiving amp Installation 20W 50 5W 20 1 90 PTS Interstate SP 40 340 MN2414 Section 4 Operation Operator Control Panel Each operator panel is slightly different depending on features of the generator you purchased The Operator Control Panel of Figure 4 1 is shown because it has most of the available features This will be used to explain how the controls operate Figure 4 1 Operator Control Panel GENERATORS ELAPSED TIME arte 307 120 VOLTS SWITCHLESS FULL POWA CENTER NEMA w VOLTMETER iy seo gt AC CIRCUIT BREAKERS O PUSH TO ESET 30 120 240 VOLTS Start Switch not shown Push to engage the engine starter if Run Switch is in the ON position Run Switch not shown OFF Turns off the engine kill switch ON Allows the engine to start and run for normal operation For a Run Stop lever is used where Run On Stop Off Elapsed Time An hour meter that measures the total hours the generator has been in use engine running AC Voltmeter Displays the voltage level at the output of the generator the 230VAC output AC Circuit Breakers Provide overcurrent prot
35. f this generator to ensure that any person who has not been trained on the safe use of this equipment does not have access to this equipment Read This Manual Thoroughly MN2414 If you do not understand any concept any procedure any safety warning statement any safety caution statement or any portion of this manual contact Baldor or your nearest authorized Baldor representative We are happy to make sure you understand the information in this manual so that you can safely enjoy the full use of this generator Product Safety Information 1 1 Precaution Statements Used In This Manual WARNING Caution Note There are three classifications of precautionary statements used in this manual The most critical is a WARNING statement then the Caution statement and the least critical is the Note statement The usage of each statement is as follows Indicates a potentially hazardous situation which if not avoided could result in injury or death Indicates a potentially hazardous situation which if not avoided could result in damage to property Additional information that is not critical to the installation or operation IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for the generator that should be followed during installation operation and maintenance of the generator For ease of reading the Warning statements are divided into four categories Operation Burn Ins
36. manual and obtain the correct type and quantity of engine motor oil and the correct battery if equipped for electric start 1 Electrical Connections 2 Ground Connection After installation the post installation checks must be performed prior to starting the engine After these checks have been performed and the system operation is verified to be good refer to Section 6 Maintenance for periodic checks that must be performed at scheduled intervals to ensure continued operation with minimal problems Electrical Connections All load connections are made at the panel using electrical cords with the proper mating plug for the receptacle being used More than one receptacle can be used as long as the total load does not exceed the continuous rating of the generator WARNING Never connect this generator to any buildings electrical system unless a licensed electrician has installed an approved transfer switch The National Electrical Code NEC requires that connection of a generator to any electrical circuit normally powered by means of an electric utility must be connected by means of approved transfer switch equipment so as to isolate the electrical circuit from the utility distribution system when the generator is operating Failure to isolate the electrical circuits by such means may result in injury or death to utility power workers due to backfeed of electrical energy onto the utility lines Use correct size insulated wire to connect the g
37. mbly X 5 61SA0016A00 Stator Assembly 6 61EP3204A01 Bearing Bracket bearing included with rotor X X 7 21 00 Cover X 7 0322 00 X 10 WD1541A33 Duplex Receptacle 250VAC at 20 Amps NEMA 5 20R X X 11 WD1541A10 Receptacle 125VAC at 30 Amps NEMA L5 30R X X 12 WD1541A14 Receptacle 125 250VAC at 30 Amps NEMA L14 30R X 12 WD1541A15 Receptacle 125 250VAC at 20 Amps NEMA L14 20R X A 2 Premier K Series MN2414 Table A 1 Generator Set Parts List Ref No Part No Description DG3E DG6E Not Shown EH0316A00 Control Box Operator Panel X Not Shown 0332 00 Control Panel Cover Operator Panel X Not Shown EH0434A00L2B Control Box Operator Panel X Not Shown EH0435A00L2B Control Panel Cover Operator Panel X 13 WD3201A02 AV Voltmeter Dual Scale X X 14 WD3201A00 Hour Meter X X 15 SP9080 Idler Switch 2 position rocker 16 SP9089 Stop Switch 2 position rocker Not Shown DI0176A01 Diode X X Not Shown RR0244A00 Varistor X Not Shown 0 3020 12 Capacitor 20MFD 370V X Not Shown OC6030F11 Capacitor 30MFD 370V 90 degree X Not Shown 01081 00 Glo Lite RED Not Shown CK0070A01 Circuit Breaker 15Amp X Not Shown CK0070A03 Circuit Breaker 30Amp X Not Shown CK0070A04 Circuit Breaker 40Amp Not Shown CK0070A05 Circuit Breaker 50Amp X Not Shown CK0070A06 Circuit Breaker 25Amp
38. n the Run position Press the Start Switch to engage the electric start motor Do not allow the starter motor to crank for more than 10 seconds at a time Allow 20 seconds between starter motor cranking attempts Once the engine has started release the start switch and do not re engage it Note If the engine does not start after a few attempts smell for fuel near the air cleaner If there Stopping Procedure 4 2 Operation 7 8 is significant fuel smell turn the choke lever off and attempt to start the engine When the engine starts turn the engine s choke lever to the OFF position Power is now present at the receptacles Connect or turn on the loads you wish to operate Disconnect Turn Off all loads connected to the generator set Move the RUN ON OFF switch to OFF if equipped For put the Run Stop lever in the STOP position Turn all fuel valves off MN2414 Section 5 Troubleshooting and Maintenance Maintenance MN2414 This manual contains only very minimal engine maintenance instructions Refer to the engine manufacturer s owner s manual for specific engine maintenance instructions for your generator set Any maintenance instructions or recommendations in the engine owner s manual take precedence over any of the following general recommendations General 1 Inspect the fuel system for leaks Replace all defective components immediatel
39. ontinued safe operation as designed Do not support the generator from the top of the wrap frame Do not tamper with or change the engine speed Engine speed is factory set to produce the correct voltage and output frequency Never operate the engine without a muffler The engine is designed to have the correct exhaust components installed and operating without these components can present a fire hazard cause excessive exhaust gases and cause damage to engine Inspect muffler periodically and replace if necessary Operate the generator only on a level surface Operation of the generator on an incline or slope may degrade engine lubrication and result in engine failure Always fill fuel tank with clean fresh fuel before use Never leave fuel in tank for long storage periods Old fuel becomes stale and can damage the fuel system causing the engine not to start Always drain the fuel tank after use before storage For electric start models do not place the key switch in the start position when engine is running This causes the starting motor to engage and may damage the starter and engine This generator must have a battery installed for operation The battery is used during stating and during operation If engine operation is attempted while the battery is removed damage to the engine s electrical components may result 1 6 Product Safety Information MN2414 Section 2 General Information Thank you for purchasing your Baldor Generator Se
40. se can cause serious or fatal injury Exhaust fumes gases are extremely dangerous and can cause severe illness or death Never breath exhaust fumes produced by a running engine Only run the engine outdoors where ventilation is plentiful Exhaust gases contain carbon monoxide a colorless odorless and extremely dangerous gas that can cause unconsciousness or death Symptoms of carbon monoxide poisoning include dizziness nausea headaches sleepiness vomiting or incoherence If you or anyone else experiences these symptoms get out into fresh air immediately Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or reinstalled in a well ventilated area Hot exhaust gasses must never be directed toward anything that may catch fire or explode This generator must not be used on or near any forest covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrestor The spark arrestor must be maintained in effective working order by the operator Some parts of this generator rotate during operation Rotating parts can present extreme danger if clothing or body extremities are caught by the rotating part and can cause serious or fatal injury Never touch a part of the generator until the engine has been stopped and all rotating parts are completely stopped Also disconnect the battery terminals to prevent accidental engine rotation during servicing Never move a
41. se serious or fatal injury Always disconnect all electrical loads before starting or stopping the generator Installation and repair procedures require specialized skills with electrical generating equipment Any person that installs or repairs this generator must have these specialized skills to ensure that this generating unit is safe to operate Contact Baldor for repairs or for any questions you may have about the safe installation and operation of this system The precaution statements are general guidelines for the safe use and operation of this generator It is not practical to list all unsafe conditions Therefore if you use a procedure that is not recommended in this manual you must determine if it is safe for the operator and all personnel in the proximity to the generator and connected loads If there is any question of the safety of a procedure please contact Baldor before starting or stopping the generator This equipment contains high voltages Electrical shock can cause serious or fatal injury Only qualified personnel should attempt the start up procedure or troubleshoot this equipment This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment Improper use can cause serious or fatal injury Only qualified personnel should attempt the start up procedure or troubleshoot this equipment System documentation must be available to anyone that operates this equipment at all times
42. serious or fatal injury Never store an engine with fuel in its tank indoors or in an enclosed poorly ventilated area where diesel fumes could reach an ignition source and cause an explosion Product Safety Information 1 5 Caution Statements Caution Caution Caution Caution Caution Caution Caution Caution Caution Caution Caution The brass connecting tab on some 120VAC duplex receptacles have been removed Each receptacle is powered by a separate generator winding When replacing a receptacle inspect the brass tab that normally links both receptacles If it is removed be sure to remove the brass tab from the replacement receptacle before it is installed Failure to remove the tab will cause a direct short to the generator windings and cause possible generator damage Avoid installing the generator set beside heat generating equipment or directly below water or steam pipes or in the vicinity of corrosive substances or vapors metal particles and dust Heat can cause engine problems to develop and unwanted substances can cause rust or generator failure over time Do not apply high voltage to windings condition Moisture can cause insulation breakdown making it necessary to return the generator to the factory for repair and consequent expense and loss of time Use only original equipment or authorized replacement parts Using the correct parts will assure c
43. t This manual contains information you need to safely and efficiently install and operate your generator set During the preparation of this manual every effort was made to ensure the accuracy of its contents This manual describes only very basic engine information A separate owner s manual for the engine is supplied with this unit for your use Please refer to the engine manual for information relative to engine operation maintenance recommendations and additional safety warnings Copyright Baldor 2004 All rights reserved This manual is copyrighted and all rights are reserved This document may not in whole or in part be copied or reproduced in any form without the prior written consent of Baldor Electric Company Inc Baldor Generators have earned the reputation of being high quality and dependable We take pride in this fact and continue to keep our quality standards high on our list of priorities We are also constantly researching new technological ideas to determine if they could be used to make our generator sets even better Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose The information in this document is subject to change without notice Baldor assumes no responsibility for any errors that may appear in this document Limited Warranty Baldor Generators will replace or repair free of charge any part or par
44. t 30 Amperes Note The nominal voltage produced by the generator at each receptacle is 120VAC or 240VAC MN2414 Operation 4 1 Pre Start Checks Before the engine is started several things must first be checked Start Up Procedure Electric Start 1 2 3 COON Place the generator set in open dry well ventilated and reasonably level location If grounding is required for your application check to make sure your unit is grounded properly see Sections Check the engine s oil level and add oil if necessary to bring it to the level recommended by the engine manufacturer Check the fuel level and add fuel to within 1 2 inch of the fill tube if necessary Open the fuel valve on the fuel tank Check the fuel system for fuel leaks and repair them prior to starting the engine Wipe up any fuel spills before starting the engine Disconnect or turn off all external loads Make sure all circuit breakers are set pushed in Tighten any bolts or nuts that may have loosened due to vibration Be sure all extension cords are in good condition before starting the generator Use only listed extension cords Move the engine s choke lever to the Choke Start position If the engine is warm or if the ambient air temperature is high try starting the engine without choking it Move the RUN ON OFF switch to ON if equipped For put the Run Stop lever i
45. t circuit breaker or replace if required Flash field Check for continuity in windings Return to factory for repair if open Check replace diode and capacitor and flash the field Output voltage varies Irregular speed fixed speed mode Fluctuating speed fixed speed mode Loose terminal or load connections Defective bearing uneven air gap Check engine for malfunction or load for fluctuation Stabilize load The addition of a lamp load resistance load may compensate partially for load changes caused by intermittent motor operation Do not overload Verify all connections are proper and check tighness torque of terminals Replace worn bearing Low output voltage Low engine speed Excessive load High resistance connections connections will be warm or hot Shorted field Low power factor Check that the Auto Idle switch is in OFF position Check engine for malfunction or system for overload Reduce load Verify all connections are proper and check tighness torque of terminals Test field coils for possible short by checking resistance with an ohmmeter or resistancebridge Return rotor assembly to factory forrepair if alternator field coils are shorted Reduce inductive motor load Some AC motors use about the same current regardless of load Do not use motors of greater horsepower rating than is necessary to move the mechanical load High output voltage Excessive speed fixed speed mode Check engine
46. tallation and Maintenance Operation WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING Gasoline and diesel fuel are flammable and can cause fire explosions injury or death For storage or refueling handle fuel with care and only in clean approved properly marked safety fuel containers Do not overfill the fuel tank Only fill the tank to within 1 2 of the top of the tank to allow space for fuel expansion Overfilling of tank may cause fuel to spill out onto engine and cause fire or explosion Clean up fuel spills by wiping completely dry before starting engine Gasoline and diesel fuel are flammable and can cause fire explosions injury or death Make sure the fuel cap is completely and securely closed after refueling to prevent spillage Gasoline and diesel fuel are flammable and can cause fire explosions injury or death Never operate this generator in a manner other than as described in this manual Operation in any manner not described in this manual should be considered unsafe and should not be attempted Never start the engine unless you have first verified that the installation and operation of the generator are as described in this manual Be sure that you are completely familiar with the safe operation of this equipment This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment Improper u
47. tems Some AE Models DLC GLC 1 Year or 3 000 Hours Whichever comes first 3 Years or 3 000 Hours Whichever comes first Industrial Standby Systems 1 Year or 1 000 Hours Whichever comes first 2 Years or 1 000 Hours Whichever comes first Industrial Prime Power Systems 1 Year or 1 000 Hours Whichever comes first 1 Year or 1 000 Hours Whichever comes first International 1 Year or 1 000 Hours Whichever comes first 1 Year or 1 000 Hours Whichever comes first For products covered under labor coverage travel expenses will be allowed up to 7 hours straight labor or 300 miles whichever occurs first and only applies to permanently wired and mounted products AE DLC GLC IDLC No warranty registration card is necessary to obtain warranty on Baldor Generators You must save the purchase receipt Proof of purchase date serial number and model number will be required for all portable and Towable products to qualify for any warranty consideration For all other products a start up inspection form warranty registration must be completed in its entirety and submitted to Baldor Generators within 30 days of start up to qualify for any warranty consideration MN2414 General Information 2 1 2 2 General Information MN2414 Section 3 Receiving amp Installation Receiving amp Inspection When you receive your generator there are several things you should do immediately 1 Observe the condition of the
48. to bring the oil level to full Caution This generator must have a battery installed for operation The battery is used during stating and during operation If engine operation is attempted while the battery is removed damage to the engine s electrical components may result Battery Connections generator is shipped with no battery installed WARNING Do not dispose of battery or batteries in a fire The battery is capable of exploding If the battery explodes electrolyte solution will be released in all directions Battery electrolyte solution is caustic and can cause severe burns and blindness If electrolyte contacts skin or eyes immediately flush the area with water and seek medical attention quickly WARNING Do not mutilate the battery The battery contains electrolyte solution which is caustic and can cause severe burns and blindness If electrolyte contacts skin or eyes immediately flush the area with water and seek medical attention quickly WARNING A battery presents a risk of electrical shock hazard and high short circuit current The following precautions are to be followed when working on batteries 1 Remove watches rings necklaces and all other metal objects 2 Use tools with insulated handles 3 Wear rubber gloves and boots WARNING The battery electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following precautions are to be followed
49. ts of the generator of their manufacture that are defective in workmanship and materials for a period of time as set forth in the Warranty Period chart below All Baldor products requiring warranty service shall be transported or shipped freight pre paid at the risk of the party requiring warranty service to a Baldor Generator repair facility or to Baldor Generators Customer Service Department in Oshkosh Wisconsin Written notification of the alleged defect in addition to a description of the manner in which the Baldor generator is used and the name address and telephone number of the party requiring warranty service must be included Baldor is not responsible for removal and shipment of the Baldor product to the service center or for the reinstallation of the Baldor product upon its return to the party requiring warranty service Problems with Baldor products can be due to improper maintenance faulty installation non Baldor additions or modifications or other problems not due to defects in Baldor workmanship or materials If a Baldor Generator repair facility determines that the problem with a Baldor product is not due to defects in Baldor workmanship or materials then the party requesting warranty service will be responsible for the cost of any necessary repairs EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE BALDOR GENERATORS DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PUR
50. ttery in a fire The battery is capable of exploding If the battery explodes electrolyte solution will be released in all directions Battery electrolyte solution is caustic and can cause severe burns and blindness If electrolyte contacts skin or eyes immediately flush the area with water and seek medical attention quickly A battery presents a risk of electrical shock hazard and high short circuit current Electrical shock can cause serious or fatal injury Never wear jewelry watch or any metal objects when in the area around the battery The battery electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive If electrolyte contacts the skin flush the area immediately with water and wash it off using soap and water If electrolyte contacts the eyes immediately flush the eye thoroughly with water and seek medical attention quickly The capacitor used in this generator can store and discharge a high voltage charge Before working with or in the area of the capacitor discharge the capacitor by shorting its leads together with a screwdriver with an insulated handle or insulated jumper wire Be extremely careful when flashing the generator When the alternator cover is removed rotating parts and high voltage are present Electrical shock can cause serious or fatal injury Rotating parts can present extreme danger if clothing or body extremities are caught by the rotating part and can cause
51. when working on batteries 1 Wear full eye protection safety glasses or goggles and protective clothing 2 Where electrolyte contacts the skin flush the area immediately with water and wash it off using soap and water 3 Where electrolyte contacts the eyes immediately flush the eye thoroughly with water and seek medical attention quickly 4 Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbonate of soda to one gallon four liters of water the bicarbonate solution is to be added until evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried WARNING A battery presents a risk of fire because they generate hydrogen gas Hydrogen gas is extremely explosive Never jump start a battery smoke in the area around the battery or cause any spark to occur in the area around the battery The following precautions are to be followed when working on batteries 1 Do not smoke when near batteries 2 Do not cause flame or spark in battery area 3 Discharge static electricity from body before touching batteries by first touching grounded metal surface 3 4 Receiving amp Installation MN2414 Battery Connections Continued Note OHV units that have an electronic governor must have a battery installed before the Genset can be started even with the pull starter If no battery is present or the
52. y Inspect and replace any fuel line that shows signs of deterioration Inspect all fuel clamps to ensure they are tight Make sure the fuel cap fits snugly on the fuel tank and that the fuel tank does not leak Inspect and clean the battery posts and the associated battery cable terminals Inspect the external wire cables and connectors used with the generator set for cuts frayed insulation or loose connections Repair or replace damaged parts before use The engine should be checked for proper speed setting s Prior to adjusting the engine speed turn the auto idler switch to OFF if present Make sure that the auto idler magnet does not touch the throttle lever of the engine when running a Disconnect all electrical loads and start the engine b Adjust the engine speed to 3720 RPM 62 Hz with no load speed c Adjust the auto idler speed after you have accomplished the above adjustment Adjust the auto idler speed by moving the electro magnet back and forth the oe bracket to achieve an engine RPM of 2500 2900 with the auto idler switch 8 Test all GFCI receptacles monthly by pressing the test button on the receptacle and making sure that the GFCI trips and and no voltage is present at the receptacle Replace any receptacle that fails the test N 1 Clean and or replace any fuel oil and or air filters per the engine manufacturers guidelines 2 oil level regularly at least every 5 to
53. y require 2 to 3 times as much current to start them Most fractional horsepower motors take about the same amount of current to start them and keep them running This is true whether they are the repulsion induction type motor capacitor type motor or the split phase type motor Other factors that influence the amount of current needed to start a motor are 1 The type of load connected to the motor If the electric motor is connected to a hard starting load such as an air compressor it will require more starting current If the same electric motor is connected to a light load such as a heater or power saw it will require less starting current 2 The brand or design of the electric motor The expected starting current for a particular size motor will vary depending on the brand of the electric motor as well as the type of electric motor Split Phase capacitor Repulsion induction type etc 3 condition of the electric motor A clean motor with free turning bearings will require less starting currents than a similar type motor that is dirty and the bearings are not as free turning as they used to be MN2414 Receiving amp Installation 3 5 Optional Wheel Kit PDG2 2 Wheel Dolly Kit and PDG4 4 Wheel Dolly Kit An optional 2 or 4 wheel dolly kit is available for these portable generators If you have purchased one of these kits refer to MN2409 for the installation instructions Recommended Engine Oil and Battery Type S
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