Baldor BALDOR GENERATOR Portable Generator User Manual
Contents
1. Be careful of hot parts The muffler and other generator parts become verv hot while the engine is running Do not jump start the generator set Sulfuric acid can cause severe injurv and can give off gases which are corrosive and potentiallv explosive Avoid contact with skin eves and clothing In case of contact flush area immediatelv with water When transporting a generator set secure it to prevent it from moving or shifting AN WARNING AN This Generator Set Produces Electricity And With That There Is The Potential Danger For Electrocution Know how to stop the engine quickly and understand the operation of all controls Do not operate electrical equipment while standing in water on wet ground or with wet hands or shoes Use extreme caution when working on electrical components Potentially dangerous voltage is present when the engine is running SAFETY WARNINGS Alwavs treat the electrical circuits as if thev were energized Disconnect all leads plugged into the unit Prior to working on it Have the electrical circuits serviced only by qualified technicians Inspect wiring frequentiv and replace fraved broken or poor leads Do not connect this unit to any building s electrical system unless you utilize an approved transfer switch or the main service entrance switch has been disconnected and locked open Circuit overload protection must be provided in accordance with national electrical codes an2. V SAFETY WARNINGS AN WARNING AN Gaseous Fuels are Highly Combustible and can Cause Explosions Fire Injury or Death oooo FOR GASOLINE OR DIESEL POWERED GENERATOR SETS 0000 Check all fuel supply piping and their connections on a monthly basis for fuel leaks Use only approved piping and componentry in your fuel supply system A professional experienced technician should oniv install the fuel supplv svstem Do not run the fuel line up against any sharp objects Comply with NFPA regulations and your local codes in regard to shut off valves regulators etc and any other recommendations or requirements they may have This Generator Set Creates A Significant Amount Of IN WARNING AN Heat And If Not Handled Properly Can Become A substantial Fire Hazard Keep the generator set at least three feet awav from buildings or other structures Keep the generator set awav from flammable and other hazardous materials trash rags lubricants explosives paints etc Keep the generator set free of grass leaves and excessive grease and oils Allow the generator set to cool before transporting it or storing it indoors Have fire extinguisher accessible and nearby while operating the generator set This generator set must not be used on or near anv forest covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester and it must be maintained in effec
3. 3 Secure the mounting tab on the bottom of the fuel tank and the blower housing with M6 X12 bolts Insert the attaching bolts on the other end of tank into the mount bracket hole and secure it with two M8 nuts 4 Connect the rubber pipe First fit the hose clamp on the rubber pipe connect the strainer and fuel tank then fasten the rubber pipe with the hose clamps Note Apply a drop of oil to the rubber pipe so that it may easily be connected to the strainer and the fuel tank 10 3 8 FUEL TANK HANDLE 1 Match the handle hole with the bolt on the top of the fuel tank and secure it with M8 nuts 2 Completely insert the breather pipe over the bolt Note There is a hole at the center of the breather pipe for air bleeding Set the breather pipe so that the hole is directed upward 3 Fix both ends of the handle cover with M3 X 10 screws Handle cover M3 x 10 Screw 2 pcs Breather pipe Handle To Carburetor Hose clamp Hose M8 Nut 2 pes Fuel strainer Fuel tank Rubber hose Cup ww Hose clamp M8 Nut 2 pcs Fig 10 34 10 3 9 FRONT COVER AND ELEMENT COVER 1 Secure the front cover on which fuel strainer Ia have been mounted with three M5 X 8 screws See Fig 10 35 Z L ET 2 Secure the element cover with M6 X 12 screws i Pe Ga gu See Fig 10 35 NI e L T _ IS Tm f 12 by kul u RES Calan aan raa amp w N
4. R If an instrument Q C meter or C meter for measuring capacity of condenser is available check the capacity of condenser NORMAL CAPACITY OF CONDENSER 10u4F R If you do not have such an instrument you can check condenser by replacing with new one and test running If the generator perform normally with new condenser the cause of trouble is defect in original condenser 11 1 3 CHECKING ROTOR 1 Remove rear cover and stator Diode rectifier Fig 11 2 2 Measure the resistance of field coil with a circuit tester See Fig 11 3 R x 12 10 Remedy mM If the resistance is not normal replace rotor with new one 3 Check the magnetic force of magnets molded in the rotor Remedy 1 If the magnetic force is weak replace the rotor with a new one 2 If the diode or the resistor is faulty replace rotor assembly with new one When all removed these parts are good assemble them and then solder 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 11 2 1 CHECKING ENGINE r p m H the engine r p m is too high or too low adjust it to the rated r p m How to adjust engine r p m R Loosen the nut on the adjusting screw B Turn the adjusting screw clockwise to in de crease engine speed or counter clockwise to increase engine speed Normal engine speed at no load is 3750 3800 r p m 11 2 2 CHECKING STATOR Check stator referring to Step 11 1 1 11 2 3 CHECKING CONDENSER Check condenser r
5. E Checking table for digital circuit tester Digital circuit tester Mor the cireult tester _Nocontnuy of the circult tester No continuity Ls L Table 9 2 2 NOTE 1 Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester polarity of tester needles should be reversed NOTE 2 Continuity means forward direction characteristics of the diode and different from short circuit condition in which a pointer of the tester goes out of its normal scale shows resistance to some extent When result of the checking indicates failure even in one section replace with a new one NOTE 3 Simpson brand analogue testers have the characteristic as same as the digital circuit tester 9 6 OIL SENSOR OPTION 1 Disconnect two 2 wires comming from the sen sor at the connection 2 Loosen the sensor to remove it from the engine Oil sensor 3 Plug the opening of oil filler hole created after sensor is removed with suitable means such as oil gauge 4 Connect the removed wires again with the oil Sensor 5 Start the engine with the oil sensor removed and confirm if a Engine stops after 5 seconds which is normal or b Engine does not stop after more than 10 seconds which is unusual NOTE The sensor will not operate properly when wire is broken or poorly connected Check the wires for correet connection If it fails to stop within 5 seconds after the wiring
6. HII TT Front cover Element cover Fig 10 35 10 3 10 CONNECTION OF WIRES 1 Connect the wires drawn out from the stator to the wires from the control box See Fig 10 36 2 Press the couplers until the locking hook engages securely 3 Connect the oil warning lamp option wire See Fig 10 36 Fig 10 36 WIRE CONNECTIONS BETWEEN CONTROL PANEL AND STATOR 6P coupler Wire color Yellow Red Green Yellow Brown White Green Yellow Brown Yellow Red White CONTROL PANEL SIDE 10 3 11 CONTROL PANEL 1 Put the control panel over the control lever and secure it with four M5 screws 2 Attach the knob to the control lever Note After the couplers and connectors have been connected and secured to the control panel secure the wires with a wire band to the control panel Fig 10 37 10 3 12 REAR COVER st rea sss M5 x 8 Screws j lt gt Secure the rear cover with three M5X8 screws and two M8 X 10 screws L 7 E 10 3 13 SIDE COVER Secure the side cover with four M5X 8 screws Fig 10 39 11 TROUBLESHOOTING 41 1 NO AC OUTPUT 11 1 1 CHECKING STATOR 1 Remove control panel and disconnect couplers on wiring 2 Measure the resistance between terminals on stator leads Refer to Table 9 1 page 28 for normal re sistance Remedy If stator is defective replace with new one Fig 11 1 11 1 2 CHECKING CONDENSER
7. Match the mounting hole of the rear bracket and that of the rotor bearing and softly strike the outside periphery of the rear bracket with a plastic hammer See Fig 10 31 2 Attach the stator cover around the stator 3 Tighten the three M6 bolts to fix the rear brack et to the front bracket TIGHTENING TORQUE 40 5 4 ft Ibs 535 735 N s Cm 55 75 kg cm 4 Putthe grommet in the groove of the rear bracket and secure the wire Fig 10 31 Note Fix the wire from the stator and diode stack with the clamp at the bottom of the groove 10 3 4 CONDENSER Put condenser to rear cover 5 0 X 10mm tapping Screw lt 55 Ke 5 Ke eee 2 pes TIGHTENING TORQUE 24 4 0 ft Ibs 325 535 N Cm 33 55 kg cm Fig 10 32 10 3 5 END COVER aa SS e y Set the end cover on the rear bracket with four Bracket Cover i jis M5 X10 screws 10 3 6 BRACKET COVER Mount the bracket cover on the rear bracket and secure them with M8 X30 bolts End cover Fig 10 33 10 3 7 FUEL TANK AND FUEL PIPE CONNECTION 1 Connect the rubber pipe to the engine carburetor and fasten it with a hose clamp Attach the banjo to the opposite end of the rubber pipe tighten it with a hose clamp and fasten the pipe to the fuel strainer with the banjo bolt Note Mount the fuel strainer with the banjo outlet upward 2 Fasten the strainer to the front bracket with the joint nuts
8. momentary lowering of the oil level due to the engine being slanted or affected by vibration in spite of sufficient oil in the crankcase d Stopping circuit 77777 This automaticallv stops the engine running Also the LED indicator for warning can be lit while the engine is being stopped We have the wires to be connected to LED available 5 5 5 CAUTIONS TO BE TAKEN ON HANDLING THE SENSOR 1 Oil sensor unit Be sure not to damage each wire Broken or short circuited power supply wires and or a grounding wire in particular may lead to malfunction or breakdown 2 Mounting and wiring of oil sensor unit Although this has been designed to have enough anti noise properties in practical use do not route the sensor wirings in the vicinity of noise generating sources such as ignition plugs or high voltage cords This may cause malfunction or breakdown 2 Since capacity of power source is limited current flown in the electronic circuit of the sensor is kept as low as possible Be sure to use terminals with a high contact reliability of more than that of tinned terminals 3 Operation of oil sensor D If operating with the engine kept tilted oil surface inside of the engine varies and the correct oil level can not to be detected which in turn obstructs the preventing function of engine seizure Operate the engine by keeping it level D When starting the engine with an insufficient oil in the crankcase engine starts once then it sto
9. table below the AC output is normal Voltage range 117 130V Table 8 2 8 3 DC OUTPUT MEASURING Load O Switch a To DC Terminal Lf Fig 8 9 Measurement of DC output is executed with the switch turned ON while the current is regulated at 8 3A by adjusting the load to the generator If the voltage is within the range from 6V to 14V the voltage output is normal Note If a battery is connected as a load to the generator the DC output voltage will increase by approximately 1 to 2V Therefore carefully observe the electrolyte level and do not overcharge the battery _ 8 4 MEASURING INSULATION RESISTANCE Use a Dr Robin generator tester in megger tester mode or use a megger tester to check the insulation resistance Connect a megger tester to one of recep tacle output terminals and the ground terminal then measure the insulation resistance An insulation re sistance of 1 megohm or more is normal The original insulation resistance at the time of shipment from the factory is 10 megohm or more If it is less than 1 megohm disassemble the gener ator and measure the insulation resistance of the stator rotor and control panel individually e STATOR 1 Measure the insulation resistance between BROWN lead and the core 2 Measure the insulation resistance between YEL LOW lead and the core 3 Measure the insulation resistance between BLACK lead and the core e ROTOR Measure the i
10. EBY EXPRESSLY WAIVED BY THE BUYER UNDER NO CIRCUMSTANCES SHALL BALDOR GENERATORS BE LIABLE OR RESPONSIBLE IN ANY MANNER WHATSOEVER FOR ANY INCIDENTAL CONSEQUENTIAL OR PUNATIVE 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 Revised Effective 6 26 03 Form S PSG 003 3 Warranty Policy S PSG 003 3 doc WARRANTY PERIOD Portable Products DG Series K Series TS Whichever comes first Whichever comes first Some AE Models Whichever comes first Whichever comes first 1800 RPM Standby Systems Some AE Models DLC GLC Whichever comes first Whichever comes first Systems Whichever comes first Whichever comes first Whichever comes first Whichever comes first Labor coverage for warrantable repairs is provided for the applicable period not to exceed published rates as contained in the Baldor Generators Warranty Policy Mileage is allowed only for permanent installations not to exceed published rates as contained in the Baldor Generators Warranty Policy Year or 3 000 Hours 3 Years or 3 000 Hours Whichever comes first Whichever comes first Warranty registration within 30 days of purchas
11. OPERATOR S MANUAL FOR YOUR BALDOR GENERATORS MODEL PC13R SERIAL NUMBER BALDOR GENERATORS 3815 OREGON STREET 0 P O BOX 200 0 OSHKOSH WI 54902 0200 TELEPHONE 920 236 4200 0 FAX 920 236 4219 FORM S PSG 002 25 D ISO9001 FORMS S PSG 002 37 msw EFFECTIVE REVISED 6 29 01 FORWARD This manual contains the information you need to safely and efficiently operate your generator set During the preparation of this manual every effort was made to ensure the accuracy of its contents DO NOT OPERATE THIS GENERATOR SET UNTIL YOU CAREFULLY READ THIS MANUAL AND UNDERSTAND THE SAFETY WARNINGS AND INSTRUCTIONS CONTAINED IN IT While safety is built into every Baldor Pow R Gard generator set careless or improper operation could possibly result in mechanical failure property damage severe injury or even death Note that this manual covers only very basic information in regards to the engine A separate owner s manual for the engine is supplied with this unit for your use Please refer to this manual for information relative to engine operation maintenance recommendations and additional safety warnings As soon as you receive your generator set inspect it closely for shipping damage If you find some damage notify the transportation company immediately and file a freight damage claim Think of this manual as a tool to help you get the most out of your generator set WE STRONGLY SUGGEST THAT YOU KEEP THIS MANUAL WITH YOUR GENERATOR SE
12. R COIL Me FN pus s E l CONDENSER Fig 5 7 w 5 3 1 GENERATION of NO LOAD VOLTAGE 1 When the generator starts running the permanent magnet built in to the rotor generates 3 to 6V of AC voltage in the main coil and condenser coil wound on the stator 2 As one or two condensers are connected to the condenser coil the small voltage at the condenser coil generates a minute current which flows through the condenser coil At this time a small flux is produced with which the magnetic force at the rotor s magnetic pole is intensified When this magnetic force is intensified the respective voltages in the main coil and condenser coil rise up As the current increases the magnetic flux at the rotor s magnetic pole increases further Thus the voltages at the main coil and condenser coil keep rising by repeating this process 3 As AC current flows through the condenser coil the density of magnetic flux in the rotor changes This change of magnetic flux induces AC voltage in the field coil and the diode rectifier in the field coil circuit rectifies this AC voltage into DC Thus a DC current flows through the field coil and magnetizes the rotor core to generate an output voltage in the main coil 4 When generator speed reaches 3000 to 3300 r p m the current in the condenser coil and field coil increases rapidly This acts to stabilize the output voltage of each coils If generator speed further increases to the rated value
13. REVENTION Resistor spark plug prevent electric wave noise for radio T V etc e OIL SENSOR optional The oil sensor detects when oil decreases below the designated level stopping the engine and preventing engine damage 4 GENERAL DESCRIPTION 4 1 EXTERNAL VIEW of GENERATOR DC terminal Engine control switch Frequency adjusting CHOKE RUN STOP screw internal Ground terminal Voltmeter Recoil starter receptacle AC circuit breaker DC circuit breaker Fuel cock Fuel strainer Muffler Oil warning lamp Air cleaner cover With oil sensor type Spark plug cover Carrying handle Fuel tank cap Fuel tank Engine emission label Drain plug Oil filler cap Fig 4 1 4 2 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped on the LABEL MODEL NAME stuck on the fuel tank NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service Label Model name Fig 4 2 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION BP coupler Rotor complete End cover Stator complete Rear cover LLRs r gt y PN Diode rectifier Ball bearing Stator cover Condenser Mount rubber Through bolt Front cover Fig 5 1 5 2 FUNCTION 5 2 1 STATOR The stator consists of a laminated silicon steel sheet core a main coil and a condenser coil which are woun
14. Robin reserves the right to modify alter or improve any engines or parts without incurring any obligation to modify or replace any engine or parts previously sold without such modification alteration or improvement No person is authorized to give any other warranty or to assume any additional obligation on Robin s behalf unless made in writing and signed by an officer of Robin THIS WARRANTY AND ROBIN S OBLIGATION HERE UNDER ARE IN LIEU OF ANY OTHER WARRANTIES OR OBLIGATIONS OF ANY KIND EXPRESSED OR IMPLIED INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE OF ROBIN SHALLIN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES LIMITED WARRANTY Unless otherwise provided Baldor generators are warranted against defects in Baldor workmanship and materials for a period of time as set forth in the Warranty Period chart on the following page All warranty claims must be submitted to a Baldor Generator repair facility prior to the expiration of the warranty period Baldor Generators shall have no responsibility or liability for any defect latent or otherwise discovered after the expiration of the warranty period provided herein Extended warranties are available for certain Baldor products These warranties are described in Baldor s catalog and other sales literature Extended warranties are subject to the terms and conditions of this L
15. T AND MAKE IT AVAILABLE TO ANYONE USING THE GENERATOR SET You should refer to the manual when questions arise in regards to the operation of the generator set and carefully observe all safety warnings and instructions contained in it Baldor Generators formerly Pow R Gard Generator Corporation has been in business since 1965 The generator sets we manufacture have earned the reputation of being of high quality and a dependable product 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 Thank you for purchasing your Baldor Pow R Gard Generator Set SAFETY WARNINGS Improper Maintenance or Repair Can Result in AA WARNING N Property Damage Mechanical Failure Severe Injury or Death Place protective covers and guards over the rotating parts if rotating parts such as the drive shaft pullev belt etc are left exposed they are potentially hazardous When cleaning repairing or inspecting make sure all moving parts have stopped Prior to working on the generator set disconnect the spark plug and batterv to prevent accidental starting Use only original equipment or authorized replacement parts Use of correct parts will assure the operator of the safetv integritv that was designed into the unit Unauthorized modifications to the generator
16. V Type with an output voltage of 110 or 120V Oto 300V Type with an output voltage of 220 230 or 240V 0 to 150V 0 to 330V Dual voltage type 2 AMMETERS AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10A 20A 100A 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meters input voltage range 4 CIRCUIT TESTER This circuit tester is used for measuring re sistance etc S MEGGER TESTER Used for measuring generator insulation re sistance Select one with testing voltage range of 500V 6 ENGINE TACHOMETER There are various types of tachometers such as contactless type contact type and strobe type The contact type can be used only when the generator and engine have been disassembled The contactless type is recommended The PET 2100E engine tachometer is available from your Robin distributors Please inquire by the part number PET 2100E Fig 8 5 8 2 AC OUTPUT MEASURING Switch ma FO A Load Co JO Q A OY ore To AC receptacle te MA J Q Fig 8 8 Measurement is executed with the circuit as shown in Fig 8 8 An electric heater or an incandescent lamp with a power factor of 1 0 is suitable as a load for the generator When the AC output measured at the rated load and rated speed is confirmed to be within the voltage range specified in the
17. a period listed below from the date of sale to the original retail purchaser Robin s obligation under this Limited Warranty shall be limited to the repair and replacement at Robin s option of any part or parts which upon examination is are found in Robin s judgment to have been defective in material or workmanship It shall be a condition of Robin s obligation under this limited warranty that Robin directly or through one of its Distributors or Service Centers authorized to service the particular engine involved receive prompt notice of any warranty claim and that the engine or the part or parts claimed to be defective be promptly delivered transportation prepaid to such Distributor or Service Center for inspection and repair All repairs qualifying under this Limited Warranty must be performed by Robin or one of its authorized Distributors or Service Centers WARRANTY PERIODS Robin Four Cycle Air Cooled Gasoline Engines Limited 3 Years Warranty Robin Four Cycle Air Cooled Diesel Engines Limited 1 Year Warranty The repair or replacement of any part or parts under this Limited Warranty shall not extend the term of the engine warranty beyond the original term as set forth above LIMITATIONS AND EXCLUSIONS This limited Warranty shall not apply to 1 Bent or broken crankshaft or resultant damage caused by vibration related to bent or broken crankshaft Also damage caused by loose engine mounting bolts or improper or imbalanced accessories or bl
18. ades mounted to the crankshaft 2 Repairs required because of prolonged storage including damage caused by old or contaminated fuel in the fuel tank fuel lines or carburetor sticky valves or corrosion and rust of engine parts 9 Repair required due to overheating Most often caused by overloaded or clogged or damaged or missing flywheel fan inlet air passages cooling fins or air shrouds 4 Dirt or grit related wear caused by improper air cleaner maintenance most often resulting in worn piston rings cylinders valve guides carburetor or other internal components 5 Broken or scored parts caused by low oil level dirty or improper grade of oil 6 Engine tune ups and normal maintenance service including but not limited to valve adjustment normal replacement of service items fuel and lubricating oil etc 7 Any engine which has been subject to negligence misuse accident mis application or over speeding 8 Any engine that has been installed repaired or altered by anyone in a manor which in Robin s sole judgment adversely affects its performance or reliability J Any engine which has been fitted with or repaired with parts or components not manufactured or approved by Robin which in Robin s sole judgment adversely affects its performance or reliability 10 Instances when normal use has exhausted the life of a component or an engine The customer is responsible for all transportation charges in connection with any warranty work
19. ake or ship the Baldor product to a Baldor Generator repair facility or who desire a repair to be made by other than a Baldor Generator repair facility should contact Baldor Generators Customer Service Department at 920 236 4200 Baldor in advance of such service must approve a repair by anyone other than a Baldor Generator repair facility in writing 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 requiring warranty service will be responsible for the cost of any necessary repairs Parties requiring warranty service not satisfied with a determination that a problem is outside of warranty coverage should contact Baldor Generators Customer Service Department at 920 236 4200 for further consideration 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 PURPOSE AND MECHANTABILITY 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 HER
20. cal appliance As a result the load can be damaged b Table 7 2 shows voltage drops per 100 meters of cable Voltage drop per 100 m Sectlonal Allowable Gauge No current wire element sezzjoni A No mm 30 0 18 2 5V 8V 50 0 18 1 5V 5V 37 0 26 1 0V 3V 45 0 32 1 5V 70 0 32 iv Tabie 7 2 Voltage drop indicates as V a x R x Ix C R means resistance 2 100 m on the above table I means electric current through the wire A means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools 7 2 DC OUTPUT NOTE Do not use DC and AC output simultaneously Due to a characteristic of the condenser voltage regulation simultaneous use of DC and AC output creates voltage drop in DC output resulting in incapability for charging batteries When the generator is employed to charge batteries attentions should be paid to the specific gravity of electrolyte in the battery 7 2 1 SPECIFIC GRAVITY OF BATTERY ELECTROLYTE The specific gravity of electrolyte varies by temperature so it must be converted to the one at 20 C San t 0 0007 t 20 where S20 The specific gravity at 20 C Sr Measured value t Temperature at the time of measurement Electrolyte 7 2 2 SPECIFIC GRAVITY OF BATTERY ELECTROLYTE AND CHARGING CONDITION Specific gravity 20 C Charging condintion Charging is not necessary immediate Charging is necessar
21. d in the core slots The condenser coil excites the rotor field coil which generates AC voltage in the main coil 5 2 2 CONDENSER A condenser is mounted on the rear cover and is connected to the condenser coil which is wound on ww the stator This condenser and condenser coil regu late the output voltage b em e Fig 5 3 5 2 3 ROTOR The rotor consists of a laminated silicon steel sheet core and field coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided for the primary exciting action A cooling fan is pressure fitted on the end of the rotor shaft to cool the coils cores rectifier and other generator parts See Fig 5 4 A diode rectifier and resister are mounted inside of the insulator See Fig 5 5 Cooling air is sucked by the rotor fan through the slits of the rear cover and is expelled through the outlets of the front cover 5 2 4 CONTROL PANEL The control panel has a double AC receptacle with a ground terminals and DC terminals The voltmeter displays output voltage of the gener ator The circuit breaker for AC and DC protects the generator from getting damages caused by over loading or defective appliance Fig 5 6 5 3 GENERATOR OPERATION w PERMANENT MAGNET FOR INITIAL EXCITATION STATOR MAIN COIL FIELD COIL RECEPTACLE val RESISTER or l APPLIANCE SURGE ABSORBER DIODE x CONDENSE
22. d local regulations Check GFCI Receptacles monthly by using the Test and Reset buttons designed into them Depending on vour application it mav be mandatorv to ground or not ground this unit to earth ground Comply with local electrical codes oooo FOR GASOLINE OR DIESEL POWERED GENERATOR SETS 0000 Gasolme And Diesel Fuel Are Flammable And Can WARNING Cause Explosions Fire Injury Ur Death Operate the generator set on a level surface If the generator set is tilted fuel spillage may result Handle fuel with care It is highly flammable Use only clean properly marked and approved safety containers for refueling and storing fuel Stop the engine and allow it to cool before refueling 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 If fuel is spilled wipe it up carefully and wait until the fuel has dried before starting the engine Make sure the fuel cap is properly closed after refueling Never operate the generator set while smoking Never operate the generator set near an open flame Never store the generator set with fuel in the tank indoors or in an enclosed poorly ventilated enclosure where fuel fumes may reach an open flame electrical spark or pilot light as on a furnace water heater clothes dryer etc When transporting over long distances or rough roads drain the fuel tank to prevent leakage and spillage
23. e is required for portable and towable products to qualify for any warrantv consideration Proof of purchase date serial number and model number will be required for all warranty work 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 Owner s Responsibilities The owner is obligated to operate and maintain the generator in accordance with the recommendations published by Baldor Generators in the Operator s Manual for the generator The owner is responsible for the costs associated with maintenance and any adjustments that may be required The owner is responsible for payment of any of the following expenses that might be incurred as a result of a failure under the terms of this warranty 1 Rental equipment used to replace the equipment being repaired 2 Telephone or other communication expenses 3 Living and travel expenses of persons performing service except as specifically included within the terms of specific warranty 4 The premium costs for overtime labor requested by the owner 5 All parts transportation costs Revised Effective 6 26 03 Form S PSG 003 3 Warranty Policy S PSG 003 3 doc Limitations Baldor Generators is not responsible for the repair of generators required because of normal wear accident misuse abuse improper installation lack of maint
24. e rere erereeservneserecs 8 3A DC output serrsesrsosentenegceoconcuon 100W The voltage curve shown in the left indicates the characteristic of DC output when charging a battery The voltage may be decreased by 20 when the resistance load is applied VOLTAGE V CURRENT A b 3 FEATURES e LOW NOISE v Mounting of Air cooled 4 Cycle Super Side Valve ROBIN Engine EY15D SSVR and introduction of a larger muffler into the machine realized low noise operation e LIGHT WEIGHT lt COMPACT The machine is easy to carried about due to its light weight 27 5kg and compact design e HIGH OUTPUT increased maximum output The 1300W output is an increase of 100W over the 60Hz maximum output of the current R1210 e EASY OPERATION The one touch engine control switch integrates the engine on off switch and the choke All controls are conveniently located on the front panel e LONG OPERATION The large 0 9 U S gal 3 5 liter fuel tank allows about 3 6 hours of continuous operation at 60Hz rated load e MINIMAL MAINTENANCE ww The brushless design and condenser voltage regulator system ensure maintenance free operation e FUNCTIONAL FEATURES e The AC DC push button circuit breaker allows for easy and safe operation when an overload occurs or when the machine is not functioning properly Equipped with voltmeter for reading AC output voltage e DC output can be obtained for the re chargeable battery e NOISE P
25. eather pipe 3 Remove the handle body by taking off 12mm box wrench the two M8 nuts Handle cover Breather pipe M3 x 10 Screw 2 pes Handie Fuel tank M8 Nut 2 pcs Fig 10 9 8 Fuel tank 1 Remove the two M6X12 flange bolts 10mm box wrench from the blower housing See Fig 10 10 2 Remove the fuel tank by taking off the two M8 nuts from the bottom of the 12mm box wrench tank See Fig 10 11 Fig 10 11 1 Remove the bracket cover from the generator by loosening the two M8 X 30 bolts See Fig 10 12 12mm box wrench Cover 10 End cover 1 Remove the end cover from the generator by unscrewing the four M5 X10 screws See Fig 10 12 Driver i I rimm 1 MI Bracket Cover N A G 9 iz JONI Fig 10 12 bie mmn m 11 Rear bracket 1 Loosen and take out the three M6 cover 10mm box wrench bolt See Fig 10 13 2 Remove condenser from rear bracket Box spanner 3 Remove the connector of the diode Box spanner and rectifier and then remove the earth cable screw driver terminal from the rear bracket See Fig 10 14 NL Earth cable terminal L emg Condenser X bracket k L jU Ne I v Condenser b L or l Z Diode rectifier U Fig 10 13 Fig 10 14 4 Remove the rear bracket tapping it Plastic mallet evenly with a plastic mallet See Fig 10 15 5 Remove moun
26. eferring to Step 11 1 2 11 2 4 CHECKING ROTOR Check rotor referring to Step 11 1 3 l 5 P ww 12 WIRING DIAGRAM JO SISOY XN due Ai eee eee a e anam Noea T P moni josues no r PO17 moria paa TROIS i l eid gt 1 su puoo luu ere 192819 2108 4q 2 HM581q a Jd i a a V JB euw 27 ped gA MM ma foo Sq le A e C ueei6 ae a ae r JSJALLIJJOA 6 auum L HT 2 TS 0000000 7 MO DA pune Q ue x _ l 2 S JO SISOY l ba monak LS e usesb 981d 281 are S OV umo1q 7 UMO1q UMO1Q N qjospjela 1auga1 YNI JV H 1109 10 JOD UIEN BALDOR w GENERATORS SUBARU HAVE JOINED FORCES TO BRING YOU THE BEST ENGINE GENERATOR WARRANTY IN THE INDUSTRY 3 YEAR WARRANTY ON BALDOR GENERATORS AND ROBIN SUBARU ENGINES SEE ATTACHED WARRANTY STATEMENTS FOR DETAILS BALDOR GENERATORS 3815 OREGON STREET OSHKOSH WI 54902 PHONE 920 236 4200 FAX 920 236 4219 WWW BALDOR COM Robin Subaru Limited Engine Warranty For Baldor Generators Effective for original Robin Subaru engines powering Baldor portable generators purchased after August 16 2000 Robin America Inc a division of Fuji Heavy Industries Ltd herein Robin warrants that each new engine sold by it will be free under normal use and service from defects in material and workmanship for
27. enance unauthorized modifications or improper storage Normal Wear This warranty will not cover repair where normal use has exhausted the life of a part or generator It should be remembered that the service life of any generator is dependent on the care it receives and the conditions under which it has to operate Some applications are very often used in dusty or dirty conditions which can cause what appears to be excessive wear Such wear when caused by dirt dust grit or other abrasive material which has entered the generator because of improper maintenance is not covered by Warranty For all product lines the engine manufacturer warrants engine systems Contact Baldor Generators for current engine warranties BALDOR GENERATORS 3815 Oregon Street 7 Oshkosh Wisconsin 54902 Phone 920 236 4200 9 800 872 7697 Fax 920 236 4219 www baldor com Revised Effective 6 26 03 Form S PSG 003 3 Warranty Policy S PSG 003 3 doc 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 Diesel engine exhaust and some constituents are known to the state of California to cause cancer birth defects and other reproductive harm Revised 4 13 01 C ISO9001 FORMS S PSG 001 1 msw Effective 2 26 98 Form S PSG 001 1 Service is just a p
28. equires 800W to 1200W power source to be turned on A rated 1000W generator can power one 400W mercury lamp Initially loaded motor driven appliances such as water pumps compressors etc These appliances require large starting wattage which is 3 to 5 times of running wattage Example A rated 900W compressor requires a 4500W generator to drive it NOTE 1 Motor driven appliances require the aforementioned generator output only at the starting Once their motors are started the appliances consume about 1 2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrical appliances NOTE 2 Motor driven appliances mentioned in items 3 and 4 vary in their required motor starting power depending on the kind of motor and start up load If it is difficult to determine the optimum generator capacity select a generator with a larger capacity 5 Appliances without any indication as to power consumption Some appliances have no indication as to power consumption but instead the work load output is indicated In such a case power consumption is to be worked out according to the numerical ws formula mentioned below t i l Output of electrical appliance Power consumption Efficiency Efficiencies of some electrical appliances are as follows Single phase motor iii 0 6 0 75 The smaller the motor the Three phase motor sisien 0 65 0 9 lower the efficiency Fluorescent
29. g Discon 6P couplers Yellow Red Green hook nection Yellow Brown White See Fig 10 4 2 Disengage the connectors of oil warning lamp option See Fig 10 5 Press the hook of the coupler and pull out to disconnect Press the hook of the coupler and pull out to disconnect CONTROL PANEL SIDE STATOR SIDE Fig 10 5 5 cover 1 Remove Se element cover by Driver unscrewing M6 X 12 screw See Fig 10 6 2 Remove the front cover by unscrewing Driver three M5 X 8 screws See Fig 10 6 ida we EA d aa 4 i jib A l issib cover Element cover 7 Fig 10 6 H ii 6 Fuel pipe 1 Discharge fuel from the tank Use utmost care about and plug 1 Shut the fuel striner fire hazard Discon 2 Remove the strainer cup nection 3 Put a vessel to receive fuel under the Wipe off spilt fuel strainer and open the fuel cock to discharge fuel See Fig 10 7 4 Attach the strainer cup to the strainer body throughly Do not lose the filler screen 2 Disconnect fuel hose from the strainer Loosen the hose clamp on top of the strainer and pull out the fuel hose from the strainer See Fig 10 8 7 Fuel tank 1 Remove the handle cover by unscrewing The fuel tank can be Driver handle the two M3 X10 screws removed without w disassembling the handle 2 Pull off the br
30. g a current flowing across a pair of electrodes inner and outer with the reference in such a way that if a current flows between the electrodes more than the reference sufficient oil is in the crankcase on the other hand if a current flows less than the reference oil is not sufficient Since an electric current is flown to detect oil quantity this is called the electrical conductivity detection type of sensor The oil level to be detected is determined by the length of electrodes and their mounting positions with the engine 5 5 3 HOW IT OPERATES Power supply The sensor makes use of a part of primary power source for ignition of the engine igniter to drive the sensor circuit Power to the sensor can usually be derived from the stop button by branching wires out Judgement of oil level When sufficient oil is in the crankcase both of inner and outer electrodes are immersed in the oil through which current flows across the electrodes The sensor judges that oil in the crankcase is sufficient When oil level goes down and the inner electrode is exposed to the air due to consumption of oil no current flow between the electrodes as air is considered to be electrically non conductive The sensor in this case judges that oil is insufficient Decision of oil shortage Oil level at the electrodes may go down momentarily probably due to the engine being slanted or affected by vibration even if a sufficient oil is in
31. ghly from rotor shaft and engine PTO shaft i N Naa Fig 10 24 Front bracket 1 Remove the front bracket which is mounted on the main bearing cover of the engine bv taking out four M8 X 18 bolts See Fig 10 25 12mm box spanner or Socket wrench 12mm box spanner Fig 10 25 Mount 1 Remove mount bracket from engine 12 mm wrench rubbers Remove mount rubbers from mount bracket 8 Nut 3pcs or 2pcs L y JB TeX Mount bracket Mount rubber Fig 10 26 10 3 ASSEMBLY PROCEDURES 10 3 1 FRONT BRACKET Install the front bracket on the main bearing cover of the engine engaging the faucet joint See Fig 10 27 M8 X 18mm bolt and washer assy x 4pcs TIGHTENING TORQUE 8 7 10 1 ft Ibs 1175 1370 N lt Gm 120 140 Ka Cm 10 3 2 ROTOR 1 Wipe off oil from the tapered portion of engine shaft and matching tapered hole of rotor shaft See Figs 10 28 and 10 29 Fig 10 28 2 Install rotor on the engine shaft and tighten the through bolt Apply a wrench on the head of through bolt and hit wrench handle clockwise with a hammer to tighten See Fig 10 30 If an impact wrench is available use it TIGHTENING TORQUE 8 7 10 1 ft Ibs 1175 1370 N lt Cm 120 140kg cm I YUS TU Ta N LALA Fig 10 27 Fig 10 30 10 3 3 STATOR 1 Holding the rear bracket and stator fit them to the front bracket
32. hone call away 800 872 7697 www baldor com products generators asp BALDOR GENERATORS 3815 Oregon Street Oshkosh WI 54902
33. imited Warranty as modified by the additional terms of the extended warranty If a Baldor product is defective due to Baldor workmanship or materials and the defect occurs during the warranty period then Baldor will either repair the product or replace it with a new one whichever Baldor believes to be appropriate under the circumstances Warranty service is available for all Baldor Generator products from Baldor Generators Customer Service Department in Oshkosh Wisconsin and from Baldor Generator repair facilities A list of Baldor s generator repair facilities may be obtained by contacting Baldor Generators at Customer Service Baldor Generators 3815 Oregon Street Oshkosh Wisconsin 54902 920 236 4200 telephone 920 236 4219 facsimile All Baldor products requiring warranty service shall be transported or shipped freight pre paid at the risk of the party requiring warranty service to Baldor Generators Customer Service Department in Oshkosh Wisconsin or to a Baldor Generator repair facility 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 Customers who are unable to t
34. l See Fig 9 1 9 1 3 CIRCUIT BREAKER Check continuity between the two terminals at the rear side of the circuit breaker using a circuit tester while it is mounted on the control panel If continuity is confirmed when the breaker is ON and no continuity is confirmed when the breaker is OFF the circuit breaker is normal 9 1 4 VOLTMETER Check the voltmeter if it operates correctly by apply ing specified voltage Voltmeters cannot be checked with a circuit tester because its internal resistance is too large Voltmeter Fig 9 3 9 2 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a Dr Robin or a circuit tester referring to the follow ing table N CAS Fig 9 4 a nans eae RX12 10 Condenser Winging Voltage Brown Brown White Black Black Table 9 1 NOTE If the circuit tester is not sufficiently accurate it may not show the values given and may give erroneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from 20 C 68 F 9 3 ROTOR 1 Using the Dr Robin or a circuit tester measure the resistance ef the field coil See Fig 9 5 R X12 10 NOTE 1 NOTE 2 Because a diode is soldered to the coil ends at the terminals resistance may be measured only when tester probes touch
35. l has a wave form with two peaks in one cycle as in the case of the output wave form shown in Fig 5 8 3 Between A and B Output waveform Wa lt Between C and B L PA LS Y 1 Cycle Current Current flowing flowing between between A and B C and B Fig 5 8 3 CAUTION Do not use DC and AC output simuitaneousiv Due to a characteristic of the condenser voltage regulation simultaneous use of DC and AC output creates voltage drop in DC output resulting in incapabilitv for charging batteries 5 4 ELECTRONIC IGNITION SYSTEM The electronic ignition system features a power transistor as the current control element Therefore the ignition system is an electronic contact point free type that operates with the power transistor impulses controlling the current This system is also called TIC transistor igniter circuit and is virtually free of ignition failure which generally results from contamination of the contact points a typical problem with contact type ignition systems Because this ignition system has no contact points it is not affected by moisture oil dust or other contaminants As a result this electronic ignition system ensures sure and positive ignition with reduced maintenance The TIC mechanism consists of a transistor incorporated ignition coil and a permanent magneto built in flywheel which is press fitted on the rotor shaft of the generator 1 When the permanen
36. lamp sent 0 7 0 8 Example 1 A 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 40 0 7 57W As explained in Item 2 multiply this power consumption value of 57W by 1 2 2 and you will get the figure of the necessary capacity of a generator In other words a generator with a rated output of 1000Wcapacity can light nine to fourteen 40W fluorescent lamps Example 2 Generally speaking a 400W motor means that its work load is 400W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570W When this motor is used for a motor driven tool the capacity of the generator should be multiplied by 1 2 to 3 and 570W as explained in the item 3 Applicable wattage Appliance ww Fluorescent lamp mercury lamp Electric tool Table 7 1 NOTES Wiring between generator and electrical appliances 1 Allowable current of cable Use a cable with an allowable current that is larger than the rated input current of the load electrical appliance If the input current is larger than the allowable current of the cable used the cable will become excessively heated and deteriorate the insulation possibly burning it out Table 7 2 shows cables and their allowable currents for your reference 2 Cable length if a long cable is used a voltage drop occurs due to the increased resistance in the conductors decreasing the input voltage to the load electri
37. nsulation across one of the soldered terminals of the rotor and the core kO ER XII Fig 8 12 e CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts Fig 8 13 Any part where the insulation resistance is less than 1M 2 has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 9 CHECKING FUNCTIONAL MEMBERS 9 1 CONTROL PANEL Voltmeter DC terminal Green Yellow Ground terminal Circuit breaker 6P coupler Oil warning lamp N i D LT l Vellow a 4 mo Roy SEF Green Yellow 9 1 1 AC RECEPTACLES Using a Dr Robin or a circuit tester check continuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel When continuity is found between the output terminals of the receptacle with a wire connected across these terminals the AC receptacle is normal When the wire is removed and no continuity is found between these terminals the receptacles are also normal Fig 9 2A Fig 9 2B 9 1 2 DC TERMINAL Check continuity between the DC terminals at the rear of the control panel using a circuit tester under l the condition that the DC terminals is mounted on the control panel See Fig 9 1 w When continuity between the DC terminals is confirmed with a wire connected across the terminals and is not confirmed if the wire is removed the DC terminals are norma
38. occurring due to insufficient amount of oil in the crankcase Since the sensor has been designed to consume a part of power supplied to the igniter to energize its electronic circuit any other external power supply is not necessary so that it can be mounted at the oil filler port Introduction of newly developed sensing principle features super durability and no change with the Fig 5 10 passage of time as it does not use any moving part TES iN ee Oil sensor Merits due to introduction of electrical conductivity detection are as follows It has resistance to mechanical shocks and property of no change with the passage of time as sensing element consists simply of electrodes having no moving parts 2 At the same time it is capable of detecting the oil level stably as it is not influenced by engine vibrations 3 No error occurs due to foam and flow of the oil Influence against the ignition system or the electronic units can be neglected because an electric current supplied to the sensor can be decreased 5 5 2 PRINCIPLE OF SENSING OIL LEVEL There is a great difference between electric resistance of air and that of oil Since the resistance of air is far higher than that of oil more electric current passes through the oil than through the air although absolute value of the current is very small The sensor detects this current difference and make use of it The sensor judges the oil quantity by comparin
39. perty Dam age Mechanical Failure Severe Injury Ur Death Know how to stop the engine quickly and understand the operation of all controls SAFETY WARNINGS Never permit anvone to operate the generator set without proper instructions Never allow children to operate the generator set Children and pets must be kept away from the area of operation due to the possibility of burns from hot engine components or injury from any equipment the generator set is powering Alwavs wear eve protection and Hearing protection when working near the generator set Operate the generator set only with the guards shields and other safety items in place and working properly Do not put hands feet tools or other objects near rotating parts Use reasonable care when moving or lifting the unit The generator set mav move around inside the wrap frame creating Pinch Points Do not run the generator set while it is being moved Do not support the generator set from the top of the wrap frame Do not operate the generator set while under the influence of alcohol drugs or medication When transporting or using a generator set with the wheel option secure the unit to prevent it from moving around Do not tamper with or change the engine speed as it has been preset at the factorv for proper operation Keep hands and face away from the carburetor when the air cleaner is being moved A sudden backfire can cause serious burns
40. ps automatically after it runs for about 5 seconds 8 When the engine has been stopped by the oil sensor voltage remained in the electronic circuit prevents the sensor from being re started for 3 seconds after the engine stop Try to re start the engine after 3 seconds or more 6 SAFETY PRECAUTIONS 1 Use extreme caution near fuel A constant danger of explosion or fire exists Do not fill the fuel tank while the engine is running Do not smoke or use open flame near the fuel tank Be careful not to spill fuel when refueling If spilt wipe it and let dry before starting the engine 2 Do not place inflammable materials near the generator Be careful not to put fuel matches gunpowder oily cloth straw and any other inflammables near the generator 3 Do not operate the generator in a room cave or tunnel Always operate in a well ventilated area Otherwise the engine may overheat and also the poisonous carbon monoxide contained in the exhaust gases will endanger human lives Keep the generator at least 1 m 4 feet away from structures or facilities during use 4 Operate the generator on a level surface If the generator is tilted or moved during use there is a danger of fuel spillage and a chance that the generator may tip over 5 Do not operate with wet hands or in the rain Severe electric shock may occur If the generator is wet by rain or snow wipe it and thoroughly dry it before starting Don t pour water o
41. s have checked the sensor is wrong Replace the sensor with new one 10 DISASSEMBLY AND ASSEMBLY 10 1 PREPARATION and PRECAUTIONS 1 Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly Tag the disassembled part with the necessary information to facilitate easier and smoother reassembling 2 For more convenience divide the parts into several groups and store them in boxes 3 To prevent bolts and nuts from being misplaced or installed incorrectly place them temporarily back at their original position 4 Handle disassembled parts with care clean them before reassembly using a neutral cleaning fluid 5 Use all disassembly assembly tools properly and use the proper tool for each specific job 10 2 DISASSEMBLY PROCEDURES 1 Side cover 1 Remove the side cover by unscrewing Plus screw four M5 X 8 screws See Fig 10 1 driver Rear cover 1 Remove the rear cover by unscrewing Plus driver three MS X 8 screws and two M8 X 10 screws See Fig 10 2 M5 x M8 x 10 Screws Screws Fig 10 1 I Fig 10 2 Controlpanel 1 Pull the knob off the control lever and Plus driver remove the control panel by unscrewing four M5 X 8 screws See Fig 10 3 Fig 10 3 Couplers 1 Disengage the couplers of stator wires Pull the couplers while and plugs from the wires of control panel pushing the lockin
42. set may impair the function and or safety of the unit Do not operate the generator set without a muffler Inspect periodicallv and replace if necessarv Do not touch the hot exhaust components or the high voltage spark plug and coil terminals While Spark Plug Voltages are not normally lethal an involuntary jerk of the hand caused by a hot surface or by an electrical shock can result in injury Repair of electrical generating equipment requires specialized skills Repair personnel must have a thorough understanding of generator and small engine repair procedures AW WARNING IA Exhaust Fumes Gases Are Extremely Dangerous And Can Cause Illness Or Death Never inhale exhaust gases Thev contain carbon monoxide a colorless odorless and extremelv dangerous gas that can cause unconsciousness or death Svmptoms of carbon monoxide poisoning can include dizziness nausea headaches sleepiness vomiting or incoherency If you or anyone else experiences any of these symptoms get out into the fresh air immediately Shut the unit down and do not operate it until it has been inspected and if necessary repaired Never Operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave CALIFORNIA PROPOSITION 65 WARNING engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm iN WARNING AN Improper Operation Can Result In Pro
43. t magneto built in flywheel start rotating power is generated in the primary coil of the ignition coil and current flows to the resistor From the resistor current flows the power transistor With this current the power transistor turns on releasing current b This stage corresponds to the closing of contact points As the flywheel comes to the point of ignition timing detecting circuit is activated while the current is flowing through the circuit When the ignition timing detecting circuit is activated the signal transmitter transistor actuates with current flowing When current starts flowing current flowing through the power transistor is cut quickly As a result high voltage is produced in the secondary coil and this voltage is applied simultaneously to the spark plug which ignites for ignition This stage corresponds to the opening of contact points 2 6 ke C Q O v e a sss e 2 Ignition timing K G a 5 s circui 5 853 c O L GE n a G Q Oss i Fig 5 9 Flywheel cooling fan Ignition coil Primary coil Secondary coil M Spark plug w 5 5 OIL SENSOR OPTION 5 5 1 DESCRIPTION e The oil sensor mainly functions to detect position of the surface of engine oil in the crankcase of engines for general use and to stop the engine automatically when the oil level goes down below the lower limit specified This prevents seizure of engine from
44. t rubbers from rear cover Wrench See Fig 10 16 Plastic mallet Mount rubber Fig 10 15 Fig 10 16 12 Stator 1 Remove the stator cover See Fig 10 17 2 Pull off the stator from the front cover Never tap on the tapping the core with a plastic mallet winding and the lead See Fig 10 18 Plastic mallet Stator cover aN lt AL u Na Nie c g Z Z x ie HUN N i ir J JI SWALI L Ra r 1 EST Fig 10 17 Fig 10 18 Stator Stator cover Stator Fig 10 20 13 Rotor 1 Take off the through bolt Box wrench Apply a box wrench on the head of Plastic hammer w through bolt Hit the wrench handle with a hammer counter clockwise to loosen Fig 10 21 2 Put the engine on the working table recoil starter side down 3 Use a bolt and oil as a tool for pulling out rotor in the following procedures w 1 Pour engine oil into the center hole of rotor shaft Fill with oil to the shaft end See Fig 10 22 2 Prepare a bolt with the following thread size M8 X P 1 25 3 Applv a few turns of seal tape around the tip of the bolt See Fig 10 23 Sea tape Fig 10 23 Rotor 4 Screw the bolt into the thread of the rotor shaft 5 Torque the bolt using a socket wrench until the rotor comes off loose The hydraulic pressure inside the rotor shaft takes apart the rotor from the engine shaft 4 Wipe off oil throu
45. the crankcase For that reason the sensor has an electronic timer circuit to prevent it from interpreting as short of oil when amount of oil is sufficient The sensor has been designed so that the engine is to be stopped only when oil shortage is detected for 5 seconds uninterrupted The timer employs an integration circuit and it is to be reset when the inner electrode is soaked in the oil again before the sensor decides it as oil shortage The oil level where the sensor decides as oil shortage when oil level goes down gradually is called threshold level Automatic stop of engine When the sensor decides as oil shortage it makes the engine to stop running automatically for protection of engine Once the stopping circuit is activated it keeps functioning until it confirms that the engine has made a complete stop then the circuit stops functioning automatically 5 5 4 BLOCK DIAGRAM OF THE CIRCUIT Power circuit Igniter LED indicator inner pote Detection L ar circuit CC Oil Outer pole Engine ground Fig 5 11 UD Power circuite This rectifies a part of power to the igniter and regulates it to supplv the stabilized power to necessary circuits Detection circuit This detects quantity of oil sufficient or not according to difference of electric resistance across inner and outer electrodes 8 Delay circuit This prevents the sensor from making an unnecessary stop of the engine by
46. the generator output voltage will reach to the rated value 5 3 2 VOLTAGE FLUCTUATIONS UNDER LOAD When the output current flows through the main coil to the appliance a magnetic flux is produced and serves to increase current in the condenser coil When current increases the density of magnetic ay flux across the rotor core rises As a result the current flowing in the field coil increases and the generator output voltage is prevented from decreasing 9 5 3 3 DC OUTPUT DC output is taken out from the DC coil and is fed to the diode stack rectifier where the output undergoes full wave rectification and is then supplied to the load The diode works to allow the current to flow in the direction 8 but does not allow the current to flow in the direction as shown in Fig 5 8 1 Fig 5 8 1 Fig 5 8 2 shows the DC output circuit of the gener D ator DC voltage is generated in the DC coil When the voltage in A is higher than that in C the current flows in the direction shown in the figure while no current flows between B and C because the current is cut off by the diodes D TER On the contrary when the voltage in is higher than coil B that in A the current flows in the direction as shown in the figure No current flows between A and B because the current is cut off by the diodes D U Ia OOO OC TA D2 Fig 5 8 2 As a result the voltage generated at the output termina
47. the right size generator it is necessary to add the total wattage of all appliances to be connected to the unit Refer to the followings to calculate the power consumption of each appliance or equipment by its type 1 2 3 4 Incandescent lamp heater etc with a power factor of 1 0 Total power consumption must be equal to or less than the rated output of the generator Example A rated 1000W generator can turn ten 100W incandescent lamps on Fluorescent lamps Motor driven tools light electrical appliances etc with a smaller power factor Select a generator with a rated output equivalent to 1 2 to 2 times of the power consumption of the load Generally the starting wattage of motor driven tools and light electrical appliances are 1 2 to 3 times lager than their running wattage Example A rated 250W electric drill requires a 400W generator to start it NOTE 1 If a power factor correction capacitor is not applied to the fluorescent lamp the more power Shall be required to drive the lamp NOTE 2 Nominal wattage of the fluorescent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption efficiency should be taken into account as explained in item 5 on the following page Mercury lamps with a smaller power factor Loads for mercury lamps require 2 to 3 times the indicated wattage during start up Example A 400W mercury lamp r
48. the terminals in one combination of polar ity Therefore if no resistance reading appears try checking in reverse polarity If the circuit tester is not sufficiently accu rate it may not show the values given and may give erroneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when meas urement is performed at ambient tem peratures different from 20 C 68 F 2 Measure the resistance of the resister 9 4 CONDENSER E Use a Dr Robin in capacitance meter mode to check the capacity of condensers See Fig 9 6 w NOTE Be sure to discharge condensers by short ing condenser leads each other before checking their capacitance or the accurate reading cannot be obtained Normal Capacity of Condenser Fig 9 6 B If such an instrument is unavailable the condenser can be checked by replacing with a new one If the generator performs good with new condenser the cause of trouble is defect in original condenser 9 5 DIODE RECTIFIER Red Green l a Green Green Green Fig 9 7 Diode rectifier Fig 9 8 l d The internal circuit of the diode rectifier is as shown in Fig 9 7 Check continuity between each terminal using a circuit tester as shown in Fig 9 8 B Checking table for analogue circuit tester Apply black CQneedie of the circult tester ofthe ciroult tester nu GIE of the circult tester No continuitv Table 9 2 1
49. tive working order by the operator Operation inside an enclosed compartment or building is a potential fire hazard and should not be done unless approval is obtained from Baldor Generators Engine Generator overheating can cause severe damage due to restricted obstructed or improper airflow that is necessarv for the proper cooling of the unit Hot exhaust gases being discharged by the engine must never be directed toward anything that could catch fire or explode CONTENTS Section Title Page 1 SPECIFICATIONS Brushless self exciting 2 pole single phase f AC Voltage Rated current 120V 8 3 A Max 1300 W AC Output Rated 1000 W DC Output 12V 8 3A 100 W Voltage regulation system Condenser system Tvoe i Forced Air cooled 4 Stroke Side Valve yp Gasoline Engine Fuel i Automotive Gasoline unleaded Starting svstem Recoil starter Dimensions L X W X H 19 3 x 11 3 x 16 1in 490 x 288 x 410mm Dry weight 60 6 Ibs 27 5 kg Specifications are subject to change without notice 2 PERFORMANCE CURVES 2 1 AC OUTPUT Output Max AET TE yas 1300W 1 Rated ere ee ree ee ENEN 1000W Frequency A AL 60Hz gt Voltage Coco reeeeseseseraugserereseone 120V G 60Hz 120V 8 3A lt al 5 gt T 8 E x Q 8 G a LL 1 2 3 4 5 6 7 8 9 10 H 120 CURRENT A 2 2 DC OUTPUT DC Voltage center oe m 12V DC Ampere ea
50. ver the generator directly nor wash it with water If the generator is wet with water the insulations will be adversely affected and may cause current leakage and electric shock 6 Do not connect the generator to the commercial power lines This may cause a short circuit or damage to the generator Never connect the generator to the existing house wiring If connected the generator will burn out when the commercial power source is recovered 7 Don t operate the generator with its cover removed The operator may be injured or suffer electric shock CAUTION If the circuit breaker tripped off as a result of using an electrical appliance the cause can be an overload or a short circuit In such a case stop operation immediately and carefully check the electrical appliance and plugs for faulty wiring 7 RANGE OF APPLICATIONS 7 1 AC OUTPUT Generally the power rating of an electrical appliance indicates the amount of work that can be done by it The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance The electrical appliances generally have a label showing their rated voltage frequency and power consumption input wattage The power consumption of an electrical appliance is the power necessary for using it When using a generator for operating an electrical appliance the power factor and starting wattage must be taken into consideration In order to determine
51. y Table 7 3 7 2 3 BATTERY CAPACITY The battery capacity is expressed in the unit of AH ampere hour One AH stands for the capacity capable of one ampere current for one hour 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1 Dr ROBIN GENERATOR TESTER The Dr Robin generator tester is exclusively de signed for fast easy diagnosis and repair of Robin generators The Dr Robin has the following features 1 Functions of voltmeter frequency meter meg ger tester capacitance meter and circuit tester are combined in one unit 2 Fast and easy readout by digital indicator 3 Built in automatic battery checker indicates the time to change batteries Fig 8 1 4 Tester and accessories are installed in a handy sturdy case for easy carrying 6 SPECIFICATIONS m a mmm Test leads with needle probes 1 set Measuring Range Accessories ee d es Weight Table 8 1 The Dr Robin generator tester can be ordered from Robin generator distributors by the following part number Dr Robin Part Number 388 47565 08 If you do not have a Dr Robin generator tester use the instruments described in the following section for checking generator parts 8 1 2 INSTRUMENTS 1 VOLTMETER AC voltmeter is necessary The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows Oto 150
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