Baldor BALDOR GENERATORS manual

REVISED/EFFECTIVE MA Y 1, 2003 C:ISO9001FORMSSPSG–002–48msw FORM#: S–PSG–002–48 PRESENTS YOUR BALDOR GENERA T ORS 3815 OREGON STREET OSHKOSH WI 54902 PHONE: 920–236–4200 F AX: 920–236–4219[...]

T OW ABLES OPERA T OR’S MANUAL T able of Contents ACCESSORIES AND EQUIPMENT WITH THIS GENERA TOR SET INCLUDES: ITEM P AGE SAFETY RECOMMENDA TIONS: These recommendations must be read and followed 1 to safely operate your generator set. VOL T AGE RA TINGS: This informational page describes features and specifications for 7 all T owable Units. ELECT[...]

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SAFETY W ARNINGS Revised: 8/13/02 Page 1 of 4 FORM#: S – PSG – 001 – 3 Effective: 2/27/98 C:ISO9001FORMSSPSG0013.msw .bbk 1 z Place protective covers and guards over the rotating parts, if rotating parts such as the drive shaft, pulley , belt, etc. are left exposed, they are potentially hazardous. z When cleaning, repairing or inspecting, [...]

SAFETY W ARNINGS Revised: 8/13/02 Page 2 of 4 FORM#: S – PSG – 001 – 3 Effective: 2/27/98 C:ISO9001FORMSSPSG0013.msw .bbk 2 z Never permit anyone to operate the generator set without proper instructions. z Never allow children to operate the generator set. z Children and pets must be kept away from the area of operation due to the possibil[...]

SAFETY W ARNINGS Revised: 8/13/02 Page 3 of 4 FORM#: S – PSG – 001 – 3 Effective: 2/27/98 C:ISO9001FORMSSPSG0013.msw .bbk 3 z Always treat the electrical circuits as if they were energized. z Disconnect all leads plugged into the unit Prior to working on it. z Have the electrical circuits serviced only by qualified technicians. z Inspect w[...]

SAFETY W ARNINGS Revised: 8/13/02 Page 4 of 4 FORM#: S – PSG – 001 – 3 Effective: 2/27/98 C:ISO9001FORMSSPSG0013.msw .bbk 4 ```` FOR GASOLINE OR DIESEL POWERED GENERA T OR SETS ```` z Check all fuel supply piping and their connections on a monthly basis for fuel leaks. z Use only approved piping and componentry in your fuel supply system. [...]

Effective: February 26, 1998 Revised 2/01/02 Form#: S – CSD – 003 – 7 C:ISO9001FORMSSCSD0037.MSW 5 FOR W ARD 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. Never operate this generator set[...]

Effective: February 26, 1998 Revised 2/01/02 Form#: S – CSD – 003 – 7 C:ISO9001FORMSSCSD0037.MSW 6[...]

7 Features & Specifications Model TS25 TS45 TS80 TS130 TS175 Standby output – 150 0 C Rise (KV A/KW) : 3 PH @ 480 V olt 25/20 48/38 81/65 134/107 175/140 3 PH @ 208/240 V olt 25/20 46/37 72/58 131/105 169/135 1 PH @ 240 V olt 18/18 27/27 45/45 70/70 80/80 Continuous Output – 125 0 C Rise (KV A/KW): 3 PH @ 480 V olt 23/18 44/35 75/60 121/97 [...]

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A V AILABLE V OL T AGE: SWITCH POSITION STUD 277/480 1 – 2 – 3 = 480 V AC, 3 Phase 1 – N, 2 – N, 3 – N = 277 V AC, 1 Phase 120/240 1 – 2 – 3 = 240 V AC, 3 Phase 2 – 3 = 240 V AC, 1 Phase 2 – N, 3 – N = 120 V AC, 1 Phase 1 – N = 180 – 200 V AC, Wild Leg 120/208 1 – 2 – 3 = 208 V AC, 3 Phase 2 – 3 = 208 V AC, 1 Phase 1 ?[...]

10 CONNECTION INFORMA TION Y our new Baldor Generator has all interconnecting wiring terminated at a junction box. All wiring will be clearly labeled as being load; remote start contacts and AC input terminals and are to be connected as described below . Load – These connections are rated and sized according to the KW of the generator . Proper le[...]

11 CONTROL P ANEL OPERA TION AND FUNCTION A. MASTER CONTROL SWITCH – This switch controls the starting and stopping of the engine via the engine control logic circuitry . W ith this switch in the “ Manual ” mode, the engine will start and run immediately after a 10 – 20 second time delay . CAUTION: Please note that once the engine has been [...]

12 E. VOL T AGE ADJUST – The rheostat allows the user to “ fine tune ” the generator set ’ s voltage output. It is normally used to adjust output voltage after switching the output of the generator set to a different voltage. F . METERS – These meters monitor and display the current operating parameters of the generator set. The V oltmete[...]

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14 OPERA TION – PRE – ST AR T PROCEDURE 1. Fill system fuel tank with clean, fresh diesel fuel. CAUTION: W ipe up any and all fuel spillage. 2. Fill engine crankcase to full mark with clean, fresh lubricating oil per attached engine operating guide. 3. Radiator coolant should be checked at the beginning of each day and filled in compliance with[...]

15 OPERA TION – ST AR TING 1. Conduct ‘ Pre – start Procedures. 2. Switch the generator set to the applicable voltage setting. 3. Connect the load(s) to the circuit breaker . W ARNING: High voltage is present when the generator set is running. 4. Move the ‘ Master Control Switch ” to the appropriate position. 5. Adjust the voltage if nece[...]

16 OPERA TION The prime mover utilized in this power generating system is controlled via an engine control module. Starting is accomplished by commanding the control to ” start ” the engine. This command can be given by a number of controls. ? The operator control mounted on the front panel. ? The remote controls via the transfer switch or remo[...]

17 3. Over – speed Adjustment – (OS) – Over Frequency Over – speed protection is provided by a frequency sensing network within the controller . The trip point of the frequency network is adjustable via a rheostat located on the top of the controller at the right hand side. Clockwise (CW) rotation increases the trip frequency and, thereby ,[...]

18 TROUBLESHOOTING – GENERA TOR As with any machine, trouble may develop in electrical generators. It may be due to long service or neglect of regular maintenance. Servicing, and checking. Should trouble develop, the follow- ing instructions will be helpful in tracing the cause and making repairs. SPEED DEVIA TIONS: The generator speed should be [...]

19 LOW VOL T AGE (Continued) CAUSE CHECK AND REMEDY High resistance connections – Make better connection electrically and Connections will be warm or hot mechanically . Shorted field. T est field coils for possible short by checking resist- ance with an ohmmeter or resistance bridge. Re- turn rotor assembly to factory for repair if alternator fie[...]

20 OVERHEA TING (continued) CAUSE CHECK AND REMEDY High room temperature. Improve ventilation. Insufficient circulation. Provide cross – ventilation. Low power factory . Reduce inductive loads or install power factor im- provement capacitors. Unbalanced load The load on each leg should be as evenly balanced as possible and should not exceed the r[...]

21 TROUBLESHOOTING – ENGINE CODE LIST OF POSSIBLE CAUSES 1. Battery capacity low . 33. Piston rings not free or are worn or broken. 2. Bad electrical connections. 34. V alve stems and/or guide worn. 3. Fault in starter motor . 35.West type air cleaner too full or wrong oil used. 4. Fault in starter motor . 36. Crankshaft bearings worn or damaged.[...]

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M M A A G G N N A A P P L L U U S S G G E E N N E E R R A A T T O O R R 2 2 8 8 0 0 - - - - 4 4 3 3 0 0 F F r r a a m m e e I I n n s s t t a a l l l l a a t t i i o o n n , , O O p p e e r r a a t t i i o o n n a a n n d d M M a a i i n n t t e e n n a a n n c c e e M M a a n n u u a a l l M M a a r r a a t t h h o o n n E E l l e e c c t t r r i [...]

2 2 T T A A B B L L E E O O F F C C O O N N T T E E N N T T S S S S A A F F E E T T Y Y .............................................................................................................................................................................................. 4 4 R R E E C C E E I I V V I I N N G G A A N N D D S S T T O O R R A A[...]

3 3 R R E E T T U U R R N N E E D D G G O O O O D D S S ...................................................................................................................................................................... 1 1 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G ...........................................................[...]

4 4 S S A A F F E E T T Y Y P P L L E E A A S S E E R R E E M M E E M M B B E E R R S S A A F F E E T T Y Y F F I I R R S S T T . . I I f f y y o o u u a a r r e e n n o o t t s s u u r r e e o o f f t t h h e e i i n n s s t t r r u u c c t t i i o o n n s s o o r r p p r r o o c c e e d d u u r r e e s s c c o o n n t t a a i i n n e e d d h h e [...]

5 5 P P R R I I N N C C I I P P L L E E S S O O F F O O P P E E R R A A T T I I O O N N Rotating Assembly Main Field (rotor) (+) (-) DC (in) Rotating Rectifier Assembly 3 Phase -- Full Bridge Exciter Armature (rotor) 3 Phase AC (out) DC (in) (+) (-) Automatic Voltage Regulator Exciter Field (stator) N S PMG Field (rotor) PMG Armature (stator) PMG ([...]

6 6 P P R R I I N N C C I I P P L L E E O O F F O O P P E E R R A A T T I I O O N N M M a a g g n n a a P P L L U U S S g g e e n n e e r r a a t t o o r r s s a a r r e e a a b b r r u u s s h h l l e e s s s s , , s s e e l l f f e e x x c c i i t t e e d d , , a a n n d d e e x x t t e e r r n n a a l l l l y y v v o o l l t t a a g g e e r r e [...]

7 7 W W A A R R N N I I N N G G D D I I S S A A B B L L E E A A N N D D L L O O C C K K O O U U T T A A N N Y Y E E N N G G I I N N E E C C R R A A N N K K I I N N G G D D E E V V I I C C E E S S B B E E F F O O R R E E A A T T T T E E M M P P T T I I N N G G T T O O I I N N S S T T A A L L L L O O R R S S E E R R V V I I C C E E T T H H E E G G E [...]

8 8 E E N N V V I I R R O O N N M M E E N N T T A A L L C C O O N N S S I I D D E E R R A A T T I I O O N N S S T T h h e e M M a a g g n n a a P P L L U U S S g g e e n n e e r r a a t t o o r r i i s s d d e e s s i i g g n n e e d d f f o o r r h h e e a a v v y y - - d d u u t t y y i i n n d d u u s s t t r r i i a a l l a a p p p p l l i i c [...]

9 9 L L O O W W W W Y Y E E C C O O N N N N E E C C T T I I O O N N L 2 T 7 T 10 T 1 T 4 L 1 L 3 T 5 T 2 T 11 T 8 T 6 T 3 T 12 T 9 L - L L - N VOLTAGE (LOW WYE ) Hz L-L L-N 60 240 139 230 133 220 127 208 120 190 110 50 208 120 200 115 190 110 H H I I G G H H D D E E L L T T A A C C O O N N N N E E C C T T I I O O N N L 1 L 2 L 3 T 1 T 4 T 7 T 10 T [...]

1 1 0 0 D D O O U U B B L L E E D D E E L L T T A A - - - - S S I I N N G G L L E E P P H H A A S S E E C C O O N N N N E E C C T T I I O O N N T 3 L 1 L 2 T 1 T 4 T 7 T 10 T 6 T 5 T 2 T 12 T 9 T 11 T 8 L - N L - N L - L VOLTAGE ( DOUBL E DE L TA ) Hz L-L L-N 60 240 120 220 110 50 220 110 N N o o t t e e : : S S i i n n g g l l e e - - p p h h a a [...]

1 1 1 1 D D E E D D I I C C A A T T E E D D S S I I N N G G L L E E P P H H A A S S E E C C O O N N N N E E C C T T I I O O N N VOLT AGE (DEDICA T ED) Hz L-L L-N 60 240 120 220 110 50 220 110 200 100 O O P P E E R R A A T T I I O O N N P P R R E E - - S S T T A A R R T T I I N N S S P P E E C C T T I I O O N N B B e e f f o o r r e e s s t t a a r [...]

1 1 2 2 6 6 . . T T h h e e p p u u r r p p o o s s e e o o f f t t h h i i s s i i n n i i t t i i a a l l t t e e s s t t w w i i t t h h t t h h e e r r e e g g u u l l a a t t o o r r o o u u t t o o f f t t h h e e c c i i r r c c u u i i t t i i s s t t o o d d e e t t e e c c t t a a n n y y w w i i r r i i n n g g m m i i s s t t a a k k e [...]

1 1 3 3 D D R R Y Y I I N N G G W W I I N N D D I I N N G G S S G G e e n n e e r r a a t t o o r r s s i i n n s s e e r r v v i i c c e e m m a a y y i i n n a a d d v v e e r r t t e e n n t t l l y y h h a a v v e e t t h h e e i i r r w w i i n n d d i i n n g g s s e e x x p p o o s s e e d d t t o o s s p p l l a a s s h h i i n n g g o o r [...]

1 1 4 4 I I n n s s u u l l a a t t i i o o n n T T e e s s t t I I n n s s u u l l a a t t i i o o n n r r e e s s i i s s t t a a n n c c e e i i s s a a m m e e a a s s u u r r e e o o f f t t h h e e i i n n t t e e g g r r i i t t y y o o f f t t h h e e i i n n s s u u l l a a t t i i n n g g m m a a t t e e r r i i a a l l s s t t h h a a t [...]

1 1 5 5 C C A A U U T T I I O O N N : : F F a a i i l l u u r r e e t t o o r r e e m m o o v v e e t t h h e e e e x x c c i i t t e e r r f f i i e e l l d d l l e e a a d d s s f f r r o o m m t t h h e e a a u u t t o o m m a a t t i i c c v v o o l l t t a a g g e e r r e e g g u u l l a a t t o o r r d d u u r r i i n n g g f f l l a a s s h [...]

1 1 6 6 4 4 3 3 0 0 F F R R A A M M E E 2 2 8 8 0 0 / / 3 3 6 6 0 0 F F R R A A M M E E A A - - E E x x c c i i t t e e r r R R o o t t o o r r L L e e a a d d , , B B - - M M a a i i n n R R o o t t o o r r L L e e a a d d , , C C - - R R e e d d ( ( + + ) ) S S u u p p p p r r e e s s s s o o r r L L e e a a d d , , D D - - B B l l a a c c k k ( [...]

1 1 7 7 W W A A R R N N I I N N G G H H I I G G H H V V O O L L T T A A G G E E S S M M A A Y Y B B E E P P R R E E S S E E N N T T A A T T T T H H E E G G E E N N E E R R A A T T O O R R ’ ’ S S T T E E R R M M I I N N A A L L S S W W H H E E N N T T H H E E U U N N I I T T I I S S R R U U N N N N I I N N G G . . S S O O M M E E A A C C C C E [...]

1 1 8 8 G G E E N N E E R R A A T T O O R R P P R R O O D D U U C C E E S S L L O O W W V V O O L L T T A A G G E E W W H H E E N N L L O O A A D D A A P P P P L L I I E E D D C C A A U U S S E E C C H H E E C C K K A A N N D D R R E E M M E E D D Y Y E E x x c c e e s s s s i i v v e e l l o o a a d d R R e e d d u u c c e e l l o o a a d d . . T [...]

1 1 9 9 G G E E N N E E R R A A T T O O R R B B U U I I L L D D S S V V O O L L T T A A G G E E F F R R O O M M S S T T A A R R T T U U P P , , T T H H E E N N G G O O E E S S T T O O L L O O W W ( ( R R E E S S I I D D U U A A L L ) ) V V O O L L T T A A G G E E C C A A U U S S E E C C H H E E C C K K A A N N D D R R E E M M E E D D Y Y R R e e g [...]

2 2 0 0 S S P P E E C C I I F F I I C C A A T T I I O O N N S S E E X X C C I I T T E E R R F F I I E E L L D D N N O O L L O O A A D D T T E E R R M M I I N N A A L L V V O O L L T T A A G G E E M M O O D D E E L L G G E E N N E E R R A A T T O O R R R R E E S S I I S S T T A A N N C C E E N N O O L L O O A A D D V V O O L L T T S S W W I I T T H [...]

2 2 1 1 P P A A R R T T S S L L I I S S T T – – S S I I N N G G L L E E B B E E A A R R I I N N G G T T y y p p i i c c a a l l G G e e n n e e r r a a t t o o r r C C r r o o s s s s S S e e c c t t i i o o n n R R e e f f e e r r e e n n c c e e N N u u m m b b e e r r P P a a r r t t N N a a m m e e R R e e f f e e r r e e n n c c e e N N u [...]

2 2 2 2 S S B B 5 5 0 0 4 4 2 2 / / 9 9 4 4 ( ( R R e e v v i i s s e e d d 8 8 / / 9 9 8 8 ) ) P P A A R R T T S S L L I I S S T T – – D D U U A A L L B B E E A A R R I I N N G G T T y y p p i i c c a a l l G G e e n n e e r r a a t t o o r r C C r r o o s s s s S S e e c c t t i i o o n n R R e e f f e e r r e e n n c c e e N N u u m m b b e [...]

T able 1 – Hitch T owing Capacity Hitch Maximum Maximum Normally Class T owing Cap. T ongue Wt. Installed Sub Class I 1000 Lbs. 100 Lbs Foreign or U.S. Sub– compact vehicles Class I 2000 Lbs. 200 Lbs. Compact V ehicles Class II 3500 Lbs. 300 Lbs. Mid–size & Full Size V ehicles Class III 5000 Lbs. Plus 500 Lbs. Plus Full Size V ehicles, Pi[...]

24 ELECTRICAL TRAILER WIRING All trailers must have taillights, brake lights and turn signals connected in with the towing ve- hicle’ s electrical system. It is also recommended that a heavy – duty turn signal flasher be installed since the trailer lights place an extra load on the car flashers. TOWING HEA VY TRAILER LOADS 1. T railer brakes ?[...]

25 SAFETY CHECKS The following items should be checked before each use and once every 100 miles of towing: (1) Check lighting to be sure stop, tail and turn signals are working properly. Replace any broken lenses, reflectors or bulbs. (2) Check wires for good connections and possible fraying or wearing of insulation. (3) Check and properly maintain[...]

26 TRAILER LIGHT KIT WIRING INSTRUCTIONS Connect the wires of the short trunk connector to the vehicle wiring. Connect the brown wire to the tail light wire, the yellow wire to the left – hand stop and turn, and the green wire to the right– hand stop and turn wire. Attach the white ground wire to the vehicle frame. If vehicle has rear turn sign[...]

27 Limited W arranty Unless otherwise provided, Baldor generators are warranted against defects in Baldor workmanship an d materials for a period of time as set forth in the W arranty Period chart below . I f a Baldor product is defective due to Baldor workmanship or materials and the defect occurs during the warranty period, then Baldor will eithe[...]

28 Limited W arranty Continued Notes for W arranty Period: 1. Labor coverage for warrantable repairs is provided for the applicable period not to exceed published rates as contained in the Baldor Generators W arranty Policy . Mileage is allowed only for permanent installations not to exceed published rates as contained in the Baldor Generators W ar[...]

29 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 . 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 followin[...]

30 W ARNING: CALIFORNIA PROPOSITION 65 W ARNING: Engine exhaust from this product contains chemicals known to the state of California to cause cancer , birth defects and other reproductive harm. W ARNING: CALIFORNIA PROPOSITION 65 W ARNING: Diesel engine exhaust and some constituents are known to the state of California to cause cancer , birth defe[...]