Diesel POWR Products Generator

DG3E and DG6E

Installation & 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Owners Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3 Receiving & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use of Electric Motor Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Wheel Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Engine Oil and Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PreStart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . StartUp Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5 Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A DG Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-2 1-6 2-1 2-1 2-2 2-2 3-1 3-1 3-1 3-1 3-2 3-2 3-2 3-3 3-4 3-4 3-5 3-6 3-6 4-1 4-1 4-2 4-2 4-2 4-2 5-1 5-1 5-2 A-1 A-1 A-2 A-3

MN2414

Table of Contents i

ii Table of Contents

MN2414

Section 1 Product Safety Information

Safety Notice 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 cause 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 startup 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 startup procedure or troubleshoot this equipment. System documentation must be available to anyone that operates this equipment at all times. 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. It is the responsibility of the owner/operator of 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.

Responsibility

Read This Manual Thoroughly 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.

MN2414

Product Safety Information 1-1

Precaution Statements Used In This Manual 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: WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in injury or death. Caution: Indicates a potentially hazardous situation which, if not avoided, could result in damage to property. Note: 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, Installation, and Maintenance. Operation 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. WARNING: 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. WARNING: 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. WARNING: 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. WARNING: 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. WARNING: 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 cause serious or fatal injury. WARNING: 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. WARNING: Hot exhaust gasses must never be directed toward anything that may catch fire or explode. WARNING: This generator must not be used on or near any forest covered, brush covered, or grass covered land unless the engines exhaust system is equipped with a spark arrestor. The spark arrestor must be maintained in effective working order by the operator. WARNING: 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. WARNING: Never move a 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: 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. WARNING: Always wear safety glasses with side shields and hearing protection when working near the generator. WARNING: Improper operation may cause violent motion of connected equipment. Be certain that unexpected movement will not cause injury to personnel or damage to equipment. WARNING: 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. WARNING: 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. WARNING: Never allow children or pets to be in the area where the generator is running. The generator and the equipment being powered by the generator may cause injury or death. WARNING: Never operate the generator unless all guards, covers, shields and other safety items are properly installed. WARNING: 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. WARNING: 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. WARNING: Never operate the engine when the air cleaner is removed. An engine backfire can cause serious burns. WARNING: 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. WARNING: 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. WARNING: 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. WARNING: Do not smoke near generator during operation or while refueling. Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death. WARNING: Stop engine and allow engine to cool before refueling. Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death. WARNING: 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. WARNING: Allow generator to cool before transporting it or storing it. Always drain fuel from tank after generator has cooled. WARNING: 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. WARNING: 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. WARNING: Keep generator at least three feet away from buildings and other structures. WARNING: Keep generator away from flammable or hazardous materials (trash, rags, lubricants, explosives, paints etc.) and grass or leaf build up. WARNING: Keep a fire extinguisher near the generator while generator is in use. An extinguisher rated ABC by the National Fire Protection Association is appropriate. Continued on next page. MN2414 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. 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. 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 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 (GFCI) 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 shutoff 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 WARNING: Before servicing the generator set, be sure to disconnect the battery terminals to prevent accidental engine rotation or starting. WARNING: 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. WARNING: 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. WARNING: 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. WARNING: 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. WARNING: 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. WARNING: Do not mutilate the battery or dispose of a battery 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: 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. WARNING: 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. WARNING: 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. WARNING: 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 serious or fatal injury. 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.

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Product Safety Information 1-5

Caution Statements 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. Caution: 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. Caution: Do not apply high voltage to windings in a moisturesaturated 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. Caution: Use only original equipment or authorized replacement parts. Using the correct parts will assure continued safe operation as designed. Caution: Do not support the generator from the top of the wrap frame. Caution: Do not tamper with or change the engine speed. Engine speed is factory set to produce the correct voltage and output frequency. Caution: 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. Caution: 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. Caution: 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. Caution: 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. 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 engines electrical components may result.

1-6 Product Safety Information

MN2414

Section 2 General Information

Thank you for purchasing your Baldor Generator Set. 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 owners 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 E 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 parts 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 prepaid, 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, nonBaldor 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 PURPOSE 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

Generator Series
Portable Products (Premier, Powerchief, DG Series, K Series) Towable Products (TS)

Labor*
1 Year 1 Year or 3,000 Hours Whichever comes first 1 Year or 3,000 Hours Whichever comes first

Parts
3 Years

3 Years or 3,000 Hours Whichever comes first POWR LITE Light Towers 3 Years or 3,000 Hours Whichever comes first Excluded from any warranty coverage regardless of time period: Light Fixture, Lamps and Ballasts 3600 RPM Standby Systems 1 Year or 1,000 Hours 3 Years or 1,000 Hours (Some AE Models) Whichever comes first Whichever comes first 1800 RPM Standby Systems 1 Year or 3,000 Hours 3 Years or 3,000 Hours (Some AE Models, DLC, GLC) Whichever comes first Whichever comes first Industrial Standby Systems 1 Year or 1,000 Hours 2 Years or 1,000 Hours Whichever comes first Whichever comes first Industrial Prime Power Systems 1 Year or 1,000 Hours 1 Year or 1,000 Hours Whichever comes first Whichever comes first International 1 Year or 1,000 Hours 1 Year or 1,000 Hours Whichever comes first 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 startup inspection form/warranty registration must be completed in its entirety and submitted to Baldor Generators within 30 days of startup to qualify for any warranty consideration.

MN2414

General Information 2-1

2-2 General Information

MN2414

Section 3 Receiving & Installation

Receiving & Inspection When you receive your generator, there are several things you should do immediately.
1. 2. 3. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your system. Verify that the part number of the system you received is the same as the part number listed on your purchase order. If the 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 lbs. Use proper lift equipment and methods to avoid injury. Lift only by the tubular metal frame. Figure 3-1 DG Series Generators

Storage

If you will not be using the generator set for a significant amount of time (3 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 engines crankcase and refill it with clean oil. 4. Provide maintenance to the engine and generator set as described in the engine 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 & 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. The 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 temperature is cool and does not exceed 100F (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 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. All 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. Installation 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 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 generator 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 & Installation MN2414

Electrical Connections Continued Table 3-1 Single Phase Power Receptacle Description
Model Straight 120VAC (20Amp) 2 520R GFCI 120VAC 4 520R GFCI 120VAC Electrical Connection Information (Receptacle Provided at Panel) Twist Lock 120VAC Twist Lock 120/240VAC Twist Lock 120/240VAC (30Amp) (30Amp) (50Amp) 1 L530R 120VAC 1 L1430R 120/240VAC 1 L530R 120VAC 1 L1430R 120/240VAC Rated Watts/ (Full load Amps 120/240) 3300 / (25.0/12.5) 6000 / (50.0/25.0)

DG3E DG6E

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
W (SILVER) G (GOLD) X

NEMA L530R 125V 30A G NEMA 520R 125V 20A X (GOLD)

NEMA L1430R 125/250V 30A

Y (GOLD)

W (SILVER)

Frame Ground Connection 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. 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.

MN2414

Receiving & Installation 3-3

Frame Ground Connection Continued Figure 3-3 Frame Ground Connection

Nut Washer 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 to bring the oil level to full.

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 engines electrical components may result. Battery Connections The 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 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 a grounded metal surface.

Caution:

3-4 Receiving & 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 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 & Nut Battery Tie Down Washers & Nut Battery Tie Down Bolt Battery Rack Battery

Use of Electric Motor Loads Electric motors require much more current (amperes) to start them than to keep them running. Some motors, particularly splitphase motors are very difficult to start and require 5 to 7 times more current to start them. Repulsioninduction type motors are the easiest to start and normally only 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 repulsioninduction type motor, capacitor type motor, or the splitphase 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, Repulsioninduction type, etc.) 3. The 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 & 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 Series DG
MODEL DG3E15.70130 DG6E 15.71520 SUMMER OIL *20W/50 *20W/50 WINTER OIL *5W/20 *5W/20 OIL CAPACITY 1.55 PTS 1.90 PTS RECOMMENDED BATTERY Interstate SP40 Interstate SP40 (AMPS) COLD CRANKING 340 340

3-6 Receiving & Installation

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

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 DG3E, 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 protection 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 520R GDCI Duplex receptacle provides ground fault protection. Rated 125VAC at 20 Amperes. 30 Amps 120 Volts Twist lock NEMA L530R receptacle, rated 125 Volts at 30 Amperes. 30 Amps 120/240 Volts Twist lock NEMA L1430R receptacle rated 250Volts at 30 Amperes. Note: The nominal voltage produced by the generator at each receptacle is 120VAC or 240VAC.

MN2414

Operation 4-1

PreStart Checks Before the engine is started, several things must first be checked. 1. Place the generator set in an open, dry, well ventilated and reasonably level location. 2. If grounding is required for your application, check to make sure your unit is grounded properly (see Section3). 3. Check the engines oil level and add oil if necessary to bring it to the level recommended by the engine manufacturer. 4. Check the fuel level and add fuel to within 1/2 inch of the fill tube if necessary. 5. Open the fuel valve on the fuel tank. 6. Check the fuel system for fuel leaks and repair them prior to starting the engine. Wipe up any fuel spills before starting the engine. 7. Disconnect or turn off all external loads. 8. Make sure all circuit breakers are set (pushed in). 9. Tighten any bolts or nuts that may have loosened due to vibration. 10. Be sure all extension cords are in good condition before starting the generator. Use only U.L. listed extension cords. StartUp Procedure Electric Start 1. Move the engines 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. 2. Move the RUN ON/OFF switch to ON (if equipped). For DG3E, put the Run/Stop lever in the Run position). 3. Press the Start Switch to engage the electric start motor. 4. Do not allow the starter motor to crank for more than 10 seconds at a time. 5. Allow 20 seconds between starter motor cranking attempts. 6. Once the engine has started, release the start switch and do not reengage it. Note: If the engine does not start after a few attempts, smell for fuel near the air cleaner. If there is a significant fuel smell, turn the choke lever off and attempt to start the engine. 7. When the engine starts, turn the engines choke lever to the OFF position. 8. Power is now present at the receptacles. Connect or turn on the loads you wish to operate. Stopping Procedure 1. 2. 3. Disconnect or Turn Off all loads connected to the generator set. Move the RUN ON/OFF switch to OFF (if equipped). For DG3E, put the Run/Stop lever in the STOP position). Turn all fuel valves off.

4-2 Operation

MN2414

Section 5 Troubleshooting and Maintenance

Maintenance This manual contains only very minimal engine maintenance instructions. Refer to the engine manufacturers owners manual for specific engine maintenance instructions for your generator set. Any maintenance instructions or recommendations in the engine owners manual take precedence over any of the following general recommendations. General: 1. Inspect the fuel system for leaks. Replace all defective components immediately. 2. Inspect and replace any fuel line that shows signs of deterioration. 3. Inspect all fuel clamps to ensure they are tight. 4. Make sure the fuel cap fits snugly on the fuel tank and that the fuel tank does not leak. 5. Inspect and clean the battery posts and the associated battery cable terminals. 6. 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. 7. 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. d. Adjust the auto idler speed by moving the electromagnet back and forth in the magnet bracket to achieve an engine RPM of 25002900 with the auto idler switch ON. 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 GFCI receptacle that fails the test. Engine: 1. Clean and/or replace any fuel, oil, and/or air filters per the engine manufacturers guidelines. 2. Check oil level regularly; at least every 5 to 8 operating hours. Maintain the proper oil level. 3. Change the oil as is recommended in the engine manufacturers owners manual. 4. Clean the cooling fins on the engine to keep the engines 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 components. 4. Inspect and replace any control panel components that are broken or not working properly (receptacles, circuit breakers, switches, etc.)

MN2414

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) 2364200. Table 5-1 Troubleshooting Guide
Problem Engine will not start Possible Cause No fuel. Restricted air flow. Dead battery. Fuel or ignition problem Excessive load Debris or dirt buildup on engine Ciruit Breaker tripped or defective. Loss of residual magnetism in exciter field poles. Open in stator windings Defective exciter circuit. Irregular speed (fixed speed mode) Fluctuating speed (fixed speed mode) Loose terminal or load connections Defective bearing (uneven air gap) Low output voltage Low engine speed Excessive load High resistance connections connections will be warm or hot Shorted field Low power factor High output voltage Electrical shock when frame is touched Mechanical noise Excessive speed (fixed speed mode) Static charge. Grounded armature or field coil. Defective bearing Rotor rubbing on stator Remedy Check that fuel valves are ON. Check fuel level in fuel tank. Check/replace air filter. Check that engine switch is in Start position. Remove battery and trickle charge or replace with new battery. Never Jump Start. Refer to engine manual. Remove one or more electrical loads. Remove debris. Clean engine surfaces to allow cooling. Reset 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. 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 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. Check engine for malfunction Ground generator frame at local reference ground (see Section 3). Return to factory for repair 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.

Engine will not crank (electric start) Engine starts but will not run smoothly Engine overheats No output voltage

Output voltage varies

Loose or misaligned coupling

Service

Parts

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. A complete and accurate description of the problem. 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. A 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 manufacturers owners manual.

5-2 Troubleshooting and Maintenance

MN2414

Appendix A DG Series
Information in this Appendix applies to the following Baldor Generators: DG3E and DG6E. 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. Operator Panel Configuration Figure A-1 DG3E Operator Panel
AC VOLTS ELAPSED TIME

120V

120V

120/240V OIL AC BREAKERS

120 Volts NEMA 515R GFCI Receptacle. This ground fault circuit interrupter duplex receptacle is rated at 125VAC, 15 Amps. 120 Volts NEMA L530R Receptacle. Twistlock style receptacle rated for 125VAC, 30 Amps. 120/240 Volts NEMA L1430R Receptacle. Twistlock 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.

OIL Low Oil pressure indicator. Illuminates when oil pressure is low. AC Circuit Breakers. Provide overload protection for the generator set.

Figure A-2 DG6E Operator Panel

120 VOLTS

Elapsed Time. Displays the total run time hours of the generator set. AC Voltmeter. This voltmeter displays the voltage level being produced by the generator set.

ELAPSED TIME 120 VOLTS AC VOLTMETER 120/240 VOLTS

AC Circuit Breakers. Provide overload protection for the generator set. 120 Volts NEMA 515R GFCI Receptacle. This ground fault circuit interrupter duplex receptacle is rated at 125VAC, 15 Amps. 120 Volts NEMA L530R Receptacle. Twistlock style receptacle rated for 125VAC, 30 Amps. 120/240 Volts NEMA L1430R Receptacle. Twistlock style receptacle rated for 125/250VAC, 30 Amps.

AC CIRCUIT BREAKERS 120 VOLTS

MN2414

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. Figure A-3 Alternator Assembly
5 6

10

11
ON

12
OFF

15 1 2 3 14 4 13 7

Figure A-4 Frame Assembly

23

22

21 HB7025A00 HB7025A02 OR HB7025A06

21

HB7025A07 20 RM1088A15 (.3118x0.56) RM1088A36 (.3118x0.75)

Table A-1 Generator Set Parts List

Ref No. 1 1 2 3 4 4 4 5 5 5 6 7 7 10 11 12 12 Part No. HA9139A01 HB6178A00 HA1037A00 61FN3000 61RA0017A00 61RA0015A00 61RA0015A02 61SA0016A07 61SA0021A04 61SA0016A00 61EP3204A01 EH0321A00 EH0322A00 WD1541A33 WD1541A10 WD1541A14 WD1541A15 Description Adaptor Adaptor C" Washer Fan Rotor Assembly (includes bearing) Rotor Assembly (includes bearing) Rotor Assembly (includes bearing) Stator Assembly Stator Assembly Stator Assembly Bearing Bracket (bearing included with rotor) Cover Cover GFCI Duplex Receptacle, 250VAC at 20 Amps, NEMA 520R Receptacle, 125VAC at 30 Amps, NEMA L530R Receptacle, 125/250VAC at 30 Amps, NEMA L1430R Receptacle, 125/250VAC at 20 Amps, NEMA L1420R DG3E X X X X DG6E X X X X X X X X X X X X X X X X

A-2 Premier K Series

MN2414

Table A-1 Generator Set Parts List Continued

Ref No. Not Shown Not Shown Not Shown Not Shown 13 14 15 16 Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown 20 20 20 21 21 21 21 21 22 23 Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Part No. EH0316A00 EH0332A00 EH0434A00L2B EH0435A00L2B WD3201A02 WD3201A00 SP9080 SP9089 DI0176A01 RR0244A00 OC3020F12 OC6030F11 DI081A00 CK0070A01 CK0070A03 CK0070A04 CK0070A05 CK0070A06 TA0000A00 TA0002A02 TA0000A03 TA0002A04 TA0001A00 BA204A02L2B BA205A02L BA0217A00L2B HB7025A00 HB7025A00Z HB7025A02 HB7025A6 HB7025A07 HB7002A11 HB7025A01 RM1088A07 RM1088A36 HB6116A00 HA3187A11 LB0094C02 LB0094A35 LB0094A90 LB0094A91 LB9606A04 LB9606A06 LB9630A00 LB9639A00 RE5031A01 RE5031A10 Description Control Box (Operator Panel) Control Panel Cover (Operator Panel) Control Box (Operator Panel) Control Panel Cover (Operator Panel) AV Voltmeter (Dual Scale) Hour Meter Idler Switch, 2 position rocker Stop Switch, 2 position rocker Diode Varistor Capacitor, 20MFD / 370V Capacitor, 30MFD / 370V, 90 degree GloLite (RED) Circuit Breaker 15Amp Circuit Breaker 30Amp Circuit Breaker 40Amp Circuit Breaker 50Amp Circuit Breaker 25Amp Fuel Tank Fuel Cap with Gauge Fuel Tank Fuel Cap with Gauge Fuel Valve Base Frame Base Frame Base Frame Engine Mounting Foot Engine Mounting Foot Alternator Mounting Foot Engine Mounting Foot, Left HATZ Engine Mounting Foot, Right HATZ Engine end frame cross member Alternator end frame cross member Vibration Isolator Vibration Isolator Battery Tie Down Battery Tie Down Bolt Decal, Warning Decal, Warning Decal, Starting Decal, Fuel Valve Decal, Baldor Logo, 5.65" Decal, Baldor Logo, 9" Decal, DG3E Decal, DG6E Relay Relay DG3E X X DG6E

X X

X X X X

X X

X X X

X X X X X X X X X X

X X X X X X X X X X X X X X X X X X X X X X X X X X

Wiring Diagrams

Wiring diagrams for these generators are contained on the following pages of this appendix.

MN2414

Premier K Series A-3

Figure A-5 DG3E Wiring Diagram

A-4 Premier K Series

MN2414

Figure A-6 DG3E Wiring Diagram with Low Oil & Remote Start

MN2414

Premier K Series A-5

Figure A-7 DG6E Wiring Diagram

A-6 Premier K Series

MN2414

Baldor District Offices

UNITED STATES ARIZONA PHOENIX 4211 S 43RD PLACE PHOENIX, AZ 85040 PHONE: 6024700407 FAX: 6024700464 CALIFORNIA LOS ANGELES 6480 FLOTILLA COMMERCE, CA 90040 PHONE: 3237246771 FAX: 3237215859 HAYWARD 21056 FORBES STREET HAYWARD, CA 94545 PHONE: 5107859900 FAX: 5107859910 COLORADO DENVER 2520 W BARBERRY PLACE DENVER, CO 80204 PHONE: 3036230127 FAX: 3035953772 CONNECTICUT WALLINGFORD 65 SOUTH TURNPIKE ROAD WALLINGFORD, CT 06492 PHONE: 2032691354 FAX: 2032695485 FLORIDA TAMPA/PUERTO RICO/ VIRGIN ISLANDS 3906 EAST 11TH AVENUE TAMPA, FL 33605 PHONE: 8132485078 FAX: 8132472984 GEORGIA ATLANTA 62 TECHNOLOGY DR. ALPHARETTA, GA 30005 PHONE: 7707727000 FAX: 7707727200 ILLINOIS CHICAGO 1601 FRONTENAC ROAD NAPERVILLE, IL 60563 PHONE: 6308485100 FAX: 6308485110 INDIANA INDIANAPOLIS 5525 W. MINNESOTA STREET INDIANAPOLIS, IN 46241 PHONE: 3172465100 FAX: 3172465110 8004284141 IOWA DES MOINES 1800 DIXON STREET, SUITE C DES MOINES, IA 50316 PHONE: 5152636929 FAX: 5152636515 MARYLAND BALTIMORE 6660 SANTA BARBARA RD. SUITE 2224 ELKRIDGE, MD 21075 PHONE: 4105792135 FAX: 4105792677 MASSACHUSETTS BOSTON 6 PULLMAN STREET WORCESTER, MA 01606 PHONE: 5088540708 FAX: 5088540291 MICHIGAN DETROIT 33782 STERLING PONDS BLVD. STERLING HEIGHTS, MI 48312 PHONE: 5869789800 FAX: 5869789969 MICHIGAN Continued GAND RAPIDS 668 3 MILE ROAD NW GRAND RAPIDS, MI 49504 PHONE: 6167851784 FAX: 6167851788 MINNESOTA MINNEAPOLIS 21080 134TH AVE. NORTH ROGERS, MN 55374 PHONE: 7634283633 FAX: 7634284551 MISSOURI ST LOUIS 422 INDUSTRIAL DRIVE MARYLAND HEIGHTS, MO 63043 PHONE: 3142981800 FAX: 3142987660 KANSAS CITY 915 N W PLATTE VALLEY DR RIVERSIDE, MO 64150 PHONE: 8165870272 FAX: 8165873735 NEW YORK AUBURN ONE ELLIS DRIVE AUBURN, NY 13021 PHONE: 3152553403 FAX: 3152539923 NORTH CAROLINA GREENSBORO 1220 ROTHERWOOD ROAD GREENSBORO, NC 27406 P O BOX 16500 GREENSBORO, NC 27416 PHONE: 3362726104 FAX: 3362736628 OHIO CINCINNATI 2929 CRESCENTVILLE ROAD WEST CHESTER, OH 45069 PHONE: 5137712600 FAX: 5137722219 CLEVELAND 8929 FREEWAY DRIVE MACEDONIA, OH 44056 PHONE: 3304684777 FAX: 3304684778 OKLAHOMA TULSA 2 EAST DAWES BIXBY, OK 74008 PHONE: 9183669320 FAX: 9183669338 OREGON PORTLAND 20393 SW AVERY COURT TUALATIN, OR 97062 PHONE: 5036919010 FAX: 5036919012 PENNSYLVANIA PHILADELPHIA 1035 THOMAS BUSCH MEMORIAL HIGHWAY PENNSAUKEN, NJ 08110 PHONE: 8566611442 FAX: 8566636363 PITTSBURGH 616H BEATTY ROAD MONROEVILLE, PA 15146 PHONE: 4123807244 FAX: 4123807250 TENNESSEE MEMPHIS 4000 WINCHESTER ROAD MEMPHIS, TN 38118 PHONE: 9013652020 FAX: 9013653914 TEXAS HOUSTON 4647 PINE TIMBERS SUITE # 135 HOUSTON, TX 77041 PHONE: 7138957062 FAX: 7136904540 DALLAS 3040 QUEBEC DALLAS, TX 75247 PHONE: 2146347271 FAX: 2146348874 UTAH SALT LAKE CITY 2230 SOUTH MAIN STREET SALT LAKE CITY, UT 84115 PHONE: 8018320127 FAX: 8018328911 WISCONSIN MILWAUKEE 2725 SOUTH 163RD STREET NEW BERLIN, WI 53151 PHONE: 2627845940 FAX: 2627841215 INTERNATIONAL SALES FORT SMITH, AR P.O. BOX 2400 FORT SMITH, AR 72902 PHONE: 4796464711 FAX: 4796485895 CANADA EDMONTON, ALBERTA 405392 STREET EDMONTON, ALBERTA T6E 6R8 PHONE: 7804344900 FAX: 7804382600 OAKVILLE, ONTARIO 2750 COVENTRY ROAD OAKVILLE, ONTARIO L6H 6R1 PHONE: 9058293301 FAX: 9058293302 MONTREAL, QUEBEC 1844 WILLIAM STREET MONTREAL, QUEBEC H3J 1R5 PHONE: 5149332711 FAX: 5149338639 VANCOUVER, BRITISH COLUMBIA 1538 KEBET WAY PORT COQUITLAM, BC V3C 5M5 PHONE 6044212822 FAX: 6044213113 WINNIPEG, MANITOBA 54 PRINCESS STREET WINNIPEG, MANITOBA R3B 1K2 PHONE: 2049425205 FAX: 2049564251 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) (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) 2881519 FAX: (503) 2881518 BALDOR SUDAMERICA CALLE F, EL CANGREJO CONDOMINIO P.H. CONDADO PLAZA APT. 11D, BELLA VISTA PANAM CITY, REP. DE PANAM PHONE: (507) 2656041 CHINA SHANGHAI JIAHUA BUSINESS CENTER ROOM NO. A8421 808 HONG QIAO ROAD SHANGHAI 200030 PHONE: 862164473060 FAX: 862164078620 GERMANY DIESELSTRASSE 22 D85551 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 CH6850 MENDRISIO SWITZERLAND PHONE: 41 91 640 9952 FAX: 41 91 630 2633 JAPAN DIA BLDG 802, 2211 TSURUYACHO, KANAGAWAKU YOKOHAMA, 2210835, JAPAN PHONE: 81454124506 FAX: 81454124507 KOREA ROOM 210 BUPYEONG INDUSTRIAL COMMERCIAL COOPERATIVE 39616 CHEONGCHEON 2DONG, BUPYEONGGU INCHEON, KOREA, 403858 PHONE: 82 32 508 3252 FAX: 82 32 508 3253 MXICO KM. 2.0 BLVD. AL AEROPUERTO LEN 37545, GUANAJUATO, MXICO PHONE: 52 477 761 2030 FAX: 52 477 761 2010 MIDDLE EAST & NORTH AFRICA VSE INTERNATIONAL CORP. 3233 NORTH ARLINGTON HEIGHTS SUITE 100W ARLINGTON HEIGHTS, IL 60004 PHONE: 847 590 5547 SINGAPORE 51 KAKI BUKIT ROAD 2 K B WAREHOUSE COMPLEX SINGAPORE 417863 PHONE: (65) 6 744 2572 FAX: (65) 6 747 1708 SWITZERLAND POSTFACH 73 SCHUTZENSTRASSE 59 CH8245 FEUERTHALEN SWITZERLAND PHONE: (41) (52) 6474700 FAX: (41) (52) 6592394 TAIWAN 4F, NO. 25, SEC. 1, TUNHUA S ROAD, TAIPEI 10557, TAIWAN, R.O.C. PHONE: (8862) 25774352 FAX: (8862) 25774157 UNITED KINGDOM 6 BRISTOL DISTRIBUTION PARK HAWKLEY DRIVE BRISTOL BS32 0BF 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.

BALDOR ELECTRIC COMPANY P.O. Box 2400 Ft. Smith, AR 72901-2400 (479) 646-4711 Fax (479) 648-5792
Baldor Electric Company MN2414 Printed in USA 5/05