Baldor | TS80 | Owner`s manual | Baldor TS80 Owner`s manual

Towable Generators
(Trailer and Skid Mounted)
(Diesel Liquid Cooled)
TS25, 45, 80, 130 and 175
Installation & Operating Manual
5/05
MN2416
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3
Receiving & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Physical Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secure the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Exhaust Gasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Engine Oil and Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Post Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Towing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the Proper Towing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Driving Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Towing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre−Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5
Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A
Parts & Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents i
ii Table of Contents
MN2416
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 the generator.
Installation and repair procedures require specialized skills with electrical generating equipment
and liquid cooled engine systems. 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
service department for repairs or any questions you may have about the safe installation and
operation of this system.
The precaution statements are general guidelines for the safe use and operation of this
generator. It is not practical to list all unsafe conditions. Therefore, if you use a procedure that is
not recommended in this manual you must determine if it is safe for the operator and all
personnel in the proximity to the generator and connected loads. If there is any question of the
safety of a procedure please contact Baldor before starting or stopping the generator.
This equipment contains high voltages. Electrical shock can cause serious or fatal injury. Only
qualified personnel should attempt the start−up procedure or troubleshoot this equipment.
This equipment may be connected to other machines that have rotating parts or parts that are
driven by this equipment. Improper use can cause serious or fatal injury. Only qualified
personnel should attempt the start−up procedure or troubleshoot this equipment.
−
System documentation must be available to anyone that operates this equipment at all
times.
−
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.
Responsibility
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.
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.
MN2416
Product Safety Information 1-1
Symbols
This symbol is shown throughout the manual to indicate a connection to ground reference point.
Indicates a potentially hazardous situation which, if not avoided, could result in injury or death.
Indicates a potentially hazardous situation which, if not avoided, could result in injury or death.
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: Never allow a person to ride in or on a trailer that is being towed. All states prohibit
passengers in towed vehicles. A person can fall off and be struck be another vehicle or run
over by the towed trailer. Failure to observe this warning can result in death.
WARNING: Before using a tow vehicle with a trailer mounted generator, verify that the vehicle is designed
for the load. Using a vehicle that is too small is very dangerous. Be certain that it can handle
the M.G.T.W. (Maximum Gross Trailer Weight) and the tongue weight for safe towing and
braking.
WARNING: For a new trailer, the wheel lug nuts should be tightened to the proper torque specification
before use, after 25 miles of operation and every 100 miles of operation thereafter. Failure to
check the lug nuts for proper tightness can result in an accident due to a wheel falling from
the trailer.
WARNING: Never operate a trailer or tow vehicle that has a loose, missing or broken lug nut. The trailer
is designed for safe operation with all lug nuts installed and all at the proper torque rating.
Operating the trailer with one or more broken or missing lug nuts greatly increases the load
on the remaining nuts and can cause failure of the remaining nuts that can result in an
accident due to a wheel falling from the trailer.
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: Over crank indication can mean a loss of crank disconnect signal during the previous run
period. Attempting to restart the engine with no crank disconnect signal can destroy the
starter motor, which can cause serious personal injury.
Continued on next page.
1-2 Product Safety Information
MN2416
Operation Warning Statements Continued
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 engine’s 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.
WARNING: Over crank indication can mean a loss of crank disconnect signal during the previous run
period. Attempting to restart the engine with no crank disconnect signal can destroy the
starter motor, which can cause serious personal injury.
WARNING: Never connect or disconnect loads during operation. Always connect load circuits before
starting the engine and use external branch disconnects etc. to switch loads On/Off.
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 when close to fuel source. LPG and natural
gas fuels 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.
MN2416
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. In addition to a sever 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.
WARNING: Engine coolant is under pressure and is near the boiling point of water when engine is hot.
Do not open the coolant system until the engine has completely cooled. Hot coolant can
cause severe burns and other injuries. When engine is cool, coolant level can be checked.
Installation
WARNING: Disconnect the battery’s ground terminal before working in the vicinity of the battery or
battery wires. Contact with the battery can result in electrical shock when a tool accidently
touches the positive battery terminal or wire. The risk of such shock is reduced when the
ground lead is removed during installation and maintenance.
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: Never connect this generator to the electrical system of any building 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 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. LPG and
natural gas fuels are flammable and can cause fire, explosions, injury or death. Fuel supply
lines should be kept away from sharp objects to prevent rupture. Comply with all NFPA
regulations and local codes for shut−off valves, regulators, fuel line type, connectors etc.
WARNING: Have electrical circuits and wiring installed and checked by licensed electrician or qualified
technician. Electrical shock can cause serious or fatal injury.
Continued on next page.
1-4 Product Safety Information
MN2416
Warning Statements Continued
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.
WARNING: Never stand under or close to an object that is being hoisted or lift into position. Accidents
happen and if the object falls or tips over you or someone else could be crushed by the
weight of the object causing severe injury or death to to yourself or others. Always remain a
safe distance from the object and always wear protective head gear (hard hat).
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 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. Before
servicing the generator set, be sure to disconnect the spark plug wires and the battery
terminals to prevent accidental engine rotation or starting.
WARNING: Engine coolant is under pressure and is near the boiling point of water when engine is hot.
Do not open the coolant system until the engine has completely cooled. Hot coolant can
cause severe burns and other injuries. When engine is cool, coolant level can be checked.
WARNING: Before servicing the generator set, be sure to disconnect the spark plug wires and the battery
terminals to prevent accidental engine rotation or starting.
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 supply piping, and their connections monthly for fuel leaks. LPG and natural
gas fuels are 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.
Continued on next page.
MN2416
Product Safety Information 1-5
Caution Statements
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 (do not start the generator) in a moisture−saturated
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 frame or enclosure.
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: The Programmable Output Contacts selection must agree with the external control wiring
prior to energizing the controller. Failure to do so may cause severe equipment damage.
Caution: If a dead battery is suspected, remove the controller fuse, charge battery (or replace), and
then attempting starting. Damage to engine control may result from jump starting.
Caution: This generator must have a battery installed for operation. The battery is used during starting
and during operation. If engine operation is attempted while the battery is removed, damage
to the engine’s electrical components may result.
1-6 Product Safety Information
MN2416
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 owner’s manual for the
engine is supplied with this unit for your use. Please refer to the engine manual for information relative to engine
operation, maintenance, recommendations and additional safety warnings.
Copyright Baldor 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 pre−paid, at the risk of the party requiring
warranty service, to a Baldor Generator repair facility, or to Baldor Generators’ Customer Service Department in
Oshkosh, Wisconsin. Written notification of the alleged defect in addition to a description of the manner in which the
Baldor generator is used, and the name, address and telephone number of the party requiring warranty service must be
included. Baldor is not responsible for removal and shipment of the Baldor product to the service center or for the
reinstallation of the Baldor product upon its return to the party requiring warranty service. Problems with Baldor products
can be due to improper maintenance, faulty installation, non−Baldor additions or modifications, or other problems not due
to defects in Baldor workmanship or materials. If a Baldor Generator repair facility determines that the problem with a
Baldor product is not due to defects in Baldor workmanship or materials, then the party requesting warranty service will
be responsible for the cost of any necessary repairs. EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH
ABOVE, BALDOR GENERATORS DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING
THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR 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
Labor*
Parts
Portable Products (Premier, Powerchief,
DG Series, K Series)
Towable Products (TS)
1 Year
3 Years
3 Years or 3,000 Hours
Whichever comes first
POW’R 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 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.
MN2416
1 Year or 3,000 Hours
Whichever comes first
1 Year or 3,000 Hours
Whichever comes first
General Information 2-1
2-2 General Information
MN2416
Section 3
Receiving & Installation
Receiving & Inspection When you receive your generator, there are several things you should do immediately.
1.
Observe the condition of the shipping container and report any damage immediately to
the commercial carrier that delivered your system.
2. Verify that the part number of the system you received is the same as the part number
listed on your purchase order.
3. 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.
WARNING: Never stand under or close to an object that is being hoisted or lift into position. Accidents
happen and if the object falls or tips over you or someone else could be crushed by the
weight of the object causing severe injury or death to to yourself or others. Always remain a
safe distance from the object and always wear protective head gear (hard hat).
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 can weigh as much as 7,000 lbs. Be
sure lift or hoist equipment has appropriate tires for the terrain to avoid becoming stuck or tipping
over. If the shipping pallet is intact, use a fork lift to move the generator. If the shipping pallet has
been removed, use two steel pipes through the “Lift Point” holes to lift the generator. See Figure 3-1.
The lift points are designed only for the weight of the generator. Do not lift by these points if the
generator is mounted to a trailer or has other items attached.
Figure 3-1 Generator Lifting
Lift Point
Height
Lift Point
Length
Width
Lift Point
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 should be installed in an outdoor location so the exhaust fumes are vented to the atmosphere.
When the Generator is installed outdoors (skid mount)
If the generator is installed outdoors there should not be a cooling problem. The factory installed
enclosure is designed to keep out undesirable weather elements while providing cooling and
ventilation.
MN2416
Receiving & Installation 3-1
Several other factors should be carefully evaluated when selecting a location for installation:
1. For effective cooling and maintenance, the system should be mounted on a flat,
smooth, noncombustible level surface. A concrete pad is ideal and provides a secure
installation.
2. Installation should prevent water levels from reaching the generator. Drainage must be
adequate to keep concrete pad free from standing water.
3. Installation should prevent obstructions by buildup of leaves, grass, sand, snow, etc. If
these items pose a problem, consider building a small fence or other break to protect
the unit from accumulation of debris.
4. Installation should place the generator as close as possible to the transfer switch.
5. At least forty−eight (48) inches clearance must be provided on all sides for air flow.
6. Access must be provided to allow the enclosure covers to be opened or removed for
service and maintenance.
7. Maximum Ambient temperature is 122°F (50°C).
Figure 3-2 Generator Mounting (Skid)
A
B1
B
TS130/175 only
(4 Holes)
A1
A2
A2
TS25/45/80 only
(3 Holes)
A2
A1
A2
A1
Table 3-1 Mounting Dimensions
Generator
TS25
TS45
TS80
TS130
TS175
A
74.0
84.0
84.0
118.0
118.0
A1
8.12
8.38
8.38
16.57
16.57
A2
23.81
28.56
28.56
26.57
26.57
B
38.0
38.0
38.0
42.0
42.0
B1
36
36
36
40
40
B2
6.25
6.25
6.25
6.25
6.25
Secure the Generator (Skid Mount only)
Six mounting bolts (eight for TS130/175) in the base frame secure the generator to the shipping
pallet. Remove these bolts, lift the generator and remove the shipping pallet. Secure the
generator to the concrete pad using anchor hardware (not provided) in the base frame mounting
holes (holes are 0.66” diameter). See Figure 3-2 and Table 3-1. Anchor bolts must be long
enough to extend through the generator mounting frame.
3-2 Receiving & Installation
MN2416
Hot Exhaust Gasses
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.
Exhaust must always be directed away from living areas or buildings that are occupied by people
or animals. Never allow exhaust gases to be directed towards any openings or air entry routes
(doors, windows, vents, etc...) of an occupied building.
The direction of the discharged hot air and hot exhaust gases is important as they have the
potential to create brown spots on the lawn or shrubs. In extreme cases this extremely hot air
could cause dried grass, shrubs, trees or other debris to ignite.
It is also recommended that an exhaust rain cap be used whenever it is possible that rain could
get into the system. This will help to prevent corrosion and damage to the exhaust system and
engine.
The generator is completely assembled, tested and adjusted at the factory before it is shipped to
you. The procedures presented in this manual are suggestions and it is the responsibility of the
Owner/Operator to arrange for these procedures to be performed by licensed contractors
according to all applicable codes including local codes for your Municipality/City/County and
State. External connections required at the time of installation are:
1. Electrical Connections − power wiring (optional transfer switch) and control wiring.
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 5 Maintenance for periodic checks that must be performed at scheduled intervals to
ensure continued operation with minimal problems.
WARNING: Disconnect the battery’s ground terminal before working in the vicinity of the battery or
battery wires. Contact with the battery can result in electrical shock when a tool accidently
touches the positive battery terminal or wire. The risk of such shock is reduced when the
ground lead is removed during installation and maintenance.
Fuel Connections
Fuel connections are not required. A self contained fuel tank is located within the base of the
generator set.
Installation
MN2416
Receiving & Installation 3-3
Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a class 2
circuit. It is the responsibility of the owner/operator to arrange for these procedures to be
performed by a licensed electrical contractor and ensure conformance to all applicable codes
including local codes peculiar to your municipality/city/county and state. Wire size and insulation
type should be as required by NEC (National Electrical Code) and local codes.
Warning: Never connect this generator to the electrical system of any building 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 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: 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.
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.
Intended Use The intended purpose of this generator set is to provide emergency power when the main utility
power supply is interrupted. Therefore, it is important that all the wiring that connects the
generator set with your house, transfer switch, distribution box, battery charger, etc. be properly
installed.
Protection
Single Phase circuit protection is provided within the generator. The power output connections
are rated and sized according to the KW of the generator. Proper lead wire from these points to
the automatic transfer switch (or load switching device) is mandatory. See transfer switch
information for corresponding generator input terminals.
Three phase circuit protection is not provided with the generator. When connecting the
generator output to an electrical load, a UL listed circuit breaker with the appropriate ratings shall
be provided within 25 feet of the Genset. Use only copper wires.
Generator
Catalog No.
TS25
TS45
TS80
TS130
TS175
3-4 Receiving & Installation
3 Phase VAC
208/240/480
208/240/480
208/240/480
208/240/480
208/240/480
Input Breaker
3 Phase Amps
62.5/54.1/27.1
121.4/105.3/52.6
190.8/165.4/90.2
329.6/285.7/145.8
433.7/375.9/203.0
MN2416
Single Phase Connections
Single phase connections are made at load receptacles located by the operator panel, see
Figure 3-3. Simply open the rear panel access door and make the connections. When the panel
door is closed, the connections are weather tight.
Figure 3-3 Receptacle Panel (Single Phase)
TS25
Use mating plug for a
CS6369 250V 50A
receptacle.
240V(50A)
240V(50A)
120V(20A)
120V(20A)
TS45/80
For power to be applied to
these receptacle, the Output
Voltage Selector Switch must
be in the 120/240V position.
Use mating plug for a
CS6369 250V 50A
receptacle.
120V(20A)
120V(20A)
240V(50A)
240V(50A)
240V(50A)
120V(20A)
TS130/175
Use mating plug for a
CS6369 250V 50A
receptacle.
240V(50A)
240V(50A)
240V(50A)
240V(50A)
120V(20A) 120V(20A) 120V(20A) 120V(20A)
Three Phase Connections
Three phase connections are made at L1, L2, L3 and N connections shown in Figure 3-4.
Figure 3-4 Three Phase and Remote Start Connections
RR1 RR2
For power to be applied to these
terminals, the Output Voltage
Selector Switch must be in the
120/208V or 277/480V positions.
Remote Start Connections
Customer Connections
L1, L2, L3 and N
MN2416
Receiving & Installation 3-5
Transfer Switch Considerations
The following are general considerations for the safe use of a transfer switch:
1. The transfer switch should be located inside the building near the main breaker box or
the disconnect box.
2. The transfer switch must be kept away from any location that might allow water to get
on it.
3. If the transfer switch is mounted outside, it must be protected from the environment and
it’s elements.
4. Do not mount the transfer switch on the generator set.
5. Do not mount the transfer switch where flammable liquids or vapors are present.
Remote Start Contacts
This two−wire connection will start and stop the generator, when properly connected to a remote
start contact, shown in Figure 3-4. These contacts RR1 and RR2 are connected to the “Engine
Start Contacts” of the automatic transfer switch. A two pole normally open, closed to operate
switch may also be used to start the generator.
AC Input
These connections are for units with float type battery charger or engine block heater. A
constant supply of 120 volts AC (or as specified) is needed at these terminals to power these
devices when generator is not operating.
Note: Power is not required when the unit is in operation. Internal battery charging and radiant
heat during operation eliminate the need for these devices.
Battery Charger Considerations
1. Mount the battery charger inside the generator enclosure as close to the battery as is
reasonably possible.
2. Do not mount the battery charger where flammable liquids or vapors are present.
When the battery is charging it produces explosive gasses.
General Wiring Considerations
1. When routing the interface wiring, do not route it up against anything that could cut or
chafe the wiring. do not route the wire up against any hot or potentially hot object.
2. Make sure that all the electrical components (generator set, transfer switch, battery
charger, etc.) share a common ground.
3. Check with your local building inspector to determine what you must do to comply with
the local regulations for grounding of this type of permanent installation.
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.
It is important for safety reasons that the Generator set, transfer switch and battery charger share
a common Ground and neutral.
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 3-5. Use the appropriate size wire as required by NEC and local codes.
3-6 Receiving & Installation
MN2416
Figure 3-5 Frame Ground Connection
Nut
Washer
Ground Wire Lug
Washer
Earth Ground
Stud
Frame
1.
2.
Open the enclosure access panel door 2 ( Figure 3-2).
Connect the ground wire to the “earth ground” terminal shown in Figure 3-5.
This ground is the local reference ground to ground the generator frame only.
Caution: This generator must have a battery installed for operation. The battery is used during starting
and during operation. If engine operation is attempted while the battery is removed, damage
to the engine’s electrical components may result.
Battery Connections The generator is shipped with no battery installed.
WARNING: Installation and servicing of batteries is to be performed or supervised by personnel
knowledgeable of batteries and the required precautions. Keep unauthorized personnel away
from batteries.
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 safety goggles, 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.
MN2416
Receiving & Installation 3-7
WARNING: Disconnect the battery’s ground terminal before working in the vicinity of the battery or
battery wires. Contact with the battery can result in electrical shock when a tool accidently
touches the positive battery terminal or wire. The risk of such shock is reduced when the
ground lead is removed during installation and maintenance.
Procedure:
The correct type battery must be installed in the battery compartment provided, see Table 3-2.
Installation and servicing of batteries is to be performed or supervised by personnel
knowledgeable of batteries and the required precautions.
Keep unauthorized personnel away from batteries.
1. Open access doors and locate battery tray.
2. Remove battery cables from the battery, the (−) negative first then the (+) positive.
3. Remove the Battery Hold Down Bar and Rods.
4. Remove the old battery and place the correct new battery (see Table 3-2) on the tray.
5. Install the Battery Hold Down Bar and Rods as shown in Figure 3-6.
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.
Figure 3-6 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
Battery Hold Down Bar
(Install away from terminals)
Washers & Nut
Battery Hold Down Rod
Battery Tray
6.
7.
8.
9.
10.
Connect the positive lead to the positive (+) battery terminal.
Connect the negative lead to the negative (−) battery terminal.
Do not lay tools or metal parts on top of batteries.
Connect charging source to the battery terminals.
Disconnect the battery’s ground terminal before working in the vicinity of the battery or
battery wires. Contact with the battery can result in electrical shock when a tool
accidently touches the positive battery terminal or wire. The risk of such shock is
reduced when the ground lead is removed during installation and maintenance.
Recommended Engine Oil and Battery Type
When replacing batteries, use only the recommended battery for your generator, see Table 3-2.
Table 3-2 Oil & Battery Recommendations
MODEL
TS25
TS45
TS80
TS130
TS175
SUMMER
OIL
SAE. 20W/50
SAE. 20W/50
SAE. 20W/50
SAE. 20W/50
SAE. 20W/50
3-8 Receiving & Installation
WINTER
OIL
5W/30
5W/30
5W/30
5W/30
5W/30
OIL
CAPACITY
7.0 QTS
14.0 QTS
14.5 QTS
18.0 QTS
33.75 QTS
RECOMMENDED
BATTERY
BCI Group 24
BCI Group COM
BCI Group COM
BCI Group COM
BCI Group COM
(AMPS) COLD
CRANKING
925
925
925
(2) 750
(2) 750
MN2416
Post Installation Checks
When the initial installation is complete, these checks must be performed before starting the
engine. These checks are not required before each start, only after the initial installation.
1. Generators that have been in transit or storage for long periods may be subjected to
extreme temperature and moisture changes. This can cause excessive condensation,
and the generator windings should be thoroughly dried before bringing the generator
up to full nameplate voltage. If this precaution is not taken, serious damage to the
generator can result.
Caution: Do not apply high voltage to windings (do not start the generator) in a moisture−saturated
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.
Note: These precautions are especially necessary in locations such as seaboard installations
and other high humidity areas. Some installations will be in atmospheres that are much
more corrosive than others. Prevention of a failure is better than being forced to make a
repair.
2. Verify that the transfer switch is in Utility Power mode. No power must be present at
the generator or transfer switch connections. Verify with a voltmeter.
3. Verify that the engine starting battery is disconnected so accidental starting is not
possible.
4. Verify generator is securely mounted and anchored to cement pad (skid mount only).
5. Verify that proper clearance exists on all sides and top of enclosure.
6. Verify no debris (buildup of leaves, grass, sand, snow, etc.) is present.
7. Assure generator is a safe distance from any flammable or combustible material.
8. Verify that the three phase generator power (L1, L2, L3 and N) are properly connected
to the transfer switch (3 phase power only).
9. Verify that the generator and transfer switch load are voltage compatible.
10. Verify that no load is connected to the circuit breaker and/or transfer switch.
11. Inspect the engine and generator and verify that there are no loose wires or
components. Tighten if necessary.
12. Verify that the ground conductor is of correct wire size and properly connected.
13. Verify engine oil level is full. Refer to engine manual if necessary.
14. Verify engine coolant level is full. Refer to engine manual if necessary.
15. Verify exhaust system to assure it is in properly connected and pointing away from
occupied living space, air entry routes (doors, windows, vents etc.) and combustible
materials.
MN2416
Receiving & Installation 3-9
Post Installation Checks Continued
16. Place the voltage output selector switch in the appropriate position (120/240 so the
receptacles are powered or as required for your load).
17. Verify all loads are disconnected.
18. Verify that the Master Control Switch is still in the “Stop” position.
Connect the engine starting battery to the starter. Verify it is installed correctly.
19. Verify the fuel source is ON and the pressure and flow rate is correct.
20. Remove all tools, rags, etc. from inside the generator enclosure. Close all enclosure
doors and be sure no hands are inside the generator enclosure when it starts.
21. Start the generator.
22. The engine should begin to crank and start when the fuel moves through the pipe to
the carburetor. If the engine fails to start, refer to Section 5 Troubleshooting.
23. With the engine running, several checks must be made:
a. Verify there are no fuel leaks. If a fuel leak is detected, stop the engine (move the
Master Control Switch to the “Stop” position) immediately and repair the leak
before proceeding.
b. Verify there are no coolant or oil leaks. If a leak is detected, stop the engine
(move the Master Control Switch to the “Stop” position) immediately and repair the
leak before proceeding.
c. Verify that operation is smooth. If squeals, vibrations or other abnormal sources of
noise exist, stop the engine (move the Master Control Switch to the “Stop”
position) immediately and repair before proceeding.
d. Verify that the correct voltage exists at the receptacles.
WARNING: Engine coolant is under pressure and is near the boiling point of water when engine is hot.
Do not open the coolant system until the engine has completely cooled. Hot coolant can
cause severe burns and other injuries. When engine is cool, coolant level can be checked.
24. After the operation checks are made, stop the engine (move the Master Control Switch
to the “Stop” position) and wait 2 hours for the engine to cool. When the engine is cool,
check engine oil and coolant levels as instructed in the engine operation manual.
25. Close all enclosure covers. The post installation checks are now complete.
3-10 Receiving & Installation
MN2416
Section 4
Operation
Towing the Generator
WARNING: Never allow a person to ride in or on a trailer that is being towed. All states prohibit
passengers in towed vehicles. A person can fall off and be struck be another vehicle or run
over by the towed trailer. Failure to observe this warning can result in death.
WARNING: Before using a tow vehicle with a trailer mounted generator, verify that the vehicle is designed
for the load. Using a vehicle that is too small is very dangerous. Be certain that it can handle
the M.G.T.W. (Maximum Gross Trailer Weight) and the tongue weight for safe towing and
braking.
WARNING: For a new trailer, the wheel lug nuts should be tightened to the proper torque specification
before use, after 25 miles of operation and every 100 miles of operation thereafter. Failure to
check the lug nuts for proper tightness can result in an accident due to a wheel falling from
the trailer.
WARNING: Never operate a trailer or tow vehicle that has a loose, missing or broken lug nut. The trailer
is designed for safe operation with all lug nuts installed and all at the proper torque rating.
Operating the trailer with one or more broken or missing lug nuts greatly increases the load
on the remaining nuts and can cause failure of the remaining nuts that can result in an
accident due to a wheel falling from the trailer.
S
Make sure the tow vehicle is able to tow the load. Vehicle brake capacity is extremely
critical and the tow vehicle must be able to handle the additional weight of the trailer
mounted generator. Radiator and transmission cooling must also be considered.
S
Be sure hitch capacity is equal to or greater than the load when mounted on the
vehicle.
S
Be sure the size and rating of the hitch ball is equal to or greater than the load.
S
Make sure the safety chain(s) rating is equal to or greater than twice the maximum
gross trailer weight rating of your trailer.
S
It is against the law to carry passengers in the back of any trailer.
S
Reduce weight in car trunk and rear seat areas by the amount of tongue weight of your
trailer.
S
Any alterations or changes made to the trailer void any express or implied warranties
on the trailer or towing equipment.
Selecting the Proper Towing Equipment
When selecting the proper towing equipment, the two most important factors that must be
considered are the M.G.T.W. (Maximum Gross Trailer Weight) and the Tongue Weight. The
M.G.T.W. is the total weight of the trailer plus the payload in the trailer. The tongue weight is the
downward pressure exerted at the coupler. The easiest way to measure the gross trailer weight
is to place the loaded trailer on a vehicle scale making sure that the scales are supporting the
entire weight of the loaded trailer.
The easiest method to measure tongue weight (up to 300 lbs.) is to place the jack stand (trailer
tongue) on a bathroom scale making sure the trailer is level. For heavier tongue weights, place a
board across the bathroom scale and a solid object of the same thickness as the scales with a
piece of pipe between each. The trailer tongue should be level and in its normal towing position.
Multiply the scale reading by three (3) to obtain the tongue weight. Tongue weight should be 10%
of trailer weight and not more than10% of M.G.T.W.
Tow Vehicle
Make sure the vehicle you are using to tow the trailer is capable of towing the weight. Check the
vehicle Owner’s Manual for towing capability of the towing vehicle or contact the car dealer for
this information. Make sure the tow vehicle is able to tow the load. Vehicle brake capacity is
extremely critical and the tow vehicle must be able to handle the additional weight of the trailer
mounted generator. Radiator and transmission cooling must also be considered.
Table 4-1 Tow Hitch Capacity
Tow Vehicle
Compact Vehicle
Compact Vehicle
Mid & Full Size Vehicle
3/4 Ton or larger Truck
MN2416
Hitch Class
Sub Class I
Class I
Class II
Class III & 4
Maximum Tow Capacity
1000 Lbs.
2000 Lbs.
3500 Lbs.
5000 Lbs. Plus
Maximum Tongue Weight
100 Lbs.
200 Lbs.
300 Lbs.
500 Lbs. Plus
Operation 4-1
Selecting the Proper Towing Equipment Continued
Electrical Trailer Wiring
All trailers must have taillights, brake lights and turn signals connected to the towing vehicle’s
electrical system. It is also recommended that a heavy duty turn signal flasher and emergency
flasher (if separate) be installed since the trailer lights place an extra load on car flasher units.
Towing Heavy Trailer Loads
1. Trailer brakes. In all cases refer to your vehicle’s owner manual and the trailer
operating manual to be certain you have an adequate braking system to handle the
vehicle/trailer combination. Also, State requirements, road and weather conditions and
grade of road, etc. should be considered for trailer braking.
2. Additional equipment. The following items may be helpful for towing heavy loads.
Consult your vehicle’s owner manual or dealership for recommended towing
accessories.
a. Overload Springs
b. Overload or air shocks
c. Transmission Oil Cooler
d. Engine Oil Cooler
e. Coolant recovery System
f.
Heavy Duty Fan
g. Side View Mirrors
h. Sway Control
Safe Driving Tips
1. Loading Trailer. The trailer should be loaded so that the downward tongue weight is
approximately 10% of the gross trailer weight.
2. Following and stopping distance. The stopping distance is increased when towing a
trailer. A rule of thumb for the minimum distance that should be maintained between
you and the preceding car on dry pavement is one car and trailer length (2 car lengths)
for every 10 MPH you are traveling. The distance should be increased accordingly
depending on road and weather conditions. Avoid sudden stops if possible.
3. Passing. Accelerating and passing should be done slowly to allow extra distance for
passing. Signal well in advance when passing and returning to the proper lane. Allow
for the extra length of the trailer before changing lanes. Never change lanes abruptly
as this may cause the trailer to sway and push the tow vehicle into a “jack knife”
condition.
4. Turning. Allow for the extra length of the trailer. Drive slightly beyond normal turning
point to avoid running over curbs and soft shoulders. Turning radius increases when
towing.
5. Uphill and Downhill Grades. Reduce speed and use a lower transmission gear for
steep or long up or down hill grades. Maintain safe distance from other vehicles.
6. Parking.
S
Avoid parking on uphill or downhill grades
S
Place transmission in “PARK”
S
Apply parking brake.
S
Use wheel chucks.
S
In a parking lot, avoid parking close to other vehicles. Turning radius is greater
and it may be impossible to get out of a parking space after a few other vehicles
have parked around your vehicle.
7. Trailer Sway. If trailer sways, reduce speed by applying trailer brakes rather than car
brakes to control sway. If excessive sway persists, consult your local dealer for help.
8. Trailer Backing. Backing a trailer can be frustrating. The most important item to
remember is that the trailer will go in the opposite direction of the tow vehicle. It is
helpful to have another person help you back the trailer and watch for objects.
Turn the vehicle’s wheels to the right to make the trailer go left, and vice versa.
Put your hand at the bottom of the steering wheel. The trailer will go in the same
direction your hand moves (moving your hand to the right will cause the trailer to go
right, and vice versa). Sharp steering wheel corrections will cause the trailer to
jackknife and may cause damage to the rear of the tow vehicle or the front of the trailer.
4-2 Operation
MN2416
Figure 4-1 Trailer Component Identification
Lift Hook
Jack
Battery
Compartment
Coupler Handle
Coupler
Tow Vehicle Mounted
Pintle Hook
Trailer Brake
Pintle
Safety
Chains
Ball Coupler
Caution:
Safety
Chains
Jack
Trailer
Single or
Double Axle
Engine
Compartment
Large “Engine Compartment Doors” on each side of enclosure must remain closed during
operation. If doors remain open, engine will overhead due to restricted air flow.
Safety Checks The following items should be checked before each use and once every 100 miles of towing:
1. Verify the tow vehicle is designed to tow the trailer before trailer is connected to the
vehicles hitch. Using a tow vehicle that is too small is very dangerous.
2. Verify the stop, tail and turn signals are working properly.
Replace damaged lenses, reflectors or bulbs.
3. Check wires for good connections and possible fraying or wearing of insulation.
4. Check and properly maintain the trailer, hitch, jack, ball and coupler.
5. Inspect hitch and ball for damage. Ball or hitch can be damaged in parking, hitting
curbs, dragging when crossing ditches or railroad tracks.
6. Check and properly tighten all bolts on trailer, hitch, ball and coupler (including wheels).
7. Check safety chains for wear and do not allow them to drag on ground or roadway.
8. Test breakaway system.
Hydraulic surge brake system, normally has a cable or chain connected to the tow
vehicle. In a break away condition, this cable or chain activates the master cylinder and
operates the brakes as the trailer stops.
An electric brake system, the emergency breakaway system has a battery, charger,
breakaway switch with a pull pin and cable connected to the tow vehicle. In a break
away condition, this cable operates the electric brakes (power provided by the brake
battery) as the trailer stops.
9. Check all generator mounting hardware for tightness. (Loosens with vibration).
10. Check tow vehicle tires for wear and proper inflation (check vehicle’s owner manual for
proper level of inflation of tires for towing a trailer).
11. Check trailer tires for wear and proper inflation. Replace only with a tire of the same
size and capacity ratings.
12. Carry emergency flares, reflectors and fire extinguisher (required in some states).
13. Carry spare light bulbs and fuses.
14. Wheel bearings should be checked and replaced after the first 100 miles, and every
4000 miles thereafter or at least once a year. Wheel bearing grease or a good grade of
multi−purpose grease should be used for packing wheel bearings. If you don’t know
how to repack your wheel bearing, take your trailer to a service shop. Be sure to
properly tighten the axle nut and wheel nuts during assembly.
15. For proper tow vehicle maintenance while towing a trailer, check vehicle’s owner
manual and manufacturer’s specifications.
MN2416
Operation 4-3
See Figure 4-1 for component identification.
1. Be sure the generator is off.
2. Shut all enclosure doors and latch the locks.
3. Back the tow vehicle to within a few inches of the trailer coupler (Pintle or Ball).
4. Be sure the Coupler Handle is in the “UP” (open) position or the Pintle Hook is Open.
5. Adjust the trailer jack for the height of the hitch on the tow vehicle.
6. Back the tow vehicle so the trailer coupler is directly over the tow vehicle ball hitch or
the Pintle hook.
7. Lower the trailer so the trailer coupler rests securely on the ball hitch of the tow vehicle.
Move the Coupler Handle to the horizontal position and lock it in place to securely hold
the ball hitch of the tow vehicle.
OR
Latch the Pintle and lock the Pintle device securely.
Note: If this is not done properly, the trailer may become unhitched when it is towed.
8. Retract the front jack, pull the jack pin and rotate the jack 90 degrees from vertical to
the horizontal position, making sure the self−locking pin reseats and the jack is secured
to the tow bar (stowed position).
9. Connect safety chains, making sure to cross them. If a safety chain is too long, simply
twist it a few turns to shorten the chain before attaching to the tow vehicle.
10. Connect the trailer light connector to the tow vehicle.
11. Test the trailer lights to ensure they are operational.
12. Check tires for 32 psi inflation.
13. Check wheel lug nuts for correct tightness, 90 lb−ft torque.
14. Verify that all jacks, pins, cables, and doors are secured.
15. Remove tire chocks (if used). These prevent the trailer from moving when parked.
See Figure 4-1 for component identification. Carefully read all instructions before starting.
Trailer Setup
1. Locate a suitable, level location. Also be sure there are no overhead wires or
obstructions.
The trailer is balanced so the majority of the weight rests on the tow bar (Jack).
If on a minor incline, the safest way to position the tailer is to have the tow bar facing
down the incline (front of the trailer lower than the rear of the trailer).
2. Install tire chocks if used. These prevent the trailer from moving when parked.
3. Disconnect the safety chains and the trailer light connector from the tow vehicle.
4. Pull the pin on the front jack and rotate the jack 90 degrees to the vertical position.
Lock the jack in the vertical position using the pin to secure it.
5. Move the Coupler Handle to the vertical position to release the ball hitch.
OR
Release the Pintle hook.
6. Use the jack to raise the trailer coupler from the ball hitch of the tow vehicle.
7. The tow vehicle can now be moved away from the trailer.
8. Use the jack to level the trailer for operation.
Pre−Start Procedure
The operator panel is shown in Figure 4-2.
Before attempting to start the generator set, several things must first be verified or performed.
These are:
1. Fill system fuel tank with clean, fresh diesel fuel.
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 the engine manufacturer’s guidelines.
4. Secure the generator for operation.
a. Skid mounted − the power generating system should be mounted to a smooth,
hard surface suitable for supporting the system under all stress conditions.
b. Trailer mounted − block wheels to prevent accidental movement.
Towing Instructions
4-4 Operation
MN2416
Caution:
c. Adequate clearance must be provided for access doors to fully open.
Note: The exhaust also exits radiator end. When positioning a generator system ensure position
does not cause a concentration of toxic emissions.
5. Switch the generator set to the applicable voltage setting.
6. Connect the load(s) at the Receptacle panel connections (Figure 4-3).
7. Verify that all electrical cables and wiring are in good condition, no cracked or frayed
wires or cable insulation.
8. Ensure that an external ground connection is made when required for safety.
Large “Engine Compartment Doors” on each side of enclosure must remain closed during
operation. If doors remain open, engine will overhead due to restricted air flow.
9. Ensure that Engine Compartment doors are closed for proper ventilation.
Figure 4-2 Operator Control Panel
RUN TIME (HOURS)
Panel Light
VOLTAGE
HERTZ
Panel Light
AMPERAGE
HIGH TEMPERATURE
LOW OIL PRESSURE
OVERSPEED
OVERCRANK
CONTROLLER FUSE
FIELD FUSE
PANEL LIGHT FUSE
Battery
Volts
Engine
Temp
Oil Pressure
AMMETER
PANEL LIGHTS
OFF
3
1
2
Panel Lights switch (On−Off )
Turns on two lamps to illuminate the operator panel.
Panel Light Fuse Fuse for panel lights.
Filed Fuse Fuse for generator field.
Controller Fuse Fuse for engine controller.
Master Control switch (Manual Run−Stop − Auto Start)
Manual Run − Starts the engine manually.
Stop − Stops the engine and generator.
Auto Start − Starts the engine from a remote source whenever the
utility AC power is lost.
Fault Display Lamps
High Temperature − Indicates excessive engine coolant temperature.
Low Oil Pressure − Indicates low engine oil pressure (<15PSI).
Overspeed − Indicates engine speed is greater than preset limit.
Overcrank − Failure of the engine to start by the end of the crank period
results in an overcrank" shutdown and alarm indication.
Voltage Adjust
Increase or Decrease the Generator output voltage (displayed on
VOLTAGE meter)
MN2416
ON
OFF
STOP
−
+
VOLTAGE
ADJUST
MANUAL
RUN
AUTO
START
MASTER
CONTROL
Voltage meter
Analog display of generator output voltage in RMS volts.
AMMETER switch (3 position)
Off − No current is measured by the Amperage meter.
1 − Phase 1 current is measured by the Amperage meter.
2 − Phase 2 current is measured by the Amperage meter.
3 − Phase 3 current is measured by the Amperage meter.
Amperage meter
Analog display of generator output current in RMS amps.
Hertz meter
Analog display of generator output frequency in Hertz.
Battery Volts meter
Displays the voltage of the engine starting battery.
Engine Temperature meter
Displays the temperature of the engine coolant.
Oil Pressure meter
Displays engine oil pressure.
Run Time (Hours) meter
Total elapsed time indicator of generator set operation.
Operation 4-5
Figure 4-3 Receptacle Panel (Single Phase)
TS25
Use mating plug for a
CS6369 250V 50A
receptacle.
240V(50A)
240V(50A)
120V(20A)
120V(20A)
TS45/80
For power to be applied to
these receptacle, the Output
Voltage Selector Switch must
be in the 120/240V position.
Use mating plug for a
CS6369 250V 50A
receptacle.
120V(20A)
120V(20A)
240V(50A)
240V(50A)
240V(50A)
120V(20A)
TS130/175
Use mating plug for a
CS6369 250V 50A
receptacle.
240V(50A)
240V(50A)
240V(50A)
240V(50A)
120V(20A) 120V(20A) 120V(20A) 120V(20A)
Operating Procedures The engine−generator controller is designed to start and stop an engine from either a local
(“Manual”) or remote (“Automatic”) mode. When a start command is issued, the controller issues
a run and crank output signal. The controller then monitors engine speed and when crank
disconnect speed is reached, the crank signal is terminated. While the engine accelerates to
normal speed, the controller continuously monitors the engines speed signal. Should the engine
speed exceed the maximum predetermined setpoint, the overspeed shutdown fault circuit will
activate, terminating the run signal.
In addition to overspeed shutdown, the engine controller also monitors many other engine
protection circuits and should they be activated, the engine will be stopped and/or alarm initiated.
The engine will automatically stop for any shutdown condition, or when the remote and/or local
start signal is removed. The engine controller operation includes time delay circuits for normal
operating conditions such as start delays, cool down and cranking periods.
Manual Start/Stop
First, ensure all “Pre−start Procedures” are complete.
To manually Start the Gen−Set, set the Master Control switch to the “Manual Run” position. The
following happens:
1. When the “RUN” push−button is pressed, an ENGINE START DELAY timer is initiated.
(The start sequence will not be initiated if any shutdown fault condition is present.)
2. When the engine start delay time expires, an engine RUN and CRANK output signal
will be initiated. (The RUN output may be programmed to only energize when a start
signal is initiated and an engine speed signal is detected.)
3. When the engine starts and begins to accelerate to nominal speed, the controllers
speed sensor will terminate the CRANK output when engine speed reaches
approximately 20% speed (i.e. CRANK DISCONNECT speed setpoint).
To manually Stop the Gen−Set, set the Master Control switch to the “Stop” position. The
controllers RUN output will be immediately terminated which will initiate the engine stop
sequence. The engine is locked out and will not run with the Master Control switch in “Stop”.
4-6 Operation
MN2416
Automatic Start/Stop
First, ensure all “Pre−start Procedures” are complete.
To setup the generator for automatic operation, set the Master Control switch to the “Auto Start”
position. The following happens:
1. The engine will automatically start upon activation of the remote start contact input.
The remote device initiates a start sequence upon contact closure.
2. When the remote start signal is activated, the engine will start as per the sequence of
operation described for the manual start sequence.
3. The automatic stop sequence will be initiated by removal of the remote start signal.
4. When the start signal is removed, a cool down delay function will be initiated.
5. When the cool down time delay period expires (typically 5 minutes), the controllers
RUN output will be immediately terminated which will initiate the engine to stop.
Automatic Fault Shutdown
When a fault circuit is programmed as a SHUTDOWN, the engine will immediately stop when the
fault is activated. A specific shutdown fault can be programmed with a definite time transient
delay period that must expire before the shutdown is activated. The stop sequence will cause the
controllers RUN output to be immediately terminated which will cause the engine to stop.
“Low Oil Pressure” Monitoring of oil pressure begins for a preset time after unit starts and
remains in effect until unit is shut down (except as noted in “Loss of Frequency Input”). The LOP
signal is derived from an oil pressure switch gauge mounted on the control panel
“High Temperature” The engine temperature monitoring begins immediately with the start
signal. However, if engine temperature is excessive prior to start (i.e., heat soak after shutdown),
the unit is permitted to start. and run for up to 60 seconds. The high temperature condition is
permitted to exist for up to 60 seconds after start before shutdown when alarm occurs. If the
excessive temperature condition is corrected within the 60 seconds, normal operation continues.
“Overspeed”
Over speed protection is provided by a frequency sensing network within the controller. The trip point
of the frequency network is adjustable by a rheostat located on the top of the controller at the right
hand side. Clockwise (CW) rotation increases the trip frequency and the shutdown speed.
“Loss of Frequency” (engine RPM)
Internal protection against loss of frequency input to the cranking disconnect circuit is set after
the unit has started normally. If the frequency goes to zero (engine runs out of fuel, frequency
signal source fails, etc.) the LOP shutdown circuit is bypassed and a 12 second wait period is
initiated. If frequency returns within this time period, LOP monitoring resumes and operation
continues normally. If frequency has not returned at the end of this time period, the engine oil
pressure status is observed to determine whether the engine is actually running or stopped. If the
engine has stopped (i.e., air in fuel, etc.), the cranking cycle will begin in an effort to restart the
engine. If the engine has not stopped (loss of input signal, etc.), the unit is shutdown with an
“Over crank” indication and alarm.
WARNING: Over crank indication can mean a loss of crank disconnect signal during the previous run
period. Attempting to restart the engine with no crank disconnect signal can destroy the
starter motor, which can cause serious personal injury.
“Overcrank”
The cranking disconnect signal source is a key component in this system and must be checked
out thoroughly whenever an Over crank shutdown occurs.
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.
Caution: If a dead battery is suspected, remove the controller fuse, charge battery (or replace), and
then attempting starting. Damage to engine control may result from jump starting.
Cranking Control
Over crank Protection
This feature provides a preset crank cycle time period. Failure of the engine to start by the end of
the crank period results in an Over crank shutdown and alarm indication.
Cranking Disconnect Adjustment (CDS Adjustment)
The cranking disconnect signal is obtained by a frequency network within the controller. The trip
point of the frequency network is not adjustable.
MN2416
Operation 4-7
Engine Controller Description
When a fault circuit is programmed as a SHUTDOWN, the engine will immediately stop when the
fault is activated. A specific shutdown fault can be programmed with a definite time transient
delay period that must expire before the shutdown is activated. The stop sequence will cause the
controllers RUN output to be immediately terminated which will cause the engine to stop.
Figure 4-4 ASM160 Analog Engine Controller Connections
Auto
Fuel Relay
Start Relay
Glow Plug
Relay
Stop
1
Fuel
10
2
Crank
11
3
Glow Plug
12
4
Overcrank
13
5
Overspeed
14
Magnetic Pickup
Oil Pressure
6
Oil Pressure
15
Water Temperature
7
Water Temp.
16
Spare (Delayed)
8
Run
17
Spare (Immediate)
9
Lamp Test
Relay (B+)
Manual
Remote Start
Shielded Twisted Pair Wire
18
15A
Switches shown in OFF position
ON
Starting
Battery (12VDC)
R1 R2 R3 R4
External Components
Glow Plug (ON) or Warm−up/Cooldown (OFF) Mode Select
2 Crank Attempts
1
Crank Attempts
Off Off Infinite
Cooldown Delay (1−300 seconds)
Off On 10
Glow Plug/Warm−up Delay (1−300 seconds)
On Off 5
Crank Disconnect (30−8500Hz)
On On 3
Overspeed (30−8500Hz)
Table 4-2 ASM160 Terminal Description
Pin #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Title
Fuel Relay
Crank Relay
Glow Plug/At Load
Overcrank LED
Overspeed LED
Oil Pressure LED
Water Temperature LED
Run LED
Lamp Test (input)
Manual Mode
Auto Mode
Ground
Magnetic Pickup
Oil Pressure
Water Temperature
Spare (delayed)
Spare (Immediate)
Relay Power (B+)
4-8 Operation
Description
Output − Drives a pilot relay to Open/Close the fuel valve.
Output − Drives a pilot relay to Open/Close the Starter Relay to crank engine.
Output − Drives a pilot relay to Open/Close the Glow Plug relay.
Output − On during Overcrank shutdown (engine fails to start after the number of crank cycles).
Output − On during Overspeed shutdown (engine’s speed has exceeded the overspeed setpoint).
Output − On during Low Oil Pressure shutdown
Output − On during High Water Temperature shutdown
Output − On during normal engine operation
Input − Closed to ground will turn on all LED outputs.
Input − Closed to B+ will initiate a crank cycle (manual mode)
Input − Closed to B+ will initiate a crank cycle (from a remote source, shorts pins 10 and 11 together).
Ground. Battery (−).
Input − Speed input that monitors engine RPM from engine mounted magnetic pickup. (Delayed for engine start).
Input − Oil Pressure input from sender unit that monitors oil pressure. (Delayed for engine start).
Input − Water Temperature input from sender unit that monitors water temperature. (Delayed for engine start).
Input − Extra input for shutdown fault identification and protection. (Delayed for engine start).
Input − Extra input for shutdown fault identification and protection. (Not delayed for engine start)
Input − Battery Voltage (B+).
MN2416
Factory adjustments are correct for most applications. If you choose to change the factory
settings, here is the procedure. The potentiometer and switches are shown in Figure 4-4.
Overspeed
(30−8500Hz) R1
Sets the RPM at which the engine will be shutdown if the engine speed exceeds this preset
value.
To adjust Overspeed value, turn the Overspeed Pot (R1) fully clockwise.
Run the engine up to the maximum operating speed.
Next, slowly turn the Pot (R1) counterclockwise until the engine shuts down on Overspeed.
Now, turn Pot (R1) clockwise two turns. This will adjust the Overspeed setpoint slightly greater.
Crank Disconnect (30−8500Hz) R2
Sets the engine speed (RPM) at which the starter is disengaged.
First, set the throttle at fast idle. Set Pot (R2) fully clockwise. Loosen the crank wire at Terminal
#2. Start the engine and immediately disconnect the crank wire (terminal #2) to prevent further
cranking.
Slowly turn the Pot (R2) counterclockwise until the green light (Engine Running) turns ON. This
adjustment must be complete within 90 seconds, or the engine will shut down indicating
Overcrank. (If this happens, simply connect the crank wire (terminal #2), enable starter circuit,
manually reset and try again.)
Glow Plug Delay (1 to 300 seconds.) R3 Selected when Switch #3 = On. Disabled when Switch #3 = Off.
Delays engine start to allow glow plugs to heat. When this delay expires, the auto start
sequence begins. To increase the setting, turn the Pot (R3) clockwise. To decrease the setting,
turn the Pot (R3) counterclockwise.
Warm−up Delay (1 to 300 seconds.) R3
The warm−up delay begins when the engine starts, with the output turning on when delay
expires. To increase the setting, turn the Pot (R3) clockwise. To decrease the setting, turn the Pot
(R3) counterclockwise.
Cooldown Delay (1 to 300 seconds.) R4. Selected when Switch #3 = OFF. Disabled when Switch #3 = On.
The cooldown delay begins when a stop signal is received. To increase the setting, turn the Pot
(R4) clockwise. To decrease the setting, turn the Pot (R4) counterclockwise.
Crank Attempts (Switches 1 and 2)
Allows 3, 5, 10 or infinite number of crank attempts (see Figure 4-4).
If engine fails to start after specified attempts, an Overcrank shutdown condition exists,
Overcrank LED On. (Infinite setting disables overcrank shutdown. The engine will do the crank
cycle as long as there is sufficient battery power available.)
Adjustments
MN2416
Operation 4-9
Engine Controller Operation
Auto Mode Operation
When the controller receives an automatic start signal (across pins 10 and 11), the glow plug
output turns on (if switch 3=On) and the delay begins. When the glow plug delay expires, the fuel
and crank outputs turn on. When the engine starts, the glow plug output is turned off. At this
time, the Shutdown Lockout and the Warm−up Time Delay (if selected) will begin, and the starter
is disengaged.
The Shutdown Lockout Delay causes the controller to ignore the Oil Pressure, Engine
Temperature and Spare Shutdown inputs at engine start up. If the engine false starts before the
delay expires, the engine will re−crank after a fixed delay (35 seconds), to let the engine stop
moving before engaging the starter. When the delay expires, the Loss of Speed Signal shutdown
is armed. Loss of Speed Signal occurs when both Overcrank and Overspeed LED’s turn on if the
speed drops below the crank disconnect set point.
After the Warm−up delay, the “At Load” output turns on (if selected).
The spare shutdown is armed immediately. There is no LED annunciation for either of the spare
shutdowns. They are reset by moving the Manual−Stop−Auto switch to Stop position
(disconnecting power) and back to Auto or Manual positions. If engine speed exceeds the
Overspeed set point (R1), the controller will turn off the fuel valve, turn on the Overspeed LED,
and lockout the engine from any further start attempts.
If a Low Oil Pressure or High Engine Temperature shutdown occurs while the engine is running,
the controller will turn off the fuel valve, turn on the appropriate LED and lockout the engine from
any further start attempts.
When the controller receives an automatic stop signal (remote start contacts open), the “At
Load” output turns off, and the Cooldown time delay (if switch 3=Off) will begin. When this delay
expires, the controller will turn off the fuel valve to stop the engine.
Manual Mode Operation
When the controller receives an manual start signal (pin 10) an automatic start signal is
simulated. Controller operation is the same as for Auto Mode all delays and shutdown conditions
are the same. Unless a shutdown occurs, the engine will continue to run until the controller
receives a manual stop command (by moving the Manual−Stop−Auto switch to Stop position).
Manual stop operation is the same as automatic stop operation.
4-10 Operation
MN2416
Section 5
Troubleshooting and Maintenance
Maintenance
MN2416
This manual contains only very minimal engine maintenance instructions. Refer to the engine
manufacturer’s owner’s manual for specific engine maintenance instructions for your generator
set. Any maintenance instructions or recommendations in the engine owner’s manual take
precedence over any of the following general recommendations.
General:
1. Inspect the fuel system for leaks. Replace all defective components immediately.
2. Inspect and replace any fuel line that shows signs of deterioration.
3. Inspect all the fuel clamps to ensure they are tight.
4. Make sure the fuel cap fits snugly on the fuel tank and that the fuel tank contains no
leaks.
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,
fraying, or loose connections. Repair or replace any problems prior to using the unit.
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 manufacturer’s owner’s manual.
4. Replace the spark plug(s) as is recommended by the engine manufacturer.
5. Clean the cooling fins on the engine to keep the engine’s heat dissipation potential at
it’s maximum.
6. Inspect and clean all governor and carburetor linkages so they operate properly.
7. Inspect the recoil starting rope for any damage and replace it if necessary (if
applicable).
8. Clean the trash screen around the recoil starter or other cooling air intake.
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.)
Troubleshooting and Maintenance 5-1
Problems and Solutions
Some of the more common problems are listed in Table 5-1. This information is intended to be a
check or verification that simple causes can be located and fixed. It is not an exhaustive “how to”
for all types of problems. Procedures that require in depth knowledge or skills (like flashing the
field) should be referred to the Baldor Generator Service Department by calling (920) 236−4200.
Table 5-1 Troubleshooting Guide
Problem
Engine will not start
Possible Cause
No fuel.
Restricted air flow.
No spark.
Engine will not crank
Dead battery.
Engine starts but will not run smoothly
Engine overheats
Fuel or ignition problem
Excessive load
Debris or dirt buildup on engine
Low Coolant Level
Output voltage varies
Irregular speed (fixed speed mode)
Fluctuating speed (fixed speed mode)
Loose terminal or load connections
Defective bearing (uneven air gap)
Low Voltage (0−15 VAC output)
Bad Voltmeter
Bad/Open Circuit Breaker/Fuse
Bad Connection
Loss of Residual Magnetism
Bad Voltage Selector Switch*
Bad Stator Windings
Low Voltage (15−20 VAC output)
Bad Voltmeter
Incorrect Engine Speed
Bad/Open Circuit Breaker/Fuse
Bad Connection
Bad Voltage Selector Switch*
Bad Stator Windings
Bad Voltage Adj. Rheostat*
Bad Voltage Regulator
Bad Rotor Diodes
Bad Rotor Windings
Incorrect voltage output
Bad Voltmeter*
Incorrect Engine Speed
Bad Voltage Adj. Rheostat*
Bad Voltage Regulator
Bad Connection
Bad Voltage Selector Switch*
High output voltage
Excessive speed (fixed speed mode)
5-2 Troubleshooting and Maintenance
Remedy
Check that fuel valves are ON. Check fuel level in fuel tank.
Check/replace air filter.
Check/replace spark plug(s). 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.
Replenish coolant
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
Measure the voltage across the voltage meter with an accurate
voltmeter to verify.
Check continuity across Breaker/Fuse. Replace if defective.
Check wiring including grounds, crimps and connection points.
Repair defects.
The generator needs to be flashed. Contact Baldor service to
perform this procedure.
Replace switch, contact Baldor service to perform this procedure.
Contact Baldor service to perform this procedure.
Measure the voltage across the voltage meter with an accurate
voltmeter to verify.
Remove electrical load, output should be 61−62 Hertz adjust engine
speed if necessary.
Check continuity across Breaker/Fuse. Replace if defective.
Check wiring including grounds, crimps and connection points.
Repair defects.
Replace switch, contact Baldor service to perform this procedure.
Contact Baldor service to perform this procedure.
Replace rheostat, contact Baldor service to perform this procedure.
Replace regulator, contact Baldor service to perform this procedure.
Contact Baldor service to perform this procedure.
Contact Baldor service to perform this procedure.
Measure the voltage across the voltage meter with an accurate
voltmeter to verify.
Remove electrical load, output should be 61−62 Hertz adjust engine
speed if necessary.
Replace rheostat, contact Baldor service to perform this procedure.
Replace regulator, contact Baldor service to perform this procedure.
Check wiring including grounds, crimps and connection points.
Repair defects.
Replace switch, contact Baldor service to perform this procedure.
Check engine for malfunction
MN2416
Table 5-1 Troubleshooting Guide Continued
Problem
Possible Cause
Remedy
Genset will not pull load
Incorrect Engine Speed
Load not connected properly
Load too large for unit
Remove electrical load, output should be 61−62 Hertz adjust engine
speed if necessary.
Verify voltage at the load and the connections to the proper
receptacle.
Verify load amperage is less than the generator set rated.
Note: For inductive loads, use the starting amperage rating of the
load (not the running amperage rating). Starting amps may be as
much as 5 times the running amps.
Electrical shock when frame is touched
Static charge.
Grounded armature or field coil.
Ground generator frame at local reference ground (see Section 3).
Return to factory for repair
Mechanical noise
Defective bearing
Rotor rubbing on stator
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.
Loose or misaligned coupling
Service
Parts
MN2416
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 manufacturer’s owner’s manual.
Troubleshooting and Maintenance 5-3
5-4 Troubleshooting and Maintenance
MN2416
Appendix A
Parts & Wiring Diagrams
Replacement Parts Replacement parts information is provided in this section of the manual. Engine parts are
identified in the engine manual that was provided with your generator set.
IMPORTANT:
Fuses are installed in the control box to protect the engine controller and associated
control circuits. When replacing fuses, use the exact replacement fuse (manufacturer and
part number).
Figure A-1 Isolators & Brackets
RM1088A11
RM1088A12
RM1088A25
RM1088A13
Description
SENDER, OIL PRESSURE
TEMP SENDER
SENDER ADAPTER
GAUGE, FUEL
ISOLATOR,
ISOLATOR,
MUFFLER
TANK, COOLANT RECOVERY
TANK, FUEL
CAP, COOLANT RECOVERY TANK
HOSE, RADIATOR
HOSE, RADIATOR
HOSE, RADIATOR
VALVE, FUMOTO
VALVE, DRAIN
RADIATOR
FILTER, AIR
FILTER, FUEL
VALVE,
VALVE, FUMOTO
MAGNETIC PICK−UP
VOLTAGE REGULATOR, AVC63−2.5
C.T. 50:5
C.T. 100:5
C.T. 150:5
C.T. 200:5
C.T. 300:5
C.T. 400:5
C.T. 600:5
DIODE, 1N5408
RELAY, OVER−CURRENT
RELAY, VF4−45F11
RELAY, VF7−41F11
SWITCH, LIMIT
SWITCH
LAMP
LAMP, FIXTURE
BREAKER, CIRC, 2P, 70A, 240V, DELAY
BREAKER, W/ SHUNT TRIP
CONTROLLER, ENGINE
(TS25−Green)
(TS45−Red)
(TS45−Green)
(TS80−White)
RM1088A16
TS25
EA0001A02
CT0056A00
TS45
EA0001A02
CT0055A00
WD3202A04
RM1088A11
WD3202A05
RM1088A12
RM1088A25
EA0008A13
TA0000A07
TA0000A11
TA0002A07
EA0005A00
EA0005A02
EA0005A05
EA0008A11
TA0000A07
TA0000A09
TA0002A07
EA0005A04
EA0005A16
EA0006A08
EA0015A12
EA0014A02
EA0044A01
EA0044A05
EA0007A00
EM0027A04
CT0050A04
CT0050A05
EA0006A09
EA0015A12
EA0014A02
EA0044A01
EA0044A00
EA0007A10
EM0027A04
Part Number
TS80
EA0001A02
CT0052A00
CT0053A00
WD3202A05
RM1088A25
TS130
EA0001A02
CT0052A00
CT0053A00
WD3202A05
RM1088A18
TS175
EA0001A02
EA0001A01
EA0008A14
TA0000A07
TA0000A11
TA0002A07
EA0005A25
EA0005A26
EA0008A17
TA0000A07
TA0000A14
TA0002A07
EA0005A10
EA0005A25
EA0008A21
TA0000A07
TA0000A14
TA0002A07
EA0005A04
EA0005A16
EA0006A14
EA0015A05
EA0014A02
EA0044A00
EA0044A05
EA0007A10
EA0006A13
EA0015A12
EA0014A02
EA0044A01
EA0044A05
EA0007A00
CT0050A06
CT0050A03
DI0176A00
RE5031A00
RE5031A01
RE5031A09
SP9090
SP9103
DI0180A01
DI0179A02
CK0070A45
EM0034A00
EA0044A00
EA0044A02
EA0006A09
EA0015A03
EA0044A01
EA0044A05
EA0007A00
WD3202A05
RM1088A24
CT0050A05
CT0050A00
CT0050A01
CT0050A02
DI0176A00
RE5031A00
RE5031A01
RE5031A09
SP9090
SP9098
DI0180A01
DI0180A02
CK0078A08
CK0070A39
EM0034A00
DI0176A00
RE5031A00
RE5031A01
RE5031A09
SP9090
SP9098
DI0180A01
DI0180A02
DI0176A00
RE5031A00
RE5031A01
RE5031A09
SP9090
SP9098
DI0180A01
DI0180A02
CT0050A06
CT0050A03
DI0176A00
RE5031A00
RE5031A01
RE5031A09
SP9090
SP9103
DI0180A00
DI0179A00
CK0070A40
EM0034A00
CK0070A41
EM0034A00
CK0070A49
EM0034A00
Continued on next page
MN2416
Parts & Wiring Diagrams A-1
Description
PANEL, RECEPTACLES
PANEL, CONTROLS
SWITCH, TOGGLE
SWITCH, DPDT
SWITCH, 3PH
KNOB, RHEOSTAT CONTROL
RHEOSTAT, 2K OHM, 2W
GAUGE, PRESSURE
GAUGE, TEMP
METER, VOLT
METER, ETM, 60HZ
METER, VOLT, 600ACV
METER, AMP,
METER, FREQ
RECEPTACLE, CS−6369, 250V, 50A,
RECEPTACLE, GFI, 250V 20A CSA/NEMA
BREAKER, 1 POLE 20 AMP
BREAKER, 2 POLE 50A
FUSE BUSS, MTH−5
FUSE, BUSS, AGC 2
FUSE, BUSS, ABC 15
DECAL, KEEP HANDS CLEAR
DECAL, DANGER−HIGH VOLTAGE
DECAL, CAUTION, LOAD STUD DOOR
DECAL, WARNING, AUTO START
DECAL, VOLTAGE CONNECTION
DECAL, BALDOR 22" LOGO
DECAL, STRIP W/NUMBER
DECAL, DOOR STRIP, (LEFT SIDE)
DECAL, LOGO STRIP, (RIGHT SIDE)
DECAL, OPERATING INSTRUCTIONS
DECAL, 15 SEC. DELAY (SCORED)
DECAL, RECEPT PANEL
DECAL, CONTROL PANEL
PLACARD, LO"
PLACARD, L1"
PLACARD, L2"
PLACARD, L3"
PLACARD, GROUND"
PLACARD, REMOTE START"
Wiring Diagrams
TS25
EH0353A00
EH0354A00
SP9079
SP9094
SP9095
HW2412A00
SP9082
WD3203A00
WD3204A00
WD3201A11
WD3201A00
WD3201A18
WD3201A20
WD3201A24
WD1541A28
WD1541A33
CK0070A67
CK0070A18
FU0066A00
FU0066A03
FU0066A05
LB0094A01
LB0094A11
LB0094A29
LB0094A30
LB0094A33
LB0094A61
LB0094A63
LB0094A64
LB0094A65
LB0094A74
LB0094A58
LB0094A59
LB0094A60
LB0095A14
LB0095A16
LB0095A17
LB0095A18
LB0095A37
LB0095A42
TS45
EH0356A00
EH0354A00
SP9079
SP9094
SP9095
HW2412A00
SP9082
WD3203A00
WD3204A00
WD3201A11
WD3201A00
WD3201A18
WD3201A21
WD3201A24
WD1541A28
WD1541A33
CK0070A67
CK0070A18
FU0066A00
FU0066A03
FU0066A05
LB0094A01
LB0094A11
LB0094A29
LB0094A30
LB0094A33
LB0094A61
LB0099A04
LB0094A04
LB0094A05
LB0094A93
LB0094A58
LB0094A66
LB0094A60
LB0095A14
LB0095A16
LB0095A17
LB0095A18
LB0095A37
LB0095A42
Part No.
TS80
EH0356A00
EH0354A00
SP9079
SP9094
SP9095
HW2412A00
SP9082
WD3203A00
WD3204A00
WD3201A11
WD3201A00
WD3201A18
WD3201A22
WD3201A24
WD1541A28
WD1541A33
CK0070A67
CK0070A18
FU0066A00
FU0066A03
FU0066A05
LB0094A01
LB0094A11
LB0094A29
LB0094A30
LB0094A33
LB0094A61
LB0094A63
LB0099A06
LB0099A07
LB0094A93
LB0094A58
LB0094A59
LB0094A60
LB0095A14
LB0095A16
LB0095A17
LB0095A18
LB0095A37
LB0095A42
TS130
EH0395A00
EH0396A00
SP9079
SP9094
SP9095
HW2412A00
SP9082
WD3203A00
WD3204A00
WD3201A11
WD3201A00
WD3201A18
WD3201A36
WD3201A24
WD1541A28
WD1541A33
CK0070A67
CK0070A18
FU0066A00
FU0066A03
FU0066A05
LB0094A01
LB0094A11
LB0094A29
LB0094A30
LB0094A33
LB0094A61
LB0094A63
LB0099A16
LB0099A17
LB0094A74
LB0094A58
LB0094B18
LB0094B17
LB0095A14
LB0095A16
LB0095A17
LB0095A18
LB0095A37
LB0095A42
TS175
EH0395A00
EH0396A00
SP9079
SP9094
SP9095
HW2412A00
SP9082
WD3203A00
WD3204A00
WD3201A11
WD3201A00
WD3201A18
WD3201A36
WD3201A24
WD1541A28
WD1541A33
CK0070A67
CK0070A18
FU0066A00
FU0066A03
FU0066A05
LB0094A01
LB0094A11
LB0094A29
LB0094A30
LB0094A33
LB0094A61
LB0094A63
LB0099A18
LB0099A19
LB0094A74
LB0094A58
LB0094B18
LB0094B17
LB0095A14
LB0095A16
LB0095A17
LB0095A18
LB0095A37
LB0095A42
Wiring diagrams for these generators are contained on the following pages of this appendix.
A-2 Parts & Wiring Diagrams
MN2416
Figure A-1 TS25 Connection Diagram
MN2416
Parts & Wiring Diagrams A-3
Figure A-2 TS25 Receptacle Connection Diagram
A-4 Parts & Wiring Diagrams
MN2416
Figure A-3 TS25/45/80 Control Panel Connection Diagram
MN2416
Parts & Wiring Diagrams A-5
Figure A-4 TS25/45 Generator Lead Connection Diagram
A-6 Parts & Wiring Diagrams
MN2416
Figure A-5 TS45 Connection Diagram
MN2416
Parts & Wiring Diagrams A-7
Figure A-6 TS45/80 Receptacle Connection Diagram
A-8 Parts & Wiring Diagrams
MN2416
Figure A-7 TS80 Connection Diagram
MN2416
Parts & Wiring Diagrams A-9
Figure A-8 TS80 Generator Lead Connection Diagram
A-10 Parts & Wiring Diagrams
MN2416
Figure A-9 TS80 Generator Wiring Diagram
MN2416
Parts & Wiring Diagrams A-11
Figure A-10 TS130 Connection Diagram
A-12 Parts & Wiring Diagrams
MN2416
Figure A-11 TS130 Control Panel Connection Diagram
MN2416
Parts & Wiring Diagrams A-13
Figure A-12 TS130 Generator Lead Connection Diagram
A-14 Parts & Wiring Diagrams
MN2416
Figure A-13 TS130 Receptacle Connection Diagram
MN2416
Parts & Wiring Diagrams A-15
Figure A-14 TS130 Generator Wiring Diagram
A-16 Parts & Wiring Diagrams
MN2416
Figure A-15 TS175 Control Panel Connection Diagram
MN2416
Parts & Wiring Diagrams A-17
Figure A-16 TS175 Generator Lead Connection Diagram
A-18 Parts & Wiring Diagrams
MN2416
Baldor District Offices
UNITED STATES
ARIZONA
PHOENIX
4211 S 43RD PLACE
PHOENIX, AZ 85040
PHONE: 602−470−0407
FAX: 602−470−0464
CALIFORNIA
LOS ANGELES
6480 FLOTILLA
COMMERCE, CA 90040
PHONE: 323−724−6771
FAX: 323−721−5859
HAYWARD
21056 FORBES STREET
HAYWARD, CA 94545
PHONE: 510−785−9900
FAX: 510−785−9910
COLORADO
DENVER
2520 W BARBERRY PLACE
DENVER, CO 80204
PHONE: 303−623−0127
FAX: 303−595−3772
FAX: 586−978−9969
MICHIGAN Continued
GAND RAPIDS
668 3 MILE ROAD NW
GRAND RAPIDS, MI 49504
PHONE: 616−785−1784
FAX: 616−785−1788
TEXAS
HOUSTON
4647 PINE TIMBERS
SUITE # 135
HOUSTON, TX 77041
PHONE: 713−895−7062
FAX: 713−690−4540
MINNESOTA
MINNEAPOLIS
21080 134TH AVE. NORTH
ROGERS, MN 55374
PHONE: 763−428−3633
FAX: 763−428−4551
DALLAS
3040 QUEBEC
DALLAS, TX 75247
PHONE: 214−634−7271
FAX: 214−634−8874
MISSOURI
ST LOUIS
422 INDUSTRIAL DRIVE
MARYLAND HEIGHTS, MO 63043
PHONE: 314−298−1800
FAX: 314−298−7660
KANSAS CITY
915 N W PLATTE VALLEY DR
RIVERSIDE, MO 64150
PHONE: 816−587−0272
FAX: 816−587−3735
UTAH
SALT LAKE CITY
2230 SOUTH MAIN STREET
SALT LAKE CITY, UT 84115
PHONE: 801−832−0127
FAX: 801−832−8911
WISCONSIN
MILWAUKEE
2725 SOUTH 163RD STREET
NEW BERLIN, WI 53151
PHONE: 262−784−5940
FAX: 262−784−1215
NEW YORK
AUBURN
ONE ELLIS DRIVE
AUBURN, NY 13021
PHONE: 315−255−3403
FAX: 315−253−9923
INTERNATIONAL SALES
FORT SMITH, AR
P.O. BOX 2400
FORT SMITH, AR 72902
PHONE: 479−646−4711
FAX: 479−648−5895
FLORIDA
TAMPA/PUERTO RICO/
VIRGIN ISLANDS
3906 EAST 11TH AVENUE
TAMPA, FL 33605
PHONE: 813−248−5078
FAX: 813−247−2984
NORTH CAROLINA
GREENSBORO
1220 ROTHERWOOD ROAD
GREENSBORO, NC 27406
P O BOX 16500
GREENSBORO, NC 27416
PHONE: 336−272−6104
FAX: 336−273−6628
CANADA
EDMONTON, ALBERTA
4053−92 STREET
EDMONTON, ALBERTA T6E 6R8
PHONE: 780−434−4900
FAX: 780−438−2600
GEORGIA
ATLANTA
62 TECHNOLOGY DR.
ALPHARETTA, GA 30005
PHONE: 770−772−7000
FAX: 770−772−7200
OHIO
CINCINNATI
2929 CRESCENTVILLE ROAD
WEST CHESTER, OH 45069
PHONE: 513−771−2600
FAX: 513−772−2219
CONNECTICUT
WALLINGFORD
65 SOUTH TURNPIKE ROAD
WALLINGFORD, CT 06492
PHONE: 203−269−1354
FAX: 203−269−5485
ILLINOIS
CHICAGO
1601 FRONTENAC ROAD
NAPERVILLE, IL 60563
PHONE: 630−848−5100
FAX: 630−848−5110
INDIANA
INDIANAPOLIS
5525 W. MINNESOTA STREET
INDIANAPOLIS, IN 46241
PHONE: 317−246−5100
FAX: 317−246−5110
800−428−4141
IOWA
DES MOINES
1800 DIXON STREET, SUITE C
DES MOINES, IA 50316
PHONE: 515−263−6929
FAX: 515−263−6515
MARYLAND
BALTIMORE
6660 SANTA BARBARA RD.
SUITE 22−24
ELKRIDGE, MD 21075
PHONE: 410−579−2135
FAX: 410−579−2677
MASSACHUSETTS
BOSTON
6 PULLMAN STREET
WORCESTER, MA 01606
PHONE: 508−854−0708
FAX: 508−854−0291
MICHIGAN
DETROIT
33782 STERLING PONDS BLVD.
STERLING HEIGHTS, MI 48312
PHONE: 586−978−9800
CLEVELAND
8929 FREEWAY DRIVE
MACEDONIA, OH 44056
PHONE: 330−468−4777
FAX: 330−468−4778
OKLAHOMA
TULSA
2 EAST DAWES
BIXBY, OK 74008
PHONE: 918−366−9320
FAX: 918−366−9338
OREGON
PORTLAND
20393 SW AVERY COURT
TUALATIN, OR 97062
PHONE: 503−691−9010
FAX: 503−691−9012
PENNSYLVANIA
PHILADELPHIA
1035 THOMAS BUSCH
MEMORIAL HIGHWAY
PENNSAUKEN, NJ 08110
PHONE: 856−661−1442
FAX: 856−663−6363
PITTSBURGH
616H BEATTY ROAD
MONROEVILLE, PA 15146
PHONE: 412−380−7244
FAX: 412−380−7250
TENNESSEE
MEMPHIS
4000 WINCHESTER ROAD
MEMPHIS, TN 38118
PHONE: 901−365−2020
FAX: 901−365−3914
OAKVILLE, ONTARIO
2750 COVENTRY ROAD
OAKVILLE, ONTARIO L6H 6R1
PHONE: 905−829−3301
FAX: 905−829−3302
MONTREAL, QUEBEC
1844 WILLIAM STREET
MONTREAL, QUEBEC H3J 1R5
PHONE: 514−933−2711
FAX: 514−933−8639
VANCOUVER,
BRITISH COLUMBIA
1538 KEBET WAY
PORT COQUITLAM, BC V3C 5M5
PHONE 604−421−2822
FAX: 604−421−3113
WINNIPEG, MANITOBA
54 PRINCESS STREET
WINNIPEG, MANITOBA R3B 1K2
PHONE: 204−942−5205
FAX: 204−956−4251
AUSTRALIA
UNIT 3, 6 STANTON ROAD
SEVEN HILLS, NSW 2147,
AUSTRALIA
PHONE: (61) (2) 9674 5455
FAX: (61) (2) 9674 2495
UNIT 8, 5 KELLETTS ROAD
ROWVILLE, VICTORIA, 3178
AUSTRALIA
PHONE: (61) (3) 9753 4355
FAX: (61) (3) 9753 4366
BALDOR CENTROAMERICA
RESIDENCIAL PINARES DE SUIZA
POL. 15 #44, NVA. SAN SALVADOR
EL SALVADOR, CENTRO AMERICA
PHONE: (503) 288−1519
FAX: (503) 288−1518
BALDOR SUDAMERICA
CALLE F, EL CANGREJO
CONDOMINIO P.H. CONDADO PLAZA
APT. 11D, BELLA VISTA
PANAMÁ CITY, REP. DE PANAMÁ
PHONE: (507) 265−6041
CHINA
SHANGHAI JIAHUA BUSINESS CENTER
ROOM NO. A−8421
808 HONG QIAO ROAD
SHANGHAI 200030
PHONE: 86−21−64473060
FAX: 86−21−64078620
GERMANY
DIESELSTRASSE 22
D−85551 KIRCHHEIM
MUNICH, GERMANY
PHONE: (49) (89) 90508 − 0
FAX: (49) (89) 90508 − 492
INDIA
14, COMMERCE AVENUE
MAHAGANESH COLONY
PAUD ROAD
PUNE − 411 038
MAHARASHTRA, INDIA
PHONE: 91 20 25 45 95 31/32
FAX: 91 20 24 55 95 30
ITALY
BALDOR ASR AG
SUCCURSALE DI MENDRISIO
VIA BORROMINI, 20A
CH−6850 MENDRISIO
SWITZERLAND
PHONE: 41 91 640 9952
FAX: 41 91 630 2633
JAPAN
DIA BLDG 802,
2−21−1 TSURUYA−CHO,
KANAGAWA−KU
YOKOHAMA, 221−0835, JAPAN
PHONE: 81−45−412−4506
FAX: 81−45−412−4507
KOREA
ROOM 210
BUPYEONG INDUSTRIAL
COMMERCIAL COOPERATIVE
396−16 CHEONGCHEON 2−DONG,
BUPYEONG−GU
INCHEON, KOREA, 403−858
PHONE: 82 32 508 3252
FAX: 82 32 508 3253
MÉXICO
KM. 2.0 BLVD. AL AEROPUERTO
LEÓN 37545, GUANAJUATO, MÉXICO
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
CH−8245 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: (886−2) 2577−4352
FAX: (886−2) 2577−4157
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 72902--2400
(479) 646--4711
Fax (479) 648--5792
www.baldor.com
CH
TEL: +41 52 647 4700
FAX:+41 52 659 2394
D
TEL: +49 89 90 50 80
FAX:+49 89 90 50 8491
UK
TEL: +44 1454 850000
FAX:+44 1454 850001
F
TEL: +33 145 10 7902
FAX:+33 145 09 0864
I
TEL: +39 11 562 4440
FAX:+39 11 562 5660
AU
TEL: +61 29674 5455
FAX:+61 29674 2495
CC
TEL: +65 744 2572
FAX:+65 747 1708
MX
TEL: +52 477 761 2030
FAX:+52 477 761 2010
© Baldor Electric Company
MN2416
Printed in USA
5/05 FAR200
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