OPERATOR'S MANUAL
FOR YOUR
AUTOMATIC EMERGENCY
POW'R PRODUCTS
MODEL
AE12 GENERATOR
BALDOR GENERATORS
3815 Oregon Street • Oshkosh WI 54902
Telephone 236-4200 • Fax 920-236-4219
FORM#: S-PSG-002-13
EFFECTIVE DATE: 4/2/97
AE12 COVER \MSW'00
REVISION DATE: 8/13/02
Safety Warnings
? Place protective covers and guards over the rotating parts, if rotating parts such as the drive shaft, pulley,
belt, etc. are left exposed, they are potentially hazardous.
? When cleaning, repairing or inspecting, make sure all moving parts have stopped.
?
Prior to working on the generator set, disconnect the spark plug and battery to prevent accidental
starting.
? Use only original equipment or authorized replacement parts. Use of correct parts will assure the operator
of the safety integrity that was designed into the unit.
? Unauthorized modifications to the generator set may impair the function and/or safety of the unit.
? Do not operate the generator set without a muffler. Inspect periodically and replace if necessary.
? Do not touch the hot exhaust components or the high voltage spark plug and coil terminals. While Spark
Plug Voltages are not normally lethal, an involuntary jerk of the hand caused by a hot surface or by
an electrical shock can result in injury.
? Repair of electrical generating equipment requires specialized skills. Repair personnel must have a
thorough understanding of generator and small engine repair procedures.
? Never inhale exhaust gases. They contain carbon monoxide; a colorless, odorless and extremely
dangerous gas that can cause unconsciousness or death. Symptoms of carbon monoxide poisoning
can include: dizziness, nausea, headaches, sleepiness, vomiting or incoherency. If you or anyone else
experiences any of these symptoms, get out into the fresh air immediately. Shut the unit down and
do not operate it until it has been inspected and, if necessary, repaired.
? Never Operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave.
? CALIFORNIA PROPOSITION 65 WARNING: engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects or other reproductive harm.
? Know how to stop the engine quickly and understand the operation of all controls.
? Never permit anyone to operate the generator set without proper instructions.
? Never allow children to operate the generator set.
? Children and pets must be kept away from the area of operation due to the possibility of burns from hot
engine components or injury from any equipment the generator set is powering.
? Always wear eye protection and Hearing protection when working near the generator set.
? Operate the generator set only with the guards, shields and other safety items in place and working
properly.
? Do not put hands, feet, tools or other objects near rotating parts.
? Use reasonable care when moving or lifting the unit. The generator set may move around inside the wrap
frame creating "Pinch Points".
? Do not run the generator set while it is being moved.
? Do not support the generator set from the top of the wrap frame.
? Do not operate the generator set while under the influence of alcohol, drugs or medication.
? When transporting or using a generator set with the wheel option, secure the unit to prevent it from moving
around.
? Do not tamper with or change the engine speed as it has been preset at the factory for proper operation.
? Keep hands and face away from the carburetor when the air cleaner is being moved. A sudden backfire
can
cause serious burns.
? Be careful of hot parts. The muffler and other generator parts become very hot while the engine is running.
? Do not "jump start" the generator set.
? Sulfuric acid can cause severe injury and can give off gases, which are corrosive and potentially explosive.
Avoid contact with skin, eyes, and clothing. In case of contact, flush area immediately with water.
? When transporting a generator set, secure it to prevent it from moving or shifting.
? Know how to stop the engine quickly and understand the operation of all controls.
? Do not operate electrical equipment while standing in water, on wet ground or with wet hands or shoes.
? Use extreme caution when working on electrical components. Potentially dangerous voltage is present
when the engine is running.
? Always treat the electrical circuits as if they were energized.
? Disconnect all leads plugged into the unit Prior to working on it.
? Have the electrical circuits serviced only by qualified technicians.
? Inspect wiring frequently and replace frayed, broken or poor leads.
? Do not connect this unit to any building's electrical system unless you utilize an approved transfer switch or
the main service entrance switch has been disconnected and locked open.
? Circuit overload protection must be provided in accordance with national electrical codes and local
regulations.
? Check GFCI Receptacles monthly by using the "Test" and "Reset" buttons designed into them.
? Depending on your application it may be mandatory to ground or not ground this unit to earth ground.
Comply with local electrical codes.
????
FOR GASOLINE OR DIESEL POWERED GENERATOR SETS
????
? Operate the generator set on a level surface. If the generator set is tilted, fuel spillage may result.
? Handle fuel with care. It is highly flammable. Use only clean, properly marked and approved safety
containers for refueling and storing fuel.
? Stop the engine and allow it to cool before refueling.
? Do not overfill the fuel tank. Only fill the tank to within 1/2" of the top of the tank to allow space for fuel
expansion.
? If fuel is spilled, wipe it up carefully and wait until the fuel has dried before starting the engine.
? Make sure the fuel cap is properly closed after refueling.
? Never operate the generator set while smoking.
? Never operate the generator set near an open flame.
? Never store the generator set with fuel in the tank indoors or in an enclosed, poorly ventilated enclosure
where fuel fumes may reach an open flame, electrical spark or pilot light as on a furnace, water heater,
clothes dryer, etc.
? When transporting over long distances or rough roads, drain the fuel tank to prevent leakage and spillage.
????
FOR GASOLINE OR DIESEL POWERED GENERATOR SETS
????
? Check all fuel supply piping and their connections on a monthly basis for fuel leaks.
? Use only approved piping and componentry in your fuel supply system.
? A professional, experienced technician should only install the fuel supply system.
? Do not run the fuel line up against any sharp objects.
? Comply with NFPA regulations and your local codes in regard to shut-off valves, regulators, etc. and any
other recommendations or requirements they may have.
? Keep the generator set at least three feet away from buildings or other structures.
? Keep the generator set away from flammable and other hazardous materials (trash, rags, lubricants,
explosives, paints, etc.)
? Keep the generator set free of grass, leaves and excessive grease and oils.
? Allow the generator set to cool before transporting it or storing it indoors.
? Have fire extinguisher accessible and nearby while operating the generator set.
? This generator set must not be used on or near any forest covered brush covered or grass covered land
unless the engine's exhaust system is equipped with a spark arrester and it must be maintained
in effective working order by the operator.
? Operation inside an enclosed compartment or building is a potential fire hazard and should not be done
unless approval is obtained from Baldor Generators. Engine/Generator overheating can cause severe
damage due to restricted, obstructed or improper air-flow that is necessary for the proper cooling of the
unit.
? Hot exhaust gases being discharged by the engine must never be directed toward anything that could
catch fire or explode.
TABLE OF CONTENTS
SECTION
PAGE
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . .
Prefix
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Generator Specifications . . . . . . . . . . . . . . . . . . .
2
Location Information . . . . . . . . . . . . . . . . . . . . . .
3
Connection Information . . . . . . . . . . . . . . . . . . .
4
Engine Information . . . . . . . . . . . . . . . . . . . . . . .
6
Basic Generator Maintenance . . . . . . . . . . . . . .
7
Basic Engine Maintenance . . . . . . . . . . . . . . . . . .
8
Storage or Long Term Non-Use Instructions . . . . .
9
Parts & Service Information . . . . . . . . . . . . . . . . . .
10
General Installation & Site Selection Guidelines . . .
11
Electric Installation Guidelines . . . . . . . . . . . . . . . .
13
AE8 Enclosed Assembly Diagram . . . . . . . . . . . . . .
16
Connection Box for AE8/10 Units with Enclosure. . . .
17
AE8 and AE10 Installation Diagram. . . . . . . . . . . . .
16
Basic Gaseous Fuel Information. . . . . . . . . . . . . . . .
17
Propane Gas Flow Chart . . . . . . . . . . . . . . . . . . . . .
20
Natural Gas Flow Chart. . . . . . . . . . . . . . . . . . . . . .
21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
Simple Electrical Troubleshooting . . . . . . . . . . . . . .
24
Gaseous Fuel System Troubleshooting . . . . . . . . . . .
26
Electrical System Troubleshooting . . . . . . . . . . . . . .
29
AE Series Interconnection . . . . . . . . . . . . . . . . . . . .
31
Customer Connection Wiring Diagram . . . . . . . . . . . .
33
AE12 Base Outline Drawing . . . . . . . . . . . . . . . . . . . .
34
AE12 OPEN - Connection Diagram . . . . . . . . . . . . . . . .
35
AE12 Enclosed - Wiring Diagram . . . . . . . . .. . . . . . . . .
36
AE12 Enclosed - Connection Diagram . . . . . . . . . . . . .
37
Gen End Componentry Diagram . . . . . . . . . . . . . . .. .
40
Parts Break Down for AE12 . . . . . . . . . . . . . . . . . .
41
Warranty Information . . . . . . . . . . . . . . . . . . . . . .
43
FORWARD
This manual contains the information you need to safely and efficiently operate your generator
set. During the preparation of this manual every effort was made to ensure the accuracy of its
contents.
Never operate this generator set without first carefully reading this manual and observing all
the safety warnings it presents. While safety is built into every Baldor Pow'R Gard generator
set, careless or improper operation could possibly result in mechanical failure, property damage,
severe injury or even death.
Note that this manual covers only very basic information in regards to the engine. A separate
owner's manual for the engine is supplied with this unit for your use. Please refer to this manual
for information relative to engine operation, maintenance, recommendations, and additional
safety warnings.
As soon as you receive your generator set, inspect it closely for shipping damage. If you find
some damage notify the transportation company immediately and file a freight damage claim.
Think of this manual as a tool to help you get the most out of your generator set. We strongly
suggest that you keep this manual with your generator set and refer to it when questions arise
in regards to its operation.
Baldor Generators has been in business since 1965. The generator sets we manufacture have
earned the reputation of being of high quality and dependability. We take pride in this fact and
continue to keep our quality standards high on the list of priorities. We are also constantly
researching new technological ideas to determine if they could be used to make our generator
sets even better.
Thank you for purchasing your Baldor generator set.
Effective: February 26, 1998
Revised, August 12,2002
Form#: S-PSG-001-25
Page 1 of 45
SPECIFICATIONS FOR YOUR AE12 bBALDOR GENERATOR SET
RATINGS:
12 KW
FUEL TYPE:
LP/Natural Gas
ELECTRICAL CHARACTERISTICS:
Voltage:
120/240
Phase:
1
Power Factor:
1
Amps:
100/50
Hertz:
60
Voltage Regulation (+/-):
1%
Frequency Regulation:
5%
Total Harmonic Distortion: <8%
Motor Starting (HP):
6
Dimensions w/ enclosure - IN. (LxWxH) :
Dimensions w/o enclosure - IN. (LxWxH) :
ENGINE CHARACTERISTICS:
Make:
ONAN
Model:
P224
Cooling:
Air
No. Cylinders 2
H.P.
24.0
R.P.M.:
3600
FUEL CONSUMPTION (Full Load):
LP Gas: 96 C.F.H
Natural Gas: 260 C.F.H.
44 1/2 x 29 x 38 3/4
33 x 27 x 30
Weight: 585 Lbs.
Weight: 389 Lbs.
NOTE: The enclosed information covers basic installation, operating and maintenance for this
specific generator.
Installation of this generator is the sole responsibility of the owner.
Baldor Generators provides an AE Installation manual with the shipment of your
generator which contains more specific information regarding the installation of your
AE Unit.
Any questions regarding this information may be directed to the Customer Service
department at Baldor Generators.
This information is designed to be a guide for an experienced electrician. Those not
qualified should not attempt installation.
Page 2 of 45
LOCATION
The following information is provided to assure that you get the best service from your
Automatic Emergency Generator. Several factors should be taken into consideration in choosing
the best location in which to permanently mount this unit.
SURFACE: Baldor Generators strongly recommends that your AE Unit be installed on a
concrete or cement slab of appropriate size relative to the generator's base which is at least five
(5) feet from any building, structure, shrubbery, or any other obstruction that could possibly
catch fire due to the extreme heat output of this generator set.
MOISTURE: All electrical equipment should be protected from excessive moisture. Failure to
do so will result in deterioration of the wiring insulation and may result in short circuits and a
possible electrocution hazard.
OPERATING ELECTRICAL EQUIPMENT IN WET ENVIRONMENTAL
CONDITIONS CREATES A POTENTIAL ELECTROCUTION HAZARD.
DO NOT OPERATE ELECTRICAL EQUIPMENT WHILE STANDING IN
WATER, ON WET GROUND, OR WITH WET HANDS OR SHOES.
DIRT: Foreign materials such as dust, sand, and other abrasive materials have a tendency to
cause excessive wear to both engine and generator parts. It is important that the unit be
permanently located and operated in a reasonable clean environment.
HEAT: All engines give off considerable heat when running. Since the engine and your
generator set uses air to keep it cool it is important that the temperature of the area in which it
is located does not exceed 100 degrees F (Even while it is running). Where natural ventilation is
inadequate, a fan to boost circulation should be utilized.
EXHAUST: Exhaust gases from internal combustion engines are extremely poisonous. We
recommend that this unit not be placed in an indoor environment. However, if this is the
application you choose, the engine exhaust fumes must be vented to the outside.
EXHAUST FUMES CAN CAUSE SEVERE INJURY OR DEATH. ALWAYS
OPERATE IN A WELL VENTILATED AREA.
CONFINED SPACE: This unit must not be operated in a confined space or an enclosed
compartment/area. Running the generator set in this environment is a potential fire hazard and
is not authorized. Engine and generator overheating damage could also occur due to restricted
cooling air flow to and from the unit.
OPERATING THIS UNIT IN AN AREA WITHOUT ADEQUATE
VENTILATION CREATES A POTENTIAL FIRE HAZARD. ALWAYS
OPERATE THIS UNIT IN A WELL VENTILATED AREA.
Page 3 of 45
CONNECTION INFORMATION
Your new Baldor Pow'R Gard Generator has all interconnecting wiring, which is terminated at a
junction box. All wiring will be clearly labeled as being load, remote start contacts, and AC input
terminals and are to be connected as described below:
LOAD - These connections are rated and sized according to the KW of the generator. Proper
lead wire from these points to the automatic transfer switch (or load switching device)
is mandatory. See enclosed transfer switch information for corresponding generator
input terminals.
WIRING - Use sufficiently large insulated wire to connect the generator set to the load. The
gauge of wire will depend largely on the distance, the permissible voltage drop, and the
size and type of load. If you are not sure of the gauge wire needed for your
application, consult a competent electrician.
FRAYED, CUT, BROKEN, LOOSELY CONNECTED, OR IMPROPERLY
SIZED POWER CORDS OR WIRES CAN CAUSE EQUIPMENT DAMAGE,
FIRE, SEVERE INJURY OR DEATH. INSPECT AND MAINTAIN ALL
POWER CORDS ON A REGULAR BASIS.
REMOTE START CONTACTS - This two wire connection, once connected to an appropriate
switch will start the generator and perform as described in the remote start/stop
literature. These contacts 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 chargers or engine block
heater combinations. A constant supply of 120 volts AC (or as specified) is needed at
these terminals to power these devices.
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.
NOTE - It is recommended that units utilizing an automatic transfer switch with adjustable
time delay have the initial adjustments made prior to startup.
Factory recommendations are to allow a 2 second delay on startup, and a 15 second
delay on emergency to normal (so if your public service power is interrupted, the automatic
transfer switch will tell your generator to start after two seconds of power loss. Then, once
Public Service Power is restored, the generator will continue to operate for an additional fifteen
minutes just in case there is yet another outage of power).
GROUNDING: If grounding is necessary in your application according to National Electric
Code and/or local codes, drive a 3/4" or 1" pipe into the ground as close to the
Generator Set as is possible. This pipe must penetrate moist earth (minimum of 8
feet). Connect a ground clamp to this pipe and run a No. 10 wire or larger from it to
the ground stud on the generator set.
Page 4 of 45
Do not connect the ground wire from the generator set to a water pipe or a ground used by a
radio system.
IMPROPER GROUNDING CAN CAUSE EQUIPMENT DAMAGE, SEVERE
INJURY OR DEATH. INSPECT AND MAINTAIN THE GROUNDING
SYSTEM IN ACCORDANCE WITH ALL APPLICABLE CODES.
CONNECTIONS TO HOUSE WIRING: Any electrical generator that is temporarily connected
to a building or home (where the building is also supplied electricity by a local utility)
shall be connected only by a competent electrician and only after the main service
entrance switch has been disconnected and locked open. This will isolate the building's
electrical system from the local utility's electrical transmission wires and prevent the
hazard of electrical back-feed to utility service workers.
Any generator set that is permanently connected to a building or home (where the building is
also supplied electricity by a local utility) shall be connected only by means of a double- throw
transfer switch. This will isolate the building's electrical system from the local utility's electrical
transmission wires and prevent the hazard of electrical back-feed to utility service workers.
DO NOT CONNECT THIS GENERATOR SET TO ANY BUILDING'S ELECTRICAL
SYSTEM UNLESS YOU USE AN APPROVED TRANSFER SWITCH OR THE MAIN
SERVICE ENTRANCE SWITCH HAS BEEN DISCONNECTED AND LOCKED
OPEN.
ANY TEMPORARY OR PERMANENT WIRING CONNECTIONS MADE BETWEEN
GENERATOR SET AND AN EXISTING ELECTRICAL SYSTEM MUST ONLY BE
DONE BY A QUALIFIED COMPETENT ELECTRICIAN. IMPROPER WIRING/
CONNECTIONS COULD CAUSE EQUIPMENT DAMAGE, PROPERTY DAMAGE,
INJURY OR DEATH.
CHECK ALL NATIONAL ELECTRIC CODES AND ALL LOCAL CODES IN REGARDS TO YOUR
SPECIFIC APPLICATION. ANY NATIONAL ELECTRIC CODE OR LOCAL CODE WILL TAKE
PRECEDENCE OVER ANY OF OUR GUIDELINES OR RECOMMENDATIONS.
Page 5 of 45
ENGINE INFORMATION
This operator's manual only covers basic day -to -day engine operating instructions. However,
the engine manufacturer's manual is included with your generator set and should be referred to
for any additional information you may need. Become familiar with and follow all the engine
manufacturer's operation, safety and maintenance guidelines.
OIL: Use a high quality oil of the type specified in the engine owner's manual for your specific
operating conditions. Check the oil regularly, or at minimum every 5-8 hours of
operation.
TO HELP PREVENT ENGINE DAMAGE, CHECK THE OIL LEVEL OF THE
ENGINE REGULARLY AND MAKE SURE IT IS MAINTAINED AT THE
PROPER LEVEL.
FUEL: (LP or Natural Gas): Make sure the gaseous fuel being supplied to the unit is in vapor
form and that it is being delivered to the engine's gaseous fuel regulator at the pressure
specified on it.
An engine needs 10,000 BTU's of fuel per each engine horsepower to operate properly.
GASEOUS FUEL IS EXTREMELY FLAMMABLE AND CAN CAUSE PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. CHECK THE GASEOUS FUEL SUPPLY
SYSTEM ON A MONTHLY BASIS FOR LEAKS. HAVE ANY LEAKS REPAIRED
BY AN EXPERIENCED PROFESSIONAL PRIOR TO STARTING YOUR
GENERATOR SET.
OPERATING SPEED: This generator set must be run at it's proper designed speed in order to
obtain the electrical power it was built to produce.
All engines have a tendency to slow down when a load is applied to it. The governor on the
engine is designed to hold the operating speed as nearly constant as possible. When the load
connected to the generator set is increased, the engine is more heavily loaded and as a result
the 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.
Page 6 of 45
MAINTENANCE
MAINTENANCE SHOULD ONLY BE PERFORMED ON THE GENERATOR SET
AFTER THE ENGINE HAS STOPPED AND THE GENERATOR SET HAS COOLED
DOWN. THE BATTERY AND SPARK PLUG SHOULD ALSO BE DISCONNECTED
PRIOR TO PERFORMING MAINTENANCE.
GENERATOR END MAINTENANCE
Generator end maintenance consists of cleaning the generator set, inspecting the wiring and
fuel system, and making any necessary adjustments. Generator end maintenance should be
performed on a monthly basis (or sooner if needed).
CLEANING:
v Clean the generator set and remove any and all dust, dirt, or other foreign material.
v
Inspect and clean the cooling air intake and exhaust louvers of the generator end. Make
sure they are free of 'caked -on' dirt or any other material that may restrict the cooling air
flow through the generator windings.
v
Clean the generator set and its components with a damp cloth or sponge.
Do not use sprayed water or compressed air to clean the generator set or it's components.
INSPECTING:
v Inspect the external wires of the generator set for cuts, fraying, or loose connections.
Repair or replace any problems prior to using the unit.
CUT, FRAYED, BROKEN, OR LOOSELY CONNECTED WIRES CAN
CAUSE EQUIPMENT DAMAGE, SEVERE INJURY, OR DEATH.
v
Inspect and clean the battery posts and the associated battery cable terminals.
v
Inspect and replace any control box components that are broken or not working properly
(receptacles, circuit breakers, switches, etc…).
v
Inspect the fuel system for leaks.
v
Inspect and replace any fuel line that shows signs of deterioration.
v
Make sure all the fuel clamps are tight.
v
Make sure the fuel cap fits snugly on the fuel tank and that the fuel tank contains no leaks.
REPAIR ANY FUEL SYSTEM LEAKS
PRIOR TO RUNNING THE UNIT.
Page 7 of 45
ADJUSTMENTS:
v The engine should be checked for proper speed setting(s).
v
Adjust the engine speed to 3720 RPM's (62 Hz) with no load applied to the generator set.
ENGINE MAINTENANCE
MAINTENANCE SHOULD ONLY BE PERFORMED ON THE GENERATOR SET
AFTER THE ENGINE HAS STOPPED AND THE GENERATOR SET HAS COOLED
DOWN. THE BATTERY AND SPARK PLUG SHOULD ALSO BE DISCONNECTED
PRIOR TO PERFORMING MAINTENANCE.
REPAIRS AND/OR ANY ADJUSTMENTS MADE TO THE GENERATOR SET
SHOULD ONLY BE PERFORMED BY A COMPETENT MECHANIC FAMILIAR
WITH THE OPERATION, SERVICING, AND SAFETY PRECAUTIONS
RELEVENT TO THE ENGINE BEING WORKED ON.
This manual contains only very minimal engine maintenance instructions. You should refer to
the engine manufacturer's owner's manual for specific maintenance instructions for the engine
on your generator set. Any maintenance instructions or recommendations in the engine owner's
manual take precedence over any of the following general recommendations.
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 hours of operation. Be sure the proper oil
level is maintained.
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 (if applicable to
the engine).
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 and make sure they operate
properly.
7. Inspect the recoil rope for any damage and replace it if necessary (if applicable).
8. Clean the trash screen around the recoil or other cooling air intake.
Page 8 of 45
STORAGE OR LONG TERM NON-USAGE
If you will not be using the generator set for a significant amount of time (3 months or longer)
you should store the generator to prevent any problems that could arise from sitting idle. Please
fully read the following guidelines prior to storing the unit.
1
Drain the used oil from the engine's crankcase and refill it with fresh, clean oil (if your
engine is diesel proceed to step 4).
2. Remove the spark plug and pour1 oz. of clean engine oil into the cylinder. Put a rag over
the spark plug port and turn the engine over approximately 5 times to distribute the oil
in the cylinder. Replace the spark plug but do not reconnect it. This will help prevent
accidental or unauthorized starting.
4. Provide maintenance to the engine and generator set as described in the engine and
generator maintenance sections of this manual.
5. Cover any bare metal spots with paint or another type of rust preventative.
6. Disconnect and remove the battery if your generator set is so equipped.
Page 9 of 45
ORDERING PARTS
When Generator repair parts are needed, they may be obtained by calling the Customer Service
Department at Baldor Generators or the nearest local office of Baldor Electric Motors, Drives
and Generators. Accurate information such as the following will assure that you receive
accurate parts for your particular generator:
1. Provide the model of the generator set.
2. Provide the serial number of the generator set.
3. A complete and accurate description of the part along with a part number (if known).
4. Quantity of parts.
NOTE: Engine parts can usually be obtained from a local representative of your engine
manufacturer via the information in the engine manufacturer's owner's manual.
Baldor Generators can obtain engine parts for most models if necessary. However we do not
stock engine parts nor are we a dealer in engine parts.
SERVICE
Service for your generator set can be obtained from the service department at Baldor
Generators by calling 800-872-7697. Please have the following information available prior to
contacting the factory:
1. The model of the generator set.
2. The serial number of the generator set.
3. A complete and accurate description of the problem.
Page 10 of 45
GENERAL INSTALLATION & SITE SELECTION GUIDELINES
This information is for general reference only! It must not be used as
the single source of information for installing the generator set. For more
specific/detailed information read the installation manual that
accompanied the generator set.
Incorrect installation of the generator set could result in property
damage, injury, or death! Installation of this generator set must be
performed by qualified / professional technicians or contractors.
The generator set installation along with it's fuel supply piping
should be inspected on a regular basis for potentially dangerous
situations (i.e. fuel leaks, exhaust leaks, loose or broken wiring,
etc.). Any potential problems should be corrected by a qualified
technician as soon as possible.
Baldor Generators does NOT recommend and strongly discourages
the operation of their generators inside residential or other
occupied buildings due to the hazards associated with toxic
fumes, hot operating conditions and combustible fuel.
Prior to installing the generator set, an adequate operating site should be selected for it. When
selecting a site for your generator set, take into account factors such as safety, noise, cooling
and other miscellaneous considerations.
Only generator sets with the factory installed enclosure should be
placed outdoors in constant, direct exposure to the elements. These
enclosure- equipped units should be mounted outside in a fashion
similar to home central air conditioners.
SAFETY CONSIDERATIONS
1. The generator set must not be located near any combustible material due to the substantial
amount of heat generated by the unit while it is operating.
2. When the installation is in a confined area, the exhaust must be plumbed to the outside air.
Care must be taken so that no re-circulation of exhaust fumes exists.
3. Adequate ventillation must be present whenever the generator set is running not only to
evacuate the heated cooling air and exhaust fumes, but also to prevent the potential of
an LP fume concentration.
4.
The generator set should not be located in a spot that is prone to standing water
Baldor Generators strongly recommends that your AE Unit be installed on a concrete or cement
slab of appropriate size relative to the generator's base which is at least five (5) feet from any
building, structure, shrubbery, or any other obstruction that could possibly catch fire due to the
extreme heat output of this generator set.
Page 11 of 45
COOLING CONSIDERATIONS
1. when installing the generator set, it should be mounted no closer than 5 feet away from
any wall or object that would inhibit the cooling air flow that is necessary to operate the
unit properly.
2. When installing the generator set inside a non-occupied building, an adequate supply of
cooling air must be directed/ducted to the cooling air intake of the engine. The heated
cooling air blowing off the back of the engine must be directed away from the unit so
as not to be re-circulated with the cool intake air.
3. It is extremely important that the generator set be kept clear of snow, leaves, grass and
other debris.
NOISE CONSIDERATIONS
1. This generator set will develop noise levels similar to that of common lawn and garden
equipment.
2. Units supplied with enclosures will have their noise level significantly reduced.
MISCELLANEOUS CONSIDERATIONS
1. There should be adequate access to the generator set for maintenance/repair.
Page 12 of 45
ELECTRICAL INSTALLATION GUIDELINES
Incorrect installation of the generator set could result in property
damage, injury, or death! Installation of this generator set must be
performed by qualified / professional technicians or contractors.
This information is for general reference only! It must not be used as
the single source of information for installing the generator set. For more
specific/detailed information read the installation manual that
accompanied the generator set as well as the transfer switch manual.
There are two main wiring circuits that must be installed by a licensed electrician to properly
interface your Baldor Pow'R Gard generator set with your transfer switch and the
building/facility it will be providing power to. The connection on the generator set consists of
two terminal blocks, which are located on the generator set.
On units with the factory installed enclosure, the connection box is located in the engine
enclosure bulkhead. Access to the customer connection box is achieved by removing the
appropriate louvered enclosure end panel (See Drawing on following page).
On units without the factory installed enclosure the customer connection box is located either
above the generator windings or it is mounted on the generator frame next to the unit.
REMOTE START CONNECTIONS
These terminal block- connecting points (See figure 1) are where you connect the two wires
from the remote start contacts of the transfer switch. Once a connection is made across these
connecting points (via the transfer switch or some other switch device), a circuit is completed to
the control logic of the generator set causing the unit to start. The unit will remain running until
this connection is opened. Once the remote start connection is opened, the logic circuitry
allows the engine to run for approximately 60-90 seconds before it shuts off. This time delay is
to allow the engine to run unloaded for a period of time to cool down.
Page 13 of 45
AC POWER CONNECTIONS
These terminal block connections are used to interface the wires/cables from the emergency
power supply input terminals located inside the transfer switch.
BATTERY CHARGER CONNECTIONS
(OPTIONAL)
If you purchased a Master Control Systems Inc. Battery charger with your generator set you
must run two sets of wires from the battery charger to the generator set.
UNITS WITH FACTORY INSTALLED ENCLOSURE
The terminal block that contains the connection points for the remote start on the enclosed
units also contains the connection points for interfacing the battery charger to the generator
set.
The wires from the terminals labeled DK1 and DK2 on the battery charger go to the D1 and D2
terminal connection points on the terminal block pictured in figure 3.
The wires from the terminals labeled B+ and B- on the battery charger go to the POS and NEG
terminal connection points on the terminal block pictured in figure 3.
Page 14 of 45
UNITS WITHOUT ENCLOSURE
The wires from the terminals labeled DK1 and DK2 on the battery charger must be connected
across the starter motor. One lead must go to ground and the other must go to the starter
motor (or the 'switched' B+ on the Starter Solenoid). DK1 and DK2 are not polarity sensitive
and are therefore interchangeable with one another.
Wires from the terminals labeled B+ and B- on the Battery Charger go to the battery on the
generator set. B+ goes to the positive post of the battery and B- goes to the negative post on
the battery.
It is important, not only functionally, but also for safety reasons
that the Generator set, transfer switch and battery charger
share a common Ground and neutral.
To determine the proper type and gauge of wire to use for
connecting the generator set, transfer switch, and battery
charger together, you should consult a local licensed electrician.
Page 15 of 45
Baldor Generators strongly recommends that all electrical devices share a common ground (i.e.
Generator Set, Transfer Switch, Battery Charger, Load Devices, etc.). The grounding stud for
the generator set is located under customer connection box.
Page 16 of 45
GASEOUS FUEL INFORMATION
INCORRECT INSTALLATION OF THIS GENERATOR SET COULD RESULT
IN PROPERTY DAMAGE, INJURY, OR DEATH! INSTALLATION OF THIS
GENERATOR SET MUST BE PERFORMED BY A QUALIFIED,
PROFESSIONAL TECHNICIAN OR CONTRACTOR.
THIS INFORMATION IS FOR GENERAL REFERENCE ONLY! IT MUST NOT
BE USED AS THE SINGLE SOURCE OF INFORMATION FOR INSTALLING
THE GENERATOR SET. FOR MORE SPECIFIC/DETAILED INFORMATION
READ THE INSTALLATION MANUAL THAT ACCOMPANIED THE
GENERATOR SET.
Before undertaking installation of gaseous fuel supply piping from a remote fuel source to the
generator set, a check should be made concerning local and state regulations governing the
use, application, and installation of gaseous fuel. These regulations along with the standards set
forth by the NFPA (National Fire Protection Agency) should be followed for safe, dependable,
and proper installation.
The applicable NFPA regulations are covered in the following NFPA Publications:
No. 37 - Combustion Engines No.
54 - Gaseous Appliances and piping
No. 58 - Storage and handling LPG
These publications are available at a nominal price from:
The National Fire Protection Agency P.O. Box 9101 Quincy, MA 02269
GASEOUS FUEL SUPPLY PIPING
GASEOUS FUELS ARE HIGHLY COMBUSTIBLE AND CAN CAUSE
EXPLOSIONS, FIRE, INJURY, OR DEATH! THE FUEL SUPPLY SYSTEM MUST
ONLY BE INSTALLED AND ADJUSTED BY AN EXPERIENCE, PROFESSIONAL
TECHNICIAN USING APPROVED PIPING AND COMPONENTRY.
For the purpose of calculating piping size, the fuel consumption of an engine is figured at
approximately 10,000 BTU's needed per horsepower per hour. For example, a 10 horsepower
engine will require 100,000 BTU's of gaseous fuel per hour. Operating on natural gas which
contains 1,000 BTU's per cubic foot, this engine would require 100 cubic feet of natural gas an
hour to operate properly. In addition to fuel consumption, the following factors must be
considered when installing the gaseous fuel supply piping:
1. Pressure loss due to the number of fittings (elbows, reducers, etc.).
2. Specific gravity of the gaseous fuel.
3. Pressure loss due to the length of the fuel supply piping.
The accompanying gas flow/pipe capacity charts list the capacity of various sizes and pipe run
lengths. The capacity, which is given in cubic feet per hour, is calculated for both propane and
Page 17 of 45
natural gas. A pressure drop of 0.3' (water column) is used to account for a nominal number of
fittings and metering equipment.
Referring to the fuel consumption figures, we can use this chart to calculate proper sizing. For
example, if the engine is located 30 feet from the main fuel source's primary regulator and the
engine needs 100 cubic feet of natural gas per hour, you can easily determine that the pipe size
must be at least 3/4 inch in order to deliver the volume of fuel necessary for the engine to
operate properly.
PRIMARY REGULATOR (not supplied)
The function of the primary regulator is to provide initial control of the fuel under pressure as it
comes off a transmission line, or in the case of LP gas, from a storage tank. The primary
regulator distributes line pressures to more workable pressures ranging from 4 to 6 ounces
(approximately 11" of water column).
A natural gas supplier may boost pressure somewhat to achieve even distribution. However
these pressures are usually under 50 PSI. For this reason, the primary regulator used with
natural gas systems does not have to regulate the high pressures normally associated with LP
gas systems.
SECONDARY REGULATOR (supplied)
This regulator provides the final control of the gaseous fuel prior to it entering the carburetor.
This regulator is frequently referred to as the Low Pressure Demand Regulator. This regulator
receives gas at a pressure of 4 to 6 ounces from the primary regulator, then reduces the
pressure and delivers it to the engine's carburetor as the engine demands.
LP Tanks
The fuel vessel is usually the responsibility of the fuel supplier. The fuel supply must be
adequate in order to meet the customer's needs. The fuel tanks / cylinders must meet all
requirements set forth by local and state regulations.
LP Cylinder Tanks
This type of tank is commonly used on the smaller portable generator sets and is usually only
equipped with a manual shut-off valve. Although this type of tank is of adequate strength to
withstand the high fuel pressures, it has one drawback in that the tank is normally of such a
small size that you can only achieve minimal run times off of the tank of fuel before it has to be
refilled (4 to 7 hours).
LPG bulk tanks
The American Society of Mechanical Engineers has established certain requirements for the
construction of LPG bulk tanks. These tanks range in size from 20- gallon capacity all the way
up to 90,000 gallons in increments of 20 gallons. Although some of the smaller tank sizes are
used in mobile applications, the ASME approved tank is generally used in stationary
applications.
Page 18 of 45
Because tank pressures range from 0 to 200 PSI in LPG tanks, these tanks cannot be filled to
capacity. ASME tanks are filled to 90% capacity to allow for expansion of gases during increases
in temperature.
The recommendation of the local certified professional fuel supplier should be followed when
installing storage vessels and fuel piping.
Fuel valves
While the secondary demand regulator supplied with this generator set is designed to close and
stop fuel when the engine is not running, it should not be relied upon to completely seal off the
fuel system when the engine is stopped. A ruptured diaphragm or a piece of dirt in the
regulator could prevent the regulator's valves from seating with a result that gas would
continue flowing through the carburetor, into the engine and out into the surrounding air. Since
gaseous fuels are heavier than air, they tend to settle in low areas, which could present a
serious hazard.
Electric fuel shut-off valves
This type of fuel valve interfaces with the electronic control circuitry of the generator set and is
automatically activated to seal off the fuel the instant the engine's ignition system is shut down.
This type of fuel valve is mandated by federal and state regulations in most generator set
applications.
Manual Fuel Valves
In addition to the electrical fuel shut-off valve, a LPG system should include a manually
operated safety shut-off valve located close to the fuel source. This valve may well be a valve
located on the tank itself or it may be a valve installed in the fuel transmission line.
A manual shut-off valve is often required by existing regulations in many localities.
For indoor installations by NFPA definition, an automatic positive shutoff valve must be installed to assure that the flow of fuel will be
stopped should the engine fail while it is unattended.
Page 19 of 45
PROPANE GAS FLOW CHART
Pipe Capacity in Cubic Feet
An engine needs 10,000 BTU's / HP
For Propane there are 91,547 BTU's /Gal
For Propane there are 2,516 BTU's / Cubic Ft.
Page 20 of 45
NATURAL GAS FLOW CHART
Pipe Capacity in Cubic Feet
An Engine needs 10,000 BTU's / HP
For Natural Gas there are 1,000 BTU's / Cubic Ft.
Page 21 of 45
OPERATION
PRIOR TO STARTING THE UNIT:
1. Locate and set up the generator set in an open, dry, well ventilated and reasonably level
location.
OPERATING THIS UNIT IN AN AREA NOT SUITABLE FOR IT'S PROPER USE
MAY CAUSE DAMAGE TO THE UNIT, SEVERE INJURY, OR DEATH. SEE
"LOCATION INFORMATION" SECTION LOCATED ELSEWHERE IN THIS
MANUAL.
2. If grounding is required for your application, check to make sure your unit is grounded
properly.
3. Check the engine's oil level and add whatever amount of oil is necessary to bring it up to
the level that is recommended by the engine manufacturer.
4. Check the fuel system for fuel leaks.
5. Make sure all circuit breakers are set (pushed In).
CONTROLS AND THEIR FUNCTIONS
Master Control Switch:
This switch is a three position toggle switch which allows the user to choose the automatic or
manual mode of operation.
The center position is the off position.
By putting this switch in the OFF position the generator set will not start under any conditions.
To reset the control logic after a fault has occurred, this switch must be put into the Off
position for a minimum of 10 seconds.
Run/Manual Mode: When the Master Control Switch is put into this position it immediately
energizes the crank cycle to start the generator set. The generator set will continue to
produce power until the Master Control Switch is put into the 'OFF' position or until a fault
condition develops.
Page 22 of 45
Remote/Auto Mode: This is the position you need to have the Master Control Switch set in
when you wish to operate the Generator Set automatically in conjunction with a Transfer
Switch. This way, the generator set can only be started by making a connection across the
remote start connection points on the terminal block located in the control box.
Should this remote start connection be opened up while the engine is running the engine will
shut down after a 60-90 second 'Cool Down' time delay.
The engine can be shut down immediately from this position by putting the Master Control
Switch into the 'OFF' position.
A fault condition will also shut the engine down immediately.
Fault Indicator Light:
This circular Red indicator light will come on in conjunction with the engine shutting down
whenever a fault condition develops.
One Fault Condition that will cause a shut down is if the engine's starter motor cranks for
more than 30 seconds without the engine starting. This fault shutdown is to prevent damage
to the starter motor.
Another Fault Condition will develop if the generator set stops producing power while the
engine is running. This fault shutdown is to prevent further potential damage to the generator
end itself.
Another Fault Condition will develop if the engine's Low Oil Pressure Protection System shuts
the engine down.
To reset the Control Logic once a Fault Condition has occurred, you must put the Master
Control Switch onto the 'OFF' position for a minimum of 10 seconds.
Fuse for the Control Logic Board:
This fuse is rated at 1 Amp. It's purpose is to prevent excessive and potentially damaging
current from getting to the circuit board.
Circuit Breaker:
The Circuit Breakers on the generator set provide overload protection for the generator set.
These Breakers protect the generator set against potential damage from excessive AC
current.
Page 23 of 45
SIMPLE TROUBLESHOOTING
Listed below are the more simple solutions to some of the more common problems that are
reported to the Customer Service Department at Baldor Generators. These troubleshooting
solutions are meant to be an aid for a person who has minimal electrical knowledge and
experience. More in-depth, detailed troubleshooting information for a person more
knowledgeable and experienced in electricity can be obtained by contacting the Technical
Service Department at Baldor Generators by calling (920) 236-4200.
BEFORE BEGINNING TO TROUBLESHOOT THE GENERATOR SET,
DISCONNECT THE SPARK PLUG (IF APPLICABLE) AND THE BATTERY
( IF APPLICABLE) AND ALLOW THE UNIT TO COOL DOWN.
EYE PROTECTION SHOULD BE WORN WHILE TROUBLESHOOTING
THIS GENERATOR SET.
NO OUTPUT
Possible Problems:
1. The generator speed is too slow. If the generator is turning too slow the generator set
will produce low or no output voltage. Make sure the generator is turning at the speed on
the nameplate.
2. Broken wires or loose connections. Broken wires or loose connections can cause the
generator set to have low or no output voltage. Check all wiring for broken wires and
bad/loose connections.
3. Bad circuit breaker. If a circuit breaker opens up and will not reset, or the reset button is
not free-floating, your generator will not produce power out of all the receptacles. Check
for continuity across each circuit breaker with a continuity tester or ohmmeter (The wires
must be removed from the circuit breaker prior to checking it).
4. Loss of residual magnetism. Loss of residual magnetism will not allow the generator's
excitation system to build up and thus the generator set will not produce any power. To
'Flash' the generator set, (restore residual magnetism) follow these steps:
Preferred Method
A. With the generator set stopped, remove the generator's end cover and locate the
set of three posts on the rotor plate at the tail end of the rotor (there will be a wire
wrapped around the center post and the left hand post).
B. Using a 12 VDC battery, touch the positive battery lead to the center post while
touching the negative battery lead to the right hand post. Allow the battery to
remain across these posts for 2 seconds.
C. Replace the end cover and start the unit.
Page 24 of 45
Alternate Method
With the generator running and the end cover removed, momentarily connect a 12 VDC
battery across the capacitor's terminals for a fraction of a second (Having the battery
across the capacitor longer than a fraction of a second may damage the windings of the
generator). This is called "flashing the generator". Stop the unit after doing this and
replace the end cover. If you still have no output, look for other reasons or call Baldor
Generators for Technical Support at (920) 236-4200.
BE EXTREMELY CAREFUL WHEN USING THE ALTERNATE
METHOD FOR FLASHING THE GENERATOR AS YOU WILL BE
WORKING AROUND FAST, ROTATING COMPONENTS ALONG
WITH LIVE WIRES AND BARE CONNECTIONS.
LOW VOLTAGE OUTPUT
Possible Problems:
1. Generator speed too slow. If the generator is turning too slow, the generator set will
produce low or no output voltage. Make sure the generator is turning at the speed specified
on the nameplate.
2. Broken wires or loose connections. Broken wires or loose connections can cause the
generator set to have low or no output voltage. Check all wiring for broken wires and
bad/loose connections.
HIGH VOLTAGE OUTPUT
Possible Problems:
1. Generator speed too fast. If the generator is turning too fast the generator set will
produce high output voltage. Make sure the generator is turning at the speed specified
on the nameplate.
Page 25 of 45
TROUBLESHOOTING FOR GASEOUS FUEL SYSTEM
GASEOUS FUELS ARE HIGHLY COMBUSTIBLE AND CAN CAUSE
EXPLOSIONS, FIRE, INJURY, OR DEATH! THE FUEL SUPPLY SYSTEM
MUST ONLY BE INSTALLED AND ADJUSTED BY AN EXPERIENCED,
PROFESSIONAL TECHNICIAN USING APPROVED PIPING AND
COMPONENTRY.
PRIOR TO MAKING ANY ADJUSTMENTS THAT WILL TAKE THE
GENERATOR SET OUT OF IT'S FACTORY PRESET CONDITION,
PLEASE NOTE THE CONDITION / SETTING OF THE ADJUSTING
DEVICE. THIS WILL ALLOW YOU TO RETURN TO THE FACTORY PRESET CONDITIONS IF IN
THE EVENT OF MAKING AN ADJUSTMENT THE GENERATOR SET'S PERFORMANCE GETS
WORSE.
Prior to troubleshooting the gaseous fuel systems in regards to an engine not
starting, make sure that that the engine has ignition. If the engine does not have a
'spark', the problem is not due to a faulty fuel supply, but rather is due to a problem
in the engine control circuitry or the engine itself.
BASIC DESCRIPTION
The gaseous fuel system on your generator operates on 6 ounces of pressure. If the fuel is
liquid propane (LP), it must be first vaporized before being delivered to the generator. Once at
the generator, and electric valve keeps fuel from flowing unless the engine is running. Inside
the generator is a regulator (called the secondary regulator) that delivers fuel based on engine
vacuum.
Proper maintenance is key to reliable performance. We recommend only those skilled and
licensed for repair of gaseous fuel powered generating systems be enlisted to service this
product. This basic guide is to assist those knowledgeable with generators in correction of fuel
related operation and starting problems.
INITIAL CHECKS
v Fuel supply is on and available at the fuel valve.
v Engine has spark and rotates at normal speed (if not, consult the engine operating guide for
assistance in your area).
v Battery is charged and connected properly
v Assume nothing. If you have not checked it, consider it not checked.
Page 26 of 45
PROBLEMS AND POSSIBLE SOLUTIONS
In Order of Occurrence
Inadequate Fuel Supply
v Undersized piping - check pressure at secondary regulator, 6 oz. Minimum.
v Condensation in line - check for flow potential, water traps and lines that run in and out
of buildings.
Improper Fuel Mixture
v Check main adjustment - see adjustment section (below).
v Check auto prime adjustment - see adjustment section (below).
Inoperative Fuel Valve
v Check function by connecting leads to generator battery. If click is heard, valve is working.
Engine Out of Tune
v Check condition AND function of spark plugs, generators running on gaseous fuel leave the
plugs very clean. It is important not to go by looks alone. If in doubt, change.
Some Multi-cylinder engines will appear to run well without load
but stumble with load, a bad plug is most often the problem.
v Check condition of air filter - replace if dirty- if pre-cleaner is saturated with oil, the fuel
system will be thrown out of balance and not operate properly.
v Oil Level - All Pow'R Gard engines have Low Oil Shutdown of varying types. To be sure,
check the oil level and, if no spark, the oil pressure switch function.
Auto Prime
ADJUSTMENTS
Pow'R Gard® models from 5 to 12KW can come equipped with an electric solenoid operator
'Auto Prime' device. The device is electrically connected to the starter system on the generator
and supplies an initial feed of fuel for quicker engine starting. Once started, the engine's
vacuum keeps the fuel flowing.
On generators not so equipped, the engine vacuum is used exclusively to begin and maintain
the flow of fuel.
In almost all hard starting or intermittent starting situations, the auto prime is adjusted to rich.
Please note this while making this adjustment. You would need to adjust it to be less rich.
Page 27 of 45
Begin by locating the auto prime adjustment wheel. It protrudes from the secondary regulator
mounted on the generator and is often covered by a red vinyl cap. The adjustment knob is
orange and just below the knob is a gold colored washer. To adjust, hold the washer and rotate
the orange knob counterclockwise to lean the adjustment. Try this adjustment hot and cold.
In all multi-cylinder engines, the device may be disabled in lieu of adjustment.
Main Mixture
The main mixture is located on the secondary regulator and is a very large brass screw and lock
nut.
Begin by loosening the lock nut and counting the turns until the screw just seats. Record this
number so that you may return to it later. REMEMBER, the generator DID run previously either
at the factory or at the site.
Proceed by disconnecting the generator set’s Auto Prime (if so equipped) by unplugging the
terminal on the orange wire.
Check that all fuel supply lines are turned on (where applicable).
Check that he generator’s main line output breaker is turned OFF (where applicable).
The next step is to start the generator. Voltage will be available at
the output terminals and anywhere the generator is connected.
Think ahead and warn others of your intentions.
Operate the generator with the operation switch in the “Manual-Run” mode. The engine should
begin cranking.
While the engine is cranking, turn the main adjustment screw counterclockwise until the engine
starts. Continue to rotate back and forth until smooth operation is obtained. [ Adjustments that
are too rich (too far counterclockwise) or too lean (too far clockwise) will result in the same
rough sound. Use slow, rotating motion to find the smoothest spot.]
Once set, energize the AC breaker and apply available load.
Readjust main mixture screw until generator (with or without
applied load) is smooth. This will most likely be a slight rotation
richer than initial setting at no load.
Shut off engine by placing the Operation Switch into the “OFF” position.
If operation problems persist, contact your dealer or call Baldor Generators for Technical
Support at (920) 236-4200.
Page 28 of 45
ELECTRICAL SYSTEM
GENERATOR FAILS TO START
Test each of the following and record actual findings. If your findings do not match the values
listed, contact Baldor Generators for Technical Support at (920) 236-4200.
1. With generator in “OFF” position, place meter on battery terminals in control box (Red to
B+, Black to B-).
Should have 12 VDC
Record Actual:_____________
2. Repeat when generator operation switch is in the “RUN” position.
Should have 8-12 VDC
Record Actual:_____________
(A bad battery will give you lower readings)
GO TO STARTER SOLENOID ON ENGINE
3. Checking for Ohms, place one meter lead on the solenoid’s bracket. Place the other on the
“B-“ in the control box.
Should have 1 ohm resistance or less.
Record Actual:_____________
(Bad ground would be open reading or higher resistance)
4. Place red meter lead on small terminal at starter solenoid, black on bracket.
Should have 10 VDC or more when “cranking”.
Record Actual:_____________
“Cranking” means operation switch in “RUN”, even if it does not crank right now.
5. Place red meter lead on the large solenoid terminal with wire labeled “POS”. Place black
meter lead on solenoid bracket.
Should be same as battery, step 1
Record Actual:_____________
GO TO LOGIC BOARD IN CONNECTION BOX AT ENGINE END OF GENERATOR
7. On right hand relay (there are two black enclosed relays on top of the board), unplug wire
labeled E1 or 6110. Place meter lead into wire terminal, black to ground stud.
Should have 12 VDC when not cranking.
8 – 12 when cranking.
Record
Actual:_____________
A low reading indicates a loose wire at the solenoid.
8. Remove the other terminal from the left hand relay labeled E3 or 6200. Connect the Red
meter lead to the wire, black to the ground stud.
Should be 8-12 VDC when cranking.
Page 29 of 45
Record Actual:_____________
GENERATOR RUNS CONTINUOUSLY OR FAILS TO STOP AFTER RETRANSFER
Basic Theory –
Public Service power energizes ATS
ATS holds “R” terminals open
Generator test switch or exerciser can start generator, as programmed.
Public Service power drops, ATS closes “R” terminals, generator starts.
Ground fault problems in the conduit lead to the majority of continued run problems.
1. Disconnect both the “R” wires at the generator. Put generator control switch into “AUTO”.
A. Generator should start.
B. Generator should only run for 90 seconds. If so, GO TO STEP #3.
C. If the generator continues to run, allow 15 minutes.
If the generator shuts down, but not at 90 seconds, record time and contact factory.
2. Jump momentarily the “R” terminals.
A. Generator should start.
B. Generator should only run for 90 seconds. If so, GO TO STEP #3.
C. If the generator continues to run, allow 15 minutes.
If the generator shuts down, but not at 90 seconds, record time and contact factory.
3. Place generator control switch to “OFF”
A. Reconnect the “R” terminals at generator. Now, remove the ATS connections.
B. Place generator into “AUTO” setting.
C. With the “R” wires apart, the generator should not start.
If generator starts, but did not in step 1A, bad wiring exists in conduit.
D. Momentarily hold the “R” wires together. Generator should start.
E. Open connection from step “D”.
Generator should only run for 90 seconds. If so, GO TO STEP #4.
If the generator continues to run, allow 15 minutes.
If the generator shuts down, but not at 90 seconds, record time and contact factory.
4. Check ATS “R” terminals.
A. If red light (or other indicator) is on at ATS, public service power is on. Terminals
should be open.
B. Check manual controls of ATS (generator test, exerciser).
C. Replace control logic of ATS.
Page 30 of 45
AE SERIES
INTERCONNECTION
THE FOLLOWING ARE PRINCIPLES OF INSTALLATION.
PLEASE NOTE: LOCAL, FEDERAL, OR NEC CODES PREVAIL OVER THESE SUGGESTIONS.
Abbreviations:
GEN
ATS
Load Center
Emergency Load Center
=
=
=
=
Public Service
=
Generator Assembly
Automatic Transfer Switch
Customer's Normal Panel
Those circuits in a separate load box that will
be powered by the generator.
Normal Power Supplier
GEN to ATS Wiring:
?
?
?
3 wires for AC load (4 if three phase) sized for the generator's load amperage.
A Ground wire is to connect all circuits (GEN, ATS, Load Centers) to the building's ground
system.
2 wires, 14 gauge twisted pair for GEN remote start signal.
GEN to ATS Optional:
?
?
120 -volt feed for GEN mounted battery charger.
12 -volt wires (4) for building mounted battery charger.
Load center to ATS:
?
?
3 wires for AC feed (four for three phase), sized for ATS rating.
A ground wire is connected to all circuits (GEN, ATS, Load Centers) to the building's ground
system.
ATS to emergency Load Center:
?
?
3 wires for AC feed (four for three phase), sized for ATS rating.
A ground wire is to connect all circuits (GEN, ATS, Load Centers) to the building's ground
system.
Page 31 of 45
Normal Operation:
?
?
?
Public Service power feeds the ATS which connects to the Emergency Load Center.
When Public Service power fails, the ATS closes a contact causing GEN to start. Once AC
power from generator is observed at the ATS, the ATS will switch the Emergency Load
Center over to the GEN.
When Public Service power returns, the ATS will switch the Emergency Load Center back to
Public Service power and open engine start to contact (telling GEN to shut off).
CAUTIONS:
?
?
Emergency load center loads must not exceed GEN's capacity.
The ATS shall be protected by a circuit breaker appropriate for the ATS rating in the
Customer Primary Load Center.
If you have any questions, contact Baldor Generators for technical support at (920)236-4200.
Page 32 of 45
FOR AE12 UNITS WITHOUT ENCLOSURE
OLD PART #
120.00500
47.00121A
67.00120
230.80010
387.09056
400.21300A
440.92000
480.10000
361.00010P
120.00401
520.01100
550.00435
610.00060
670.00007
671.00200
950.01700
120.00110
670.00005
671.00200
NEW PART #
EA0000A00SP
62SA0008A00
62RA0015A00
HA3188A01
BA0330A00L*
HB6181A00*
HB6022A10*
10XN3118K176*
EH0296A00*
HB6146A00
SP9094
DI0181A00SP
CK0070A11SP*
FU0066A02
FU0064A00SP*
EB1243A00SP
EM0027A01SP
FU0066A00
FU0064A00SP
DESCRIPTION
KN Gaseous Fuel Regulator
Stator assembly
Rotor Assembly
Bolt, Rotor attaching
Base
Engine Adaptor Casting
Heat Shield
Stator Bolt
Side Control Box with Cover (empty)
LOAD BLOCK, K-N
Master Control Toggle Switch
Red Indicator Glo-Lite
Circuit Breaker, 60 Amp
Fuse, AGC 1
Fuse Holder
PCB, RSS, INCL. REL Control Circuit Board
Voltage Regulator, Basler VR63-4
FUSE BUSS, MTH-5
Fuse Holder
FOR AE12 UNITS WITH ENCLOSURE
OLD PART #
120.00500
47.00121A
67.00120
400.21300A
441.05300
441.35000
450.05100
450.06200
480.10000
700.00512
710.40386
710.40960
360.09300
370.17100
520.01100
550.00435
610.10045
670.00005
670.00007
671.00200
120.00110
360.09400
370.15700
950.01700
500.20000
120.00401
*
NEW PART #
EA0000A00SP
62SA0008A00
62RA0015A00
HB6181A00
HB6001A00*
HB6021A00*
HB7025A00 *
HB7002A08 *
10XN3118K176*
RM1088A07SP
EA0008A06
EA0039A01*
EH0309A00*
EH0343A00*
SP9094*
DI0181A00SP
CK0070A29
FU0066A00
FU0066A02
FU0064A00SP
EM0027A01SP
EH0308A00*
EH0339A00*
EB1243A00SP
DI0177A00SP
HB6146A00
DESCRIPTION
KN Gaseous Fuel Regulator
Stator assembly
Rotor Assembly
Engine Adaptor Casting
Muffler Bracket
Exhaust Outlet Guard
Mounting Feet, Attached to Base
Engine Support Cross member
Stator Bolt
Vibration Isolator, Eng End
Muffler JCS-15,
Muffler Blanket
Circuit Breaker Box (empty) [Contrl Box]
Circuit breaker Box Cover
Master Control Toggle Switch
Red Indicator Glo-Lite
Circuit Breaker, 50 Amp
Fuse, MTH-5
Fuse, AGC-1
Fuse Holder
Voltage Regulator, AVC63-4
Customer Connection Box
Customer Connection Box Cover
PCB, RSS, INCL. REL Control Circuit Board
RECTIFIER, 4 TERMIN EA
LOAD BLOCK, K-N, FO EA
= Bus system may only recognize as a production component rather than a spare part
Page 41 of 45
Limited Warranty
Unless otherwise provided, Baldor generators are warranted against defects in Baldor workmanship
and materials for a period of time as set forth in the Warranty Period chart below. If a Baldor product is
defective due to Baldor workmanship or materials and the defect occurs during the warranty period,
then Baldor will either repair the product or replace it with a new one, whichever Baldor believes to be
appropriate under the circumstances. Service for warranty issues regarding any Baldor Generators
Products Warranty is available by contacting Baldor Generators’ Customer Service Department in
Oshkosh, Wisconsin. A list of Baldor’s generator repair facilities may be obtained by contacting Baldor Generators at: Customer Service, Baldor Generators, 3815 Oregon Street, Oshkosh, Wisconsin
54902, 920–236–4200 (telephone), 920–236–4219 (facsimile). All Baldor products requiring warranty service shall be transported or shipped freight pre–paid, at the risk of the party requiring warranty service, to 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. Customers who are unable to take or ship the Baldor
product to a Baldor Generator repair facility, or who desire a repair to be made by other than a Baldor
Generator repair facility, should contact Baldor Generators’ Customer Service Department at
920–236–4200. Baldor, in advance of such service, must approve a repair by anyone other than a
Baldor Generator repair facility in writing. Problems with Baldor products can be due to improper
maintenance, faulty installation, non–Baldor additions or modifications, or other problems not due to
defects in Baldor workmanship or materials. If a Baldor Generator repair facility determines that the
problem with a Baldor product is not due to defects in Baldor workmanship or materials, then the party
requesting warranty service will be responsible for the cost of any necessary repairs. Parties requiring warranty service not satisfied with a determination that a problem is outside of warranty coverage
should contact Baldor Generators’ Customer Service Department at 920–236–4200 for further consideration. EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE, BALDOR GENERATORS DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE
IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND 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
1 Year or 3,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
1 Year or 3,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
3 Years or 3,000 Hours
Whichever comes first
3 Years or 1,000 Hours
Whichever comes first
3 Years or 3,000 Hours
Whichever comes first
2 Years or 1,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
3600 RPM Standby Systems
(Some AE Models)
1800 RPM Standby Systems
(Some AE Models, DLC, GLC)
Industrial Standby Systems
Industrial Prime Power Systems
International
Limited Warranty Continued
Notes for Warranty Period:
1. Labor coverage for warrantable repairs is provided for the applicable period
not to exceed published rates as contained in the Baldor Generators
Warranty Policy. Mileage is allowed only for permanent installations not to
exceed published rates as contained in the Baldor Generators Warranty
Policy.
2. Proof of purchase date is required for all Portable and Towable products to
qualify for any warranty consideration. Serial number and model number
will be required for all warranty work.
3. For all other products, a Start–up Inspection Form / Warranty Registration
must be completed in its entirety and submitted to Baldor Generators within
30 days of start–up to qualify for any warranty consideration.
Owner’s Responsibilities:
The owner is obligated to operate and maintain the generator in accordance with the
recommendations published by Baldor Generators in the Operator’s Manual for the
generator. The owner is responsible for the costs associated with maintenance and
any adjustments that may be required.
The owner is responsible for payment of any of the following expenses that might be
incurred as a result of a failure under the terms of this warranty:
1. Rental equipment used to replace the equipment being repaired.
2. Telephone or other communication expenses.
3. Living and travel expenses of persons performing service, except as
specifically included within the terms of specific warranty.
4. The premium costs for overtime labor requested by the owner.
5. All parts transportation costs.
All warranty claims must be submitted to a Baldor Generator repair facility prior to the
expiration of the warranty period. Baldor Generators shall have no responsibility or
liability for any defect, latent or otherwise, discovered after the expiration of the
warranty period provided herein. Extended warranties are available for certain
Baldor products. These warranties are described in Baldor’s catalog and other sales
literature. Extended warranties are subject to the terms and conditions of this Limited
Warranty as modified by the additional terms of the extended warranty.
Limitations:
Baldor Generators is not responsible for the repair of generators required because of
normal wear, accident, misuse, abuse, improper installation, lack of maintenance,
unauthorized modifications or improper storage.
Normal Wear: This warranty will not cover repair where normal use has exhausted
the life of a part or generator. It should be remembered that the service life of any
generator is dependent on the care it receives and the conditions under which it has
to operate. Some applications are very often used in dusty or dirty conditions, which
can cause what appears to be excessive wear. Such wear, when caused by dirt, dust,
grit or other abrasive material, which has entered the generator because of improper
maintenance, is not covered by Warranty.
For all product lines, the engine manufacturer warrants engine systems.
Contact Baldor Generators for current engine warranties.
Owner’s Responsibilities:
The owner is obligated to operate and maintain the generator in accordance with the recommendations
. The owner is responsible for
published by Baldor Generators in the Operator
the costs associated with maintenance and any adjustments that may be required.
The owner is responsible for payment of any of the following expenses that might be incurred as a result
of a failure under the terms of this warranty:
1.
2.
3.
4.
5.
Rental equipment used to replace the equipment being repaired.
Telephone or other communication expenses.
Living and travel expenses of persons performing service, except as specifically included within the
terms of specific warranty.
The premium costs for overtime labor requested by the owner.
All parts transportation costs.
Limitations:
Baldor Generators is not responsible for the repair of generators required because of normal wear,
accident, misuse, abuse, improper installation, lack of maintenance, unauthorized modifications or
improper storage.
Normal Wear: This warranty will not cover repair where normal use has exhausted the life of a part or
generator. It should be remembered that the service life of any generator is dependent on the care it
receives and the conditions under which it has to operate. Some applications are very often used in dusty
or dirty conditions, which can cause what appears to be excessive wear. Such wear, when caused by dirt,
dust, grit or other abrasive material, which has entered the generator because of improper maintenance,
is not covered by Warranty.
No person is authorized to give any other warranties or to assume any other liabilities on Baldor
Generators’ behalf unless made or assumed in writing by an officer of Baldor Generators and no person is
authorized to give any warranties or assume any other liability on behalf of the seller unless made or
assumed in writing by the seller.
Major components, such as engines, used in Baldor Generators’ generator sets that are not
manufactured by Baldor Generators are specifically excluded from Baldor Generators coverage and are
covered separately by their respective manufacturers. Warranty terms and policies of excluded products
are included with their owners information package supplied with each product.
WARNING:
CALIFORNIA PROPOSITION 65 WARNING:
Engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects and
other reproductive harm.
WARNING:
CALIFORNIA PROPOSITION 65 WARNING:
Diesel engine exhaust and some constituents are known to the
state of California to cause cancer, birth defects and other
reproductive harm.
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.