OPERATOR'S MANUAL FOR YOUR DG SERIES GENERATOR MODEL __________ SERIAL # __________ BALDOR GENERATORS 3815 Oregon Street, Oshkosh WI 54902 Phone 1-800-USA-POWR • Fax 920-236-4219 FORM#: S-PSG-002-11 DIESEL (DG) COVER\MSW'00 EFFECTIVE DATE: 4/4/97 REVISION DATE: 3/14/03
FORWARD This manual contains the information you need to safely and efficiently operate your generator set. During the preparation of this manual every effort was made to ensure the accuracy of its contents. DO NOT OPERATE THIS GENERATOR SET UNTIL YOU CAREFULLY READ THIS MANUAL AND UNDERSTAND THE SAFETY WARNINGS AND INSTRUCTIONS CONTAINED IN IT.
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.
SAFETY WARNINGS ♦ 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.
SAFETY WARNINGS ♦ 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.
SAFETY WARNINGS ○○○○ 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.
TABLE OF CONTENTS SECTION PAGE Basic Location Information………………………………………………………………………………………..1 Basic Connection Information…………………………………………………………………………………..2 Basic Engine Information……………………………………………………………………………………………..3 Generator End Maintenance…………………………………………………………………………………………..4 Basic Engine Maintenance……………………………………………………………………………………………..5 Electric Motor Loads………………………………………………………………………………………………………..6 Parts & Service Information……………………………………………………………………………………..
LOCATION For best service from your portable generator set there are several factors, which should be taken into consideration when choosing the best location in which to operate it: MOISTURE: All electrical equipment should be protected from excessive moisture. Failure to do so will result in deterioration of the insulation and may result in short circuits and a possible electrocution hazard. OPERATING ELECTRICAL EQUIPMENT IN WET ENVIRONMENTAL CONDITIONS CREATES A POTENTIAL ELECTROCUTION HAZARD.
CONNECTIONS WIRING: Use sufficiently large insulated wire to connect the generator set to the load. The gauge of the 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.
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.
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).
ADJUSTMENTS: √ The engine should be checked for proper speed setting(s). √ Prior to adjusting the engine speed, turn the auto idler switch off (if your generator set is equipped with this feature). Adjust the engine speed to 3720 RPM's (62 Hertz) with no load applied to the generator set. √ Adjust the Auto Idler Speed after you have accomplished the above adjustment.
STORAGE If you will not be using the generator set for a significant amount of time (3 months or longer) you should store the generator to prevent any problems that could arise from sitting idle. Please fully read the following guidelines prior to storing the unit. 1. Remove all fuel from the engine's fuel tank. If your engine is a gasoline engine start the generator set and allow it to run out of fuel and then close all the fuel valves. If it is not a gasoline engine, go to step 2.
2. The brand or design of the electric motor. The expected starting current for a particular size motor will vary depending on the brand of the electric motor as well as the type of electric motor (Split Phase, capacitor, Repulsion-induction type, etc…). 3. The condition of the electric motor. A clean motor with free turning bearings will require less starting currents than a similar type motor that is dirty and the bearings are not as free turning as they used to be.
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, make sure your unit is grounded properly. 3.
STOPPING THE ENGINE: 1. Disconnect or 'Turn Off' all loads connected to the generator set. 2. Turn any engine 'On/Off' switches to the 'Off' position (On DG3E units, put the run/stop lever in the stop position). 3. Push engine 'Stop' switch if so equipped. 4. Turn any engine key switches to the 'Off' position. 5. Turn all fuel valves off.
SIMPLE TROUBLESHOOTING Listed below are the more simple solutions to some of the more common problems that are reported to the Customer Services Department at Baldor Generators of Oshkosh. These troubleshooting solutions are meant to be an aid for a person who has minimal electrical knowledge and experience.
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.
CONTROL PANEL For the DG3E A = NEMA 515R GFCI DUPLEX. This receptacle is a ground fault circuit interrupter duplex rated at 125 VAC., 20 Amps. This receptacle must be tested on a regular basis (Monthly). B = NEMA L530R RECEPTACLE. This is a twist-lock style receptacle rated for 125 VAC, 30 Amps. C = NEMA L14-20R RECEPTACLE. This is a twist-lock style receptacle rated for 120/240 VAC depending on how the mating plug is wired. It is capable of carrying 20 amps. D = VOLTMETER.
CONTROL PANEL For DG5E and DG6E Units A = THE START SWITCH. Pushing this button engages the starter motor. B = THE RUN SWITCH. When this switch is in the 'ON' position the engine will start and run once the start switch is engaged. When this switch is turned "OFF' the engine will shut down. This switch should remain in the 'OFF' position unless the unit is to be started and run. C = ELAPSED TIME METER. This meter keeps and displays a continuous running total of the hours accumulated on the unit.
GENERATOR END COMPONENTRY For DG3E Generator sets - 14 -
CONTROL BOX COMPONENTRY For DG3E Generator Sets - 15 -
PARTS BREAKDOWN FOR DG3E Units: REF LETTER A B D E F G H I L N Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown O P R R thru Z RR S SS T U V X Y OLD PART # 46.03002B 66.03002 230.02020 230.06040 230.12010 340.00000 500.16000 9370.03601C 390.00000 400.20100A 100.00340 230.26015 260.00030 261.00000 440.03800 440.50600 450.
GENERATOR END COMPONENTRY For DG5E Generator sets - 17 -
CONTROL BOX COMPONENTRY For DG5E Generator Sets - 18 -
PARTS BREAKDOWN FOR DG5E Units: REF LETTER OLD PART # A 46.00055 B 66.00055 BB 560.70020 CC 560.10025 D 230.02025 DD 560.10090 E 230.06040 ▪ F 230.12010 ▪ FF 610.00025 FF 610.00050▪ G 340.00000 ▪ H 500.16000 ▪ I 370.03602 L 390.00000 ▪ M 400.00100A N 400.20100A ▪ Not Shown 100.00305 Not Shown 100.00340 ▪ Not Shown 230.26015 ▪ Not Shown 260.00030 ▪ Not Shown 261.00000 ▪ Not Shown 440.74000 Not Shown 440.74200 Not Shown 440.03800 ▪ Not Shown 441.11500 Not Shown 450.11400 Not Shown 450.05900 Not Shown 480.
GENERATOR END COMPONENTRY For DG6E Generator sets - 20 -
CONTROL BOX COMPONENTRY For DG6E Generator Sets - 21 -
PARTS BREAKDOWN FOR DG6E Units: REF LETTER OLD PART # A B BB CC D DD E F FF FF G H I L M N Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown 46.10055J 66.00055 560.70020 560.10025 230.02025 560.10090 230.06040 230.12010 610.00025 610.00050 340.00000 500.16000 9370.03601B 390.00000 400.00100A 400.20100A 100.00340 O P RR SS U V W 410.00600 480.00065 600.
DG3E CONNECTION DIAGRAM - 23 -
DG3E CONNECTION DIAGRAM W/ LOW OIL & REMOTE START - 24 -
DG5E GENERATOR/CONTROL BOX CONNECTION DIAGRAM - 25 -
DG5E RECEPTACLE/CONTROL BOX CONNECTION DIAGRAM - 26 -
DG5-ER WIRING DIAGRAM - 27 -
DG6E HATZ/ROBIN CONNECTION DIAGRAM - 28 -
LIMITED WARRANTY Unless otherwise provided, Baldor generators are warranted against defects in Baldor workmanship and materials for a period of time as set forth in the Warranty Period chart on the following page. All warranty claims must be submitted to a Baldor Generator repair facility prior to the expiration of the warranty period. Baldor Generators shall have no responsibility or liability for any defect, latent or otherwise, discovered after the expiration of the warranty period provided herein.
WARRANTY PERIOD GENERATOR SERIES Portable Products (Premier, PowerChief, DG Series, K Series) Towable Products (TS) 3600 RPM Standby Systems (Some AE Models) 1800 RPM Standby Systems (Some AE Models, DLC, GLC) Industrial Standby Systems Industrial Prime Power Systems International Labor* Parts 1 Year 3 Years 1 Year or 3,000 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 1 Year or 3,000 H
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.
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. 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.
Service is just a phone call away: 800-872-7697 www.baldor.com/products/generators.
