OPERATOR'S MANUAL FOR YOUR PREMIER ‘R’ SERIES GENERATOR BALDOR GENERATORS 3815 Oregon Street, Oshkosh WI 54902 Telephone 236-4200 • Fax 920-236-4219 FORM#: S-PSG-002-69 SERIES 'R' COVER\MSW'00 EFFECTIVE DATE: 10/1/97 REVISION DATE: 03/12/03
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.
♦ 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.
♦ 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.
♦ 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.
○○○○ 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.
SECTION TABLE OF CONTENTS PAGE Basic Location Information……………………………………………………………………………………………….1 Basic Connection Information………………………………………………………………………………………….2 Basic Engine Information…………………………………………………………………………………………………….3 Generator End Maintenance………………………………………………………………………………………………….4 Basic Engine Maintenance…………………………………………………………………………………………………….5 Storage Information………………………………………………………………………………………………………………….6 Electric Motor Loads……………………………………………………………………………………………………………….
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 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.
USE OF ELECTRIC MOTORS Electric motors require much more current (amperes) to start them than to run them. Some motors, particularly split-phase motors are very difficult to start and requires 5 to 7 times as much current to start them as it does to run them. Capacitor Motors are a little easier to start and usually require 2 to 4 times as much current to start them as to run them.
ORDERING PARTS When Generator repair parts are needed, they may be obtained by calling the Parts Department at Baldor Generators or the nearest local office of Baldor Electric Motors and Drives. 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.
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.
3. Pull lightly on the recoil grip until you feel significant resistance, then pull sharply. Do not allow the recoil rope to 'snap' back into the recoil housing. Allow the recoil to gently rewind into the recoil housing. See your engine manual for instructions specific to your unit. If the engine does not start after turning the engine over a few times, smell for fuel near the air cleaner.
SIMPLE TROUBLESHOOTING Listed below are the more simple solutions to some of the more common problems that are reported to the Service Department at Baldor Generators. These troubleshooting solutions are meant to be an aid for a person who has minimal electrical knowledge and experience.
5. 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.
AUTO IDLER SYSTEM NOT WORKING PROPERLY (Applies only to Generator Sets equipped with this feature) For the Auto Idler System to work, the generator set must be producing normal voltage output. If the generator set is not producing any power, the Auto Idler System will not work. 1. Generator Set will not idle or it will not release from idle. The engine's speed along with the Auto Idler System must be adjusted properly for the Auto Idler System to work.
CONTROL PANEL For R30 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 = STANDARD DUPLEX RECEPTACLE. This is your standard household duplex receptacle, it is rated for 120 VAC, 15 Amps. When using this receptacle you are utilizing the ground fault protection provided by the GFCI receptacle. C = ELAPSED TIME METER.
CONTROL PANEL For the R45/R40 Units A = THE AUTO IDLER FEATURE ON/OFF SWITCH. The Auto Idler feature allows the engine on the generator set to slow down to a "slow speed position" when there is no load being applied to the unit. When a load is applied to the unit, the Auto Idler Circuitry allows the engine to speed up and operate at the engine preset speed. When this switch is turned off, the engine will continuously run at the preset speed of the engine governor. B = ELAPSED TIME METER.
CONTROL PANEL For the R60 Generator A = THE AUTO IDLER FEATURE ON/OFF SWITCH. The Auto Idler feature allows the engine on the generator set to slow down to a "slow speed position" when there is no load being applied to the unit. When a load is applied to the unit, the Auto Idler Circuitry allows the engine to speed up and operate at the engine preset speed. When this switch is turned off, the engine will continuously run at the preset speed of the engine governor. B = ELAPSED TIME METER.
Generator-End Componentry - 17 -
Control Box Componentry - 18 -
PARTS BREAKDOWN FOR R30, R40, R45, R60, R60E Units: REF LTR A A A A A A B B B C D E F G H I NOT SHOWN NOT SHOWN OLD PART # 46.00025B 46.10025B 46.00045A 46.10045A 46.00055A 46.10055A 66.00025 66.00045 66.00055 140.00200 230.02020 230.06040 230.12010 340.00000 500.16000 370.
REF LTR EE EE FF FF FF FF OLD PART # 600.00020B 600.00030C 610.00020 610.00025 610.00030 610.00040 NEW PART # OC3020F16SP OC6030F11* CK0070A02SP CK0070A06SP CK0070A03SP CK0070A04SP FF 610.00050 CK0070A05SP NOT SHOWN NOT SHOWN NOT SHOWN NOT SHOWN 700.00512 RM1088A07SP Isolators, Engine End 700.00511 RM1088A06SP Isolators, generator End 31C-36006-01 Consult Factory Fuel Tank (Robin Part Number) 043-05900-10 Consult Factory Fuel Tank Cap (Robin Part Number) 950.04000 950.
Connection Diagram R30 - 21 -
Connection Diagram R40 / R45 - 22 -
Connection Diagram R60 - 23 -
Connection Diagram R60E - 24 -
HAVE JOINED FORCES TO BRING YOU THE BEST ENGINE/GENERATOR WARRANTY IN THE INDUSTRY! 3-YEAR WARRANTY ON BALDOR GENERATORS AND ROBIN SUBARU ENGINES SEE ATTACHED WARRANTY STATEMENTS FOR DETAILS: BALDOR GENERATORS 3815 OREGON STREET OSHKOSH WI 54902 PHONE: (920) 236-4200 FAX: (920) 236-4219 WWW.BALDOR.
Robin Subaru Limited Engine Warranty For Baldor Generators (Effective for original Robin Subaru engines powering Baldor portable generators purchased after August 16, 2000) Robin America, Inc., a division of Fuji Heavy Industries, Ltd. (herein "Robin"), warrants that each new engine sold by it will be free, under normal use and service, from defects in material and workmanship for a period listed below from the date of sale to the original retail purchaser.
LIMITED WARRANTY Effective August 1, 2003 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.
*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. 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.
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.
