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Baldor DG Series - User Manual

Baldor DG Series
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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 EFFECTIVE DATE: 4/4/97
DIESEL (DG) COVER\MSW'00 REVISION DATE: 3/14/03
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Baldor DG Series Specifications

General IconGeneral
BrandBaldor
ModelDG Series
CategoryPortable Generator
LanguageEnglish

Summary

LOCATION

MOISTURE

Protect electrical equipment from moisture to prevent deterioration and hazards.

DIRT

Operate in a clean environment to prevent excessive wear on engine and generator parts.

HEAT

Ensure adequate ventilation as engines produce heat; maintain area temperature below 100°F.

EXHAUST

Vent exhaust fumes to the outside when operating indoors; fumes are poisonous.

CONFINED SPACE

Do not operate in confined spaces due to fire hazard and overheating risk.

CONNECTIONS

WIRING

Use appropriately gauged insulated wire; consult an electrician if unsure about wire gauge.

GROUNDING

Follow National Electric Code for grounding; use a pipe driven into moist earth.

CONNECTIONS TO HOUSE WIRING

Connect to house wiring only via transfer switch or locked-open service entrance for safety.

ENGINE INFORMATION

OIL

Use high-quality oil as specified; check level regularly every 5-8 hours.

FUEL

Use clean fuel of the specified type; never refuel while hot or running.

OPERATING SPEED

Operate at proper speed for correct power output; governor maintains speed under load.

MAINTENANCE

GENERATOR END MAINTENANCE

Cleaning, inspecting wiring and fuel system, and making adjustments monthly.

INSPECTING GENERATOR COMPONENTS

Inspect wires, battery posts, control box, and fuel system for damage or leaks.

ENGINE SPEED ADJUSTMENTS

Check and adjust engine speed and auto idler settings for optimal performance.

ENGINE MAINTENANCE PROCEDURES

Follow manufacturer's guidelines for oil, filters, spark plugs, and cleaning.

STORAGE

PREPARING FOR STORAGE

Remove fuel, disconnect battery, drain oil, and perform maintenance before storing.

STORAGE SAFETY

Never store with fuel indoors or in poorly ventilated areas due to explosion risk.

USE OF ELECTRIC MOTORS

STARTING CURRENT REQUIREMENTS

Motors require more current to start than to run; factors include motor type and load.

FACTORS INFLUENCING STARTING CURRENT

Includes motor type, design, condition, and connected load type.

ORDERING PARTS

INFORMATION NEEDED

Provide model, serial number, part description, and quantity for accurate part ordering.

SERVICE

CONTACTING SERVICE DEPARTMENT

Call Customer Services for assistance; have model, serial number, and problem description ready.

OPERATION

PRIOR TO STARTING THE UNIT

Locate in a suitable area, check grounding, oil, and fuel levels, and disconnect loads.

STARTING THE GEN SET

Turn on engine switch, engage starter motor, and do not crank for more than 10 seconds.

STOPPING THE ENGINE

ENGINE SHUTDOWN PROCEDURE

Disconnect loads, turn off switches, and turn off fuel valves to stop the engine safely.

SIMPLE TROUBLESHOOTING

PRECAUTIONS BEFORE TROUBLESHOOTING

Disconnect spark plug/battery, allow unit to cool, and wear eye protection.

NO OUTPUT PROBLEMS

Covers slow speed, loose connections, bad capacitor, circuit breaker issues, and loss of residual magnetism.

FLASHING THE GENERATOR

GENERATOR MAGNETIZATION

Methods to restore residual magnetism using a 12 VDC battery.

LOW VOLTAGE OUTPUT

DIAGNOSIS AND CAUSES

Potential causes include slow speed and broken/loose connections.

HIGH VOLTAGE OUTPUT

DIAGNOSIS AND CAUSES

Potential cause is generator speed being too fast.

CONTROL PANEL (DG3 E)

RECEPTACLES

GFCI, L530R, and L14-20R receptacles for power output.

INDICATORS AND METERS

Voltmeter, Low Oil Pressure Light, Elapsed Time Meter.

CIRCUIT PROTECTION

AC Circuit Breakers for overload protection.

CONTROL PANEL (DG5 E;DG6 E)

START AND RUN SWITCHES

Controls for starting, running, and stopping the engine.

METERS AND INDICATORS

Elapsed Time Meter and Voltmeter for monitoring.

RECEPTACLES AND CIRCUIT BREAKERS

Power output receptacles and overload protection.

GENERATOR END COMPONENTRY (DG3 E)

ROTOR ASSEMBLY

Exploded view of the rotor and related parts.

STATOR ASSEMBLY

Exploded view of the stator and related parts.

BEARING BRACKET

Component supporting the rotor bearings.

DIODE

Electrical component within the generator end.

PAN COVER

Cover for the generator end.

CONTROL BOX COMPONENTRY (DG3 E)

RECEPTACLES (S, T, U)

Outlets for connecting loads.

VOLTMETER (V)

Device for displaying voltage output.

CIRCUIT BREAKERS (X, Y)

Overload protection devices.

PARTS BREAKDOWN (DG3 E)

GENERATOR END COMPONENTRY (DG5 E)

ROTOR ASSEMBLY

Exploded view of the rotor and related parts.

STATOR ASSEMBLY

Exploded view of the stator and related parts.

BEARING BRACKET

Component supporting the rotor bearings.

DIODE

Electrical component within the generator end.

PAN COVER

Cover for the generator end.

CONTROL BOX COMPONENTRY (DG5 E)

METERS

Elapsed time meter and voltmeter for monitoring unit status.

RECEPTACLES

Various power outlets for connecting loads.

CIRCUIT BREAKERS AND CAPACITORS

Protection and electrical components.

PARTS BREAKDOWN (DG5 E)

GENERATOR END COMPONENTRY (DG6 E)

ROTOR ASSEMBLY

Exploded view of the rotor and related parts.

STATOR ASSEMBLY

Exploded view of the stator and related parts.

BEARING BRACKET

Component supporting the rotor bearings.

DIODE

Electrical component within the generator end.

PAN COVER

Cover for the generator end.

CONTROL BOX COMPONENTRY (DG6 E)

METERS

Elapsed time meter and voltmeter for monitoring unit status.

RECEPTACLES

Various power outlets for connecting loads.

CIRCUIT BREAKERS AND CAPACITORS

Protection and electrical components.

PARTS BREAKDOWN (DG6 E)

CONNECTION DIAGRAM (DG3 E)

WIRING LEGEND

Symbols and their meanings used in the diagram.

CIRCUIT BREAKERS AND RECEPTACLES

Diagrammatic representation of output and protection components.

METERS AND CONNECTORS

Diagrammatic representation of monitoring devices and connections.

CONNECTION DIAGRAM (DG3 E W; LOW OIL & REMOTE START)

ENGINE WIRING COMPONENTS

Diagram showing engine-related electrical parts.

CONTROL SWITCHES AND RELAYS

Diagram showing control system elements.

WIRING CONNECTIONS

Detailed layout of electrical connections.

CONNECTION DIAGRAM (DG5 E)

ENGINE WIRING

Diagram of engine electrical connections.

GENERATOR COMPONENTS

Diagram of generator electrical components.

CONTROL BOX WIRING

Diagram of control box electrical connections.

RECEPTACLE;CONTROL BOX DIAGRAM (DG5 E)

RECEPTACLE CONNECTIONS

Shows how receptacles are wired.

CIRCUIT BREAKERS AND METERS

Wiring for protection and monitoring devices.

WIRING LEGEND

Symbols and their meanings used in the diagram.

WIRING DIAGRAM (DG5-ER)

ENGINE WIRING

Diagram of engine electrical components and connections.

CONTROL WIRES

Diagram of control system wiring.

METERS AND CONNECTORS

Diagram of monitoring devices and connections.

CONNECTION DIAGRAM (DG6 E HATZ;ROBIN)

RECEPTACLE AND BREAKER CONNECTIONS

Wiring for output receptacles and protection.

METERS AND CONNECTORS

Wiring for monitoring devices and connections.

GENERATOR OUTPUT CONNECTIONS

Diagram showing how generator outputs are connected.

LIMITED WARRANTY

WARRANTY CLAIMS SUBMISSION

Procedures for submitting warranty claims to a repair facility.

WARRANTY SERVICE AVAILABILITY

Information on obtaining warranty service from Baldor or approved facilities.

EXCLUSIONS AND DISCLAIMERS

Limitations on warranty coverage and disclaimed liabilities.

WARRANTY PERIOD

PORTABLE PRODUCTS WARRANTY

Covers portable generators like Premier, PowerChief, DG, K Series.

TOWABLE PRODUCTS WARRANTY

Covers towable generator sets (TS series).

STANDBY SYSTEMS WARRANTY

Covers 3600 RPM and 1800 RPM standby systems.

INDUSTRIAL SYSTEMS WARRANTY

Covers industrial standby and prime power systems.

OWNERS RESPONSIBILITIES

MAINTENANCE AND ADJUSTMENTS

Owner must operate and maintain per manual recommendations.

COST OF REPAIRS AND EXPENSES

Owner responsible for specific costs like rental, travel, and parts transport.

LIMITATIONS

EXCLUSIONS FROM RESPONSIBILITY

Baldor not responsible for repairs due to normal wear, accident, misuse, etc.

NORMAL WEAR AND MAINTENANCE

Warranty does not cover normal wear or damage from improper maintenance.

ENGINE SYSTEM WARRANTY

Engine manufacturer warrants engine systems separately.

SAFETY WARNINGS

IMPROPER MAINTENANCE OR REPAIR

Warnings regarding improper maintenance leading to damage, injury, or death.

EXHAUST FUMES DANGERS

Hazards associated with exhaust fumes causing illness or death.

IMPROPER OPERATION DANGERS

Risks of improper operation leading to damage, injury, or death.

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