OPERATOR'S MANUAL FOR YOUR PREMIER ‘K’ SERIES GENERATOR BALDOR GENERATORS 3815 OREGON STREET OSHKOSH WI 54902 Phone: (920) 236-4200 Fax: (920) 236-4219 Toll Free: 800-872-7697
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.
♦ 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.
♦ 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.
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 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 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.
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 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.
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 K3000 A = DC POWER SWITCH - This is your On/Off switch for which to operate the generator. B = ELAPSED TIME METER. This meter displays a continuous running total of the hours accumulated on the unit. C = AC VOLTMETER. This voltmeter displays the voltage level being produced by the generator set. D = CIRCUIT BREAKER. This circuit breaker provides overload protection for the generator set. When tripped, the circuit breaker will switch to the "Off" position. E = NEMA L530R RECEPTACLE.
CONTROL PANEL For the K5000/K5000E 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 K6500/K6500E 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.
K3000 Wiring Diagram - 17 -
K5000 Wiring Diagram - 18 -
K5000E Wiring Diagram - 19 -
K6500 Wiring Diagram - 20 -
K6500E Wiring Diagram - 21 -
Generator-End Componentry - 22 -
CONTROL BOX COMPONENTRY - 23 -
PARTS BREAKDOWN BB WD1541A33SP MM MM NN OO * RM1088A06 RM1088A07 TA0000A02 TA0002A02 TA0000A03 TA0002A04 SP9129 SP9079 RR0244A00 EA5035A00L4B EA5035A01L4B Consult Factory Isolators, generator End Isolators, generator End Fuel Tank Fuel Cap W/ Gauge Fuel Tank Fuel Cap W/ Gauge Switch, 2 Position Rocker K3000 Switch, DPDT McGill (Circuit Breaker Switches) Varistor, Not Pictured Muffler, Not Pictured Muffler, Not Pictured Mate -n- Loc Kit HB7025A00 HB6150A00 HB7002A07 SP9128 WD3201A02 WD3201A00 EB1242A0
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. Revised: 4/13/01 Effective: 2/26/98 Form#:S-PSG-001-1 C:\ISO9001\FORMS\S-PSG-001-1.
Service is just a phone call away: 800-872-7697 www.baldor.com/products/generators.
