Baldor Portable Generator AE10 User Manual

Automatic Emergency

Generator

AE8, AE10, AE11 and AE25

Installation & Operating Manual

5/05

MN2415

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Table of Contents

Section 1

Product Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Section 2

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Section 3

Receiving & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Lifting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Physical Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Outdoor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Indoor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Secure the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

AE8 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

AE10 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

AE11 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

AE25 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Recommended Engine Oil and Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Post Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Section 4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Manual Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Automatic Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Automatic Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

AE11 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Warnings and Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Editing the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Garretson Model KN Fuel Valve Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Section 5

Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Continued on next page

MN2415

Table of Contents i

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Appendix A

Series AE8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Operator Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Appendix B

Series AE10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Operator Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Appendix C

Series AE11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Operator Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Conversion from LPG to Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Appendix D

Series AE25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Operator Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

ii Table of Contents

MN2415

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Section 1

Product Safety Information

Safety Notice

Be sure that you are completely familiar with the safe operation of this equipment. This

equipment may be connected to other machines that have rotating parts or parts that are

controlled by this equipment. Improper use can cause serious or fatal injury. Always

disconnect all electrical loads before starting the generator.

Installation and repair procedures require specialized skills with electrical generating equipment

and liquid cooled engine systems. Any person that installs or repairs this generator must have

these specialized skills to ensure that this generating unit is safe to operate. Contact Baldor for

repairs or any questions you may have about the safe installation and operation of this system.

The precaution statements are general guidelines for the safe use and operation of this

generator. It is not practical to list all unsafe conditions. Therefore, if you use a procedure that is

not recommended in this manual you must determine if it is safe for the operator and all

personnel in the proximity to the generator and connected loads. If there is any question of the

safety of a procedure please contact Baldor before starting or stopping the generator.

This equipment contains high voltages. Electrical shock can cause serious or fatal injury. Only

qualified personnel should attempt the start−up procedure or troubleshoot this equipment.

This equipment may be connected to other machines that have rotating parts or parts that are

driven by this equipment. Improper use can cause serious or fatal injury. Only qualified

personnel should attempt the start−up procedure or troubleshoot this equipment.

−

System documentation must be available to anyone that operates this equipment at all

times.

−

Keep non-qualified personnel at a safe distance from this equipment.

Only qualified personnel familiar with the safe installation, operation and maintenance

of this device should attempt start-up or operating procedures.

−

Always stop engine before making or removing any connections.

Always stop engine and allow it to cool before refueling.

Responsibility

When your generator is delivered, it becomes the responsibility of the owner/operator of the

generator set to prevent unsafe conditions and operation of the equipment. Some

responsibilities include (but are not limited to) the following:

1. It is the responsibility of the owner/operator of this generator to ensure that this

equipment is correctly and safely installed.

2. It is the responsibility of the owner/operator of this generator to ensure that this

equipment, when installed fully complies with all federal, state and local codes.

3. It is the responsibility of the owner/operator of this generator to ensure that any person

operating this equipment has been properly trained.

4. It is the responsibility of the owner/operator of this generator to ensure that any person

operating this equipment has access to all manuals and information required for the

safe use and operation of this equipment.

5. It is the responsibility of the owner/operator of this generator to ensure that it is properly

maintained and safety inspected at regular scheduled intervals.

6. It is the responsibility of the owner/operator of this generator to ensure that any person

who has not been trained on the safe use of this equipment does not have access to

this equipment.

Read This Manual Thoroughly

If you do not understand any concept, any procedure, any safety warning statement, any safety

caution statement or any portion of this manual, contact Baldor or your nearest authorized Baldor

representative. We are happy to make sure you understand the information in this manual so

that you can safely enjoy the full use of this generator.

MN2415

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Symbols

This symbol is shown throughout the manual to indicate a connection to ground reference point.

Indicates a potentially hazardous situation which, if not avoided, could result in injury or death.

Precaution Statements Used In This Manual

There are three classifications of precautionary statements used in this manual. The most critical

is a WARNING statement, then the Caution statement and the least critical is the Note

statement. The usage of each statement is as follows:

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in injury or

death.

Caution: Indicates a potentially hazardous situation which, if not avoided, could result in damage to

property.

Note:

Additional information that is not critical to the installation or operation.

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS − This manual contains important instructions for the generator that

should be followed during installation, operation and maintenance of the generator.

For ease of reading, the Warning statements are divided into four categories: Operation, Burn, Installation,

and Maintenance.

Operation

WARNING: Never operate this generator in a manner other than as described in this manual. Operation

in any manner not described in this manual should be considered unsafe and should not be

attempted. Never start the engine unless you have first verified that the installation and

operation of the generator are as described in this manual.

WARNING: Be sure that you are completely familiar with the safe operation of this equipment. This

equipment may be connected to other machines that have rotating parts or parts that are

controlled by this equipment. Improper use can cause serious or fatal injury.

WARNING: Exhaust fumes/gases are extremely dangerous and can cause severe illness or death. Never

breath exhaust fumes produced by a running engine. Only run the engine outdoors where

ventilation is plentiful. Exhaust gases contain carbon monoxide, a colorless, odorless and

extremely dangerous gas that can cause unconsciousness or death. Symptoms of carbon

monoxide poisoning include: dizziness, nausea, headaches, sleepiness, vomiting or

incoherence. If you or anyone else experiences these symptoms, get out into fresh air

immediately. Stop the engine and do not restart the engine until it has been inspected and if

necessary repaired or reinstalled in a well ventilated area.

WARNING: Hot exhaust gasses must never be directed toward anything that may catch fire or explode.

WARNING: This generator 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 arrestor. The

spark arrestor must be maintained in effective working order by the operator.

WARNING: Some parts of this generator rotate during operation. Rotating parts can present extreme

danger if clothing or body extremities are caught by the rotating part and can cause serious

or fatal injury. Never touch a part of the generator until the engine has been stopped and all

rotating parts are completely stopped. Also, disconnect the spark plug wires and battery

connection to prevent accidental engine rotation during servicing.

WARNING: Never move a generator set that is running. Loads should be connected and position secure

before starting the engine. Hazards are caused by moving a generator set that is running.

Continued on next page.

1-2 Product Safety Information

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Operation Warning Statements Continued

WARNING: Never connect or disconnect loads during operation. Always connect load circuits before

starting the engine and use external branch disconnects etc. to switch loads On/Off.

WARNING: Be sure that you understand how to stop the engine quickly in case of an emergency situation.

Become familiar with the controls and safety systems provided with this generator set.

WARNING: Always wear safety glasses with side shields and hearing protection when working near the

generator.

WARNING: Improper operation may cause violent motion of connected equipment. Be certain that

unexpected movement will not cause injury to personnel or damage to equipment.

WARNING: Never operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave.

Exhaust fumes are extremely dangerous to all personnel that are in or in contact with that area.

WARNING: Never permit anyone to operate the generator without proper instructions. Be sure to keep a

copy of this manual with the generator so that all users can be properly informed of its safe

operation.

WARNING: Never allow children or pets to be in the area where the generator is running. The generator

and the equipment being powered by the generator may cause injury or death.

WARNING: Never operate the generator unless all guards, covers, shields and other safety items are

properly installed.

WARNING: Do not put hands, feet, tools clothing or other objects near rotating parts such as drive shaft,

pulley, belt etc. Rotating parts cause extremely dangerous situations because they can catch

loose clothing or extremities and cause serious or fatal injury.

WARNING: When operating this generator remain alert at all times. Never operate machinery when

physically or mentally fatigued, or while under the influence of alcohol, drugs or medication.

WARNING: Never operate the engine when the air cleaner is removed. An engine backfire can cause

serious burns.

WARNING: Never “jump start” a generator to start the engine. If the battery charge is insufficient to start

the engine, charge or replace the battery and try to restart. Jump starting a battery can cause

the battery to explode and cause severe injury or death to anyone in the area.

WARNING: High voltage is present whenever engine is running. Electrical shock can cause serious or

fatal injury. Never operate electrical equipment while standing in water, on wet ground or with

wet hands, feet or shoes or while barefoot.

WARNING: High voltage is present whenever the engine is running. Electrical shock can cause serious

or fatal injury. Always stop engine before connecting or disconnecting power cords or

external devices.

WARNING: Do not smoke near generator during operation or when close to fuel source. LPG and natural

gas fuels are flammable and can cause fire, explosions, injury or death.

WARNING: Keep generator at least three feet away from buildings and other structures.

WARNING: Keep generator away from flammable or hazardous materials (trash, rags, lubricants,

explosives, paints etc.) and grass or leaf build up.

WARNING: Keep a fire extinguisher near the generator while generator is in use. An extinguisher rated

“ABC” by the National Fire Protection Association is appropriate.

Burn

WARNING: Parts of this generator are extremely hot during and after operation. To prevent severe burns,

do not touch any part of the generator until you have first determined if the part is hot. Wear

protective clothing and after use allow sufficient time for parts to cool before touching any

part of the generator.

WARNING: Do not touch the hot exhaust parts or the high voltage spark plug or coil terminals of the

engine. Although spark plug voltages are not normally lethal, a sudden involuntary jerk of the

hand or body part caused by contact with high voltage or a hot surface can result in injury to

yourself or others.

WARNING: Engine coolant is under pressure and is near the boiling point of water when engine is hot.

Do not open the coolant system until the engine has completely cooled. Hot coolant can

cause severe burns and other injuries. When engine is cool, coolant level can be checked.

Continued on next page.

MN2415

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Warning Statements Continued

Installation

WARNING: Installation and servicing of batteries is to be performed or supervised by personnel

knowledgeable of batteries and the required precautions. Keep unauthorized personnel away

from batteries.

WARNING: Disconnect the battery’s ground terminal before working in the vicinity of the battery or

battery wires. Contact with the battery can result in electrical shock when a tool accidently

touches the positive battery terminal or wire. The risk of such shock is reduced when the

ground lead is removed during installation and maintenance.

WARNING: An open bottom stationary engine generator set must be installed over noncombustible

materials and shall be located such that it prevents combustible materials from accumulating

under the generator set.

WARNING: Installation and repair procedures requires specialized skills with electrical generating

equipment and small engine systems. Any person that installs or performs repairs must have

these specialized skills to ensure that the generator set is safe to operate. Contact Baldor for

installation or repairs.

WARNING: Be sure all wiring complies with the National Electrical Code (NEC) and all regional and local

codes or CE Compliance. Improper wiring may cause a hazardous condition and exposure to

electrical hazards can cause serious injury or death.

WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power before

you ensure that grounds are connected. Electrical shock can cause serious or fatal injury. NEC

requires that the frame and exposed conductive surfaces (metal parts) be connected to an

approved earth ground. Local codes may also require proper grounding of generator systems.

WARNING: Never allow the exhaust outlet to be positioned so that the exhaust gases are directed

towards any openings or air entry routes (doors, windows, vents, etc...) of an occupied

building. When discharging the hot exhaust gases out of the building do not direct them

towards anything that could catch fire or explode.

WARNING: Place protective covers over all rotating parts such as drive shaft, pulley, belt etc. Rotating

parts cause extremely dangerous situations because they can catch loose clothing or

extremities and cause serious or fatal injury.

WARNING: Unauthorized modification of a generator set may make the unit unsafe for operation or may

impair the operation of the unit. Never start a generator set that has been modified or

tampered with. Be sure that all covers and guards are properly installed and that the unit is

safe before starting the engine. If you are unsure, contact Baldor before starting the engine.

WARNING: When moving the generator, use reasonable caution. Be careful where you place fingers and

toes to prevent injury “Pinch Points”. Never try to lift a generator without a hoist or lift means

because they are heavy and bodily injury may result.

Warning: Never connect this generator to the electrical system of any building unless a licensed

electrician has installed an approved transfer switch. The national electrical code (NEC)

requires that connection of a generator to any electrical circuit normally powered by means of

an electric utility must be connected by means of approved transfer switch equipment to

isolate the electrical circuit from the utility distribution system when the generator is

operating. Failure to isolate the electrical circuits by such means may result in injury or death

to utility power workers due to backfeed of electrical energy onto the utility lines.

WARNING: Circuit overload protection must be provided in accordance with the National Electrical Code

and local regulations.

WARNING: Check Ground Fault Circuit Interrupt (GFCI) receptacles monthly by using the “Test” and

“Reset” buttons.

WARNING: Only a professional experienced technician should install a fuel supply system. LPG and

natural gas fuels are flammable and can cause fire, explosions, injury or death. Fuel supply

lines should be kept away from sharp objects to prevent rupture. Comply with all NFPA

regulations and local codes for shut−off valves, regulators, fuel line type, connectors etc.

WARNING: Have electrical circuits and wiring installed and checked by licensed electrician or qualified

technician. Electrical shock can cause serious or fatal injury.

WARNING: Incorrect installation of this generator set could result in property damage, injury or death.

Connection of the generator to its fuel source must be done by a qualified professional

technician or contractor.

Continued on next page.

1-4 Product Safety Information

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Warning Statements Continued

Maintenance

WARNING: Before servicing the generator set, be sure to disconnect the battery terminals to prevent

accidental engine rotation or starting.

WARNING: Disconnect the battery’s ground terminal before working in the vicinity of the battery or

battery wires. Contact with the battery can result in electrical shock when a tool accidently

touches the positive battery terminal or wire. The risk of such shock is reduced when the

ground lead is removed during installation and maintenance.

WARNING: Installation and servicing of batteries is to be performed or supervised by personnel

knowledgeable of batteries and the required precautions. Keep unauthorized personnel away

from batteries.

WARNING: A battery presents a risk of fire and explosion because they generate hydrogen gas.

Hydrogen gas is extremely explosive. Never jump start a battery, smoke in the area around

the battery or cause any spark to occur in the area around the battery.

WARNING: Do not mutilate the battery or dispose of a battery in a fire. The battery is capable of

exploding. If the battery explodes, electrolyte solution will be released in all directions.

Battery electrolyte solution is caustic and can cause severe burns and blindness. If

electrolyte contacts skin or eyes, immediately flush the area with water and seek medical

attention quickly.

WARNING: A battery presents a risk of electrical shock hazard and high short circuit current. Electrical

shock can cause serious or fatal injury. Never wear jewelry, watch or any metal objects when

in the area around the battery.

WARNING: The battery electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is

electrically conductive and corrosive. If electrolyte contacts the skin, flush the area

immediately with water and wash it off using soap and water. If electrolyte contacts the eyes,

immediately flush the eye thoroughly with water and seek medical attention quickly.

WARNING: Before cleaning, inspecting, repairing or performing any maintenance to the generator set,

always be sure the engine has stopped and that all rotating parts have also stopped. After

stopping, certain components are still extremely hot so be careful not to get burned. Before

servicing the generator set, be sure to disconnect the spark plug wires and the battery

terminals to prevent accidental engine rotation or starting.

WARNING: Engine coolant is under pressure and is near the boiling point of water when engine is hot.

Do not open the coolant system until the engine has completely cooled. Hot coolant can

cause severe burns and other injuries. When engine is cool, coolant level can be checked.

WARNING: Before servicing the generator set, be sure to disconnect the spark plug wires and the battery

terminals to prevent accidental engine rotation or starting.

WARNING: Inspect all wiring frequently and replace any damaged, broken or frayed wiring or wires with

damaged insulation immediately. Electrical shock can cause serious or fatal injury.

WARNING: Disconnect all electrical wires and load devices from generator power outlets before servicing

the generator. Electrical shock can cause serious or fatal injury. Always treat electrical

circuits as if they are energized.

WARNING: Check all fuel supply piping, and their connections monthly for fuel leaks. LPG and natural

gas fuels are flammable and can cause fire, explosions, injury or death. If a leak is found,

replace only with approved pipe or components.

Continued on next page.

MN2415

Product Safety Information 1-5

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Caution Statements

Caution: Avoid installing the generator set beside heat generating equipment, or directly below water

or steam pipes or in the vicinity of corrosive substances or vapors, metal particles and dust.

Heat can cause engine problems to develop and unwanted substances can cause rust or

generator failure over time.

Caution: Do not apply high voltage to windings (do not start the generator) in a moisture−saturated

condition. Moisture can cause insulation breakdown, making it necessary to return the

generator to the factory for repair, and consequent expense and loss of time.

Caution: Use only original equipment or authorized replacement parts. Using the correct parts will

assure continued safe operation as designed.

Caution: Do not support the generator from the top of the frame or enclosure.

Caution: Do not tamper with or change the engine speed. Engine speed is factory set to produce the

correct voltage and output frequency.

Caution: Never operate the engine without a muffler. The engine is designed to have the correct

exhaust components installed and operating without these components can present a fire

hazard, cause excessive exhaust gases and cause damage to engine. Inspect muffler

periodically and replace if necessary.

Caution: The Programmable Output Contacts selection must agree with the external control wiring

prior to energizing the controller. Failure to do so may cause severe equipment damage.

Caution: This generator must have a battery installed for operation. The battery is used during starting

and during operation. If engine operation is attempted while the battery is removed, damage

to the engine’s electrical components may result.

1-6 Product Safety Information

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Section 2

General Information

Thank you for purchasing your Baldor Generator Set. This manual contains information you need to safely and efficiently

install and operate your generator set. During the preparation of this manual every effort was made to ensure the

accuracy of its contents. This manual describes only very basic engine information. A separate owner’s manual for the

engine is supplied with this unit for your use. Please refer to the engine manual for information relative to engine

operation, maintenance, recommendations and additional safety warnings.

This manual is copyrighted and all rights are reserved. This document may not, in whole or in part, be copied or

reproduced in any form without the prior written consent of Baldor Electric Company, Inc.

Baldor Generators have earned the reputation of being high quality and dependable. We take pride in this fact and

continue to keep our quality standards high on our 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.

Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied

warranties of fitness for any particular purpose. The information in this document is subject to change without notice.

Baldor assumes no responsibility for any errors that may appear in this document.

Limited Warranty

Baldor Generators will replace or repair free of charge any part or parts of the generator of their manufacture that are

defective in workmanship and materials for a period of time as set forth in the Warranty Period chart below. 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. 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. 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*

1 Year

Parts

3 Years

Portable Products (Premier, Powerchief,

DG Series, K Series)

Towable Products (TS)

1 Year or 3,000 Hours

Whichever comes first

3 Years or 3,000 Hours

Whichever comes first

POW’R LITE Light Towers

1 Year or 3,000 Hours

Whichever comes first

3 Years or 3,000 Hours Whichever comes first

Excluded from any warranty coverage regardless of

time period: Light Fixture, Lamps and Ballasts

3600 RPM Standby Systems

(Some AE Models)

1 Year or 1,000 Hours

Whichever comes first

3 Years or 1,000 Hours

Whichever comes first

1800 RPM Standby Systems

(Some AE Models, DLC, GLC)

1 Year or 3,000 Hours

Whichever comes first

3 Years or 3,000 Hours

Whichever comes first

Industrial Standby Systems

Industrial Prime Power Systems

International

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

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

*For products covered under labor coverage, travel expenses will be allowed up to 7 hours straight labor or 300 miles,

whichever occurs first and only applies to permanently wired and mounted products (AE, DLC, GLC, IDLC).

No warranty registration card is necessary to obtain warranty on Baldor Generators.

You must save the purchase receipt. Proof of purchase, date, serial number and model number will be required for all

portable and Towable products to qualify for any warranty consideration.

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.

MN2415

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2-2 General Information

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Section 3

Receiving & Installation

Receiving & Inspection When you receive your generator, there are several things you should do immediately.

1. Observe the condition of the shipping container and report any damage immediately to

the commercial carrier that delivered your system.

2. Verify that the part number of the system you received is the same as the part number

listed on your purchase order.

3. If the system is to be stored for several weeks before use, be sure that it is stored in a

location that conforms to published storage temperature and humidity specifications.

Lifting the Generator When lift or hoist equipment is used to lift the generator and move it to position, be careful not

to contact overhead wires or other obstacles. The generator can weigh as much as 1,500 lbs. Be

sure lift or hoist equipment has appropriate tires for the terrain to avoid becoming stuck or tipping

over. If the shipping pallet is intact, use a fork lift to move the generator. If the shipping pallet has

been removed, use two steel pipes through the “Lift Point” holes to lift the generator. See Figure 3-1.

Figure 3-1 Generator Lifting & Mounting

AE8 & AE10

Not To Scale

2.63

Four mounting

holes 0.38" dia.

Length

8.88

Electrical

Stub Up

7.75

Fuel Inlet on

Horizontal Surface

Height

44.50

Lift Point

(Alternator End)

29.00

Width

Lift Point

Thru Base

All dimensions are in inches.

Stub Up Area

1.50

AE11

AE25

Six mounting

holes 0.410" dia.

Stub Up

Access Panel

(Fuel & Electrical)

6.00

4.52

30.00

1.50

24.00

42.00

46.00

3.19

8.12

Fuel Inlet

Zone

72.00

3.19

28.00

24.00

Electrical

Stub Up

26.14

20.94

Four mounting

holes 0.38" dia.

29.29

(Alternator End)

31.25

LT0143A02

LT0143A30

30.29

MN2415

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Physical Location The mounting location of the system is important. It should be installed in an area that is

protected from direct harmful gases or liquids, dust, metallic particles, shock and vibration.

It should be installed in an outdoor location so the exhaust fumes are vented to the atmosphere.

WARNING: An open bottom stationary engine generator set must be installed over noncombustible

materials and shall be located such that it prevents combustible materials from accumulating

under the generator set.

Outdoor Location with Baldor Supplied Enclosure

If the generator is installed outdoors there should not be a cooling problem. The factory installed

enclosure is designed to keep out undesirable weather elements while providing cooling and

ventilation. It should be installated on a concrete pad with at least thirty−six (36) inches

clearance on all sides for air flow.

1. For effective cooling and maintenance, the system should be installated on a concrete pad

with at least thirty−six (36) inches clearance on all sides for air flow and service access.

2. Installation should prevent water levels from reaching the generator. Drainage must be

adequate to keep concrete pad free from standing water.

3. Installation should prevent obstructions by buildup of leaves, grass, sand, snow, etc. If

these items pose a problem, consider building a small fence or other break to protect

the unit from accumulation of debris.

Indoor Location Open Frame Configuration

When the Generator is installed in a building it is essential to provide:

1. Adequate control and exhausting of the heated air.

2. An adequate and constant supply of incoming cooling air.

3. Adequate control and discharge of the engine’s hot exhaust gases.

4. Adequate ventilation of the building when the engine shuts down.

Several other factors should be carefully evaluated when selecting a location for installation:

1. For effective cooling and maintenance, the system should be mounted on a flat, smooth,

non-flammable level surface. A concrete pad is ideal and provides a secure installation.

2. Installation should prevent water levels from reaching the generator. Drainage must be

adequate to keep concrete pad free from standing water.

3. Installation should prevent obstructions by buildup of leaves, grass, sand, snow, etc. If

these items pose a problem, consider building a small fence or other break to protect

the unit from accumulation of debris.

4. Installation should place the generator as close as possible to the fuel supply and

transfer switch.

5. At least forty−eight (48) inches clearance must be provided on all sides for air flow.

6. Maximum Ambient temperature is 122°F (50°C).

Engine Cooling

A sufficient flow of clean, cool air is required for combustion and to dissipate the heat produced

by the engine. Approximately 60% of the heat value of the fuel used is given off as heat (cooling

air and exhaust).

The air that will cool the engine must be brought in from outside the building. A sufficient air−flow

of rate “Cubic Feet per Minute” (CFM) will allow the incoming fresh air to cool the engine. This

requires a power ventilation system of sufficient CFM to be located at the highest possible point

of the building to exhaust hot air and draw in cool fresh air. For 8−12KW we recommend an

exhaust fan of at least 2000 CFM.

Note: The exhaust fan must not be located where it could easily become blocked by leaves,

snow, water, debris, etc.

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Indoor Location Continued

It is recommended that the cool air intake have at least three (3) times the cross−sectional area

of the power ventilation system. It is also recommended that the cool air intake be located as

close as possible to the top of the generator set.

The exhaust fan must be connected to the AC power terminals of the generator set so that when

the generator set starts it will provide immediate cooling air flow. The fan will operate until the

generator set stops.

Ventilation Test

To test the ventilation system, do the following:

1. Place a thermometer as close as you can to the cool air intake of the engine’s blower

housing but do not let the thermometer touch any material surface.

2. Place another thermometer outside the building or compartment in the open air. (Keep

the thermometer out of direct sunlight or any other heat sources).

3. Run the engine under maximum load for an extended period of time (at least one hour).

4. The temperature difference between the two should not exceed 15 degrees F.

Note that opening any door, window or other opening can upset the air−flow pattern and result in

a significant reduction in the cooling air−flow across the generator set. This may result in

overheating, fire, or explosion. To find out if this is true with your specific application run the

Ventilation Test with all doors and windows closed. Then repeat this test with different doors and

windows open, and eventually with all the windows and doors open. If any of these tests result in

a temperature difference in excess of 15° F, you must not run the generator set under those

specific conditions.

Hot Exhaust Gasses