Baldor AE25, AE11, AE8, AE10 User Manual

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Automatic Emergency

Generator

AE8, AE10, AE11 and AE25

Installation & Operating Manual

5/05 MN2415

WARNING:

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.

WARNING:

CALIFORNIA PROPOSITION 65 WARNING:

Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm.

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

Table of Contents iMN2415

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

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

Read This Manual Thoroughly

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.

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.

Product Safety Information 1-1MN2415

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

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

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

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

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:

death.

property.

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 MN2415

Operation Warning Statements 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.

Continued

Product Safety Information 1-3MN2415

Warning Statements 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

Continued on next page.

1-4 Product Safety Information MN2415

Warning Statements 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

Continued on next page.

Product Safety Information 1-5MN2415

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 MN2415

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.

Copyright Baldor { 2004. All rights reserved. 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* Parts

Portable Products (Premier, Powerchief,

*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.

DG Series, K Series)

Towable Products (TS) 1 Year or 3,000 Hours

POW’R LITE Light Towers 1 Year or 3,000 Hours

3600 RPM Standby Systems

(Some AE Models)

1800 RPM Standby Systems

(Some AE Models, DLC, GLC)

Industrial Standby Systems 1 Year or 1,000 Hours

Industrial Prime Power Systems 1 Year or 1,000 Hours

International 1 Year or 1,000 Hours

Whichever comes first

1 Year or 1,000 Hours Whichever comes first

1 Year or 3,000 Hours Whichever comes first

Whichever comes first

1 Year 3 Years

3 Years 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

3 Years or 1,000 Hours

Whichever comes first

3 Years or 3,000 Hours

Whichever comes first

2 Years or 1,000 Hours

Whichever comes first 1 Year or 1,000 Hours

Whichever comes first

General Information 2-1MN2415

2-2 General Information MN2415

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

Not To Scale

Length

Four mounting holes 0.38" dia.

7.75

AE8 & AE10

8.88 Electrical

Stub Up

Fuel Inlet on Horizontal Surface

2.63

8.88

Lift Point

Stub Up

Access Panel

(Fuel & Electrical)

Four mounting holes 0.38" dia.

LT0143A30

Thru Base Stub Up Area

1.50

Lift Point

1.50

4.52

AE11

6.00

28.00

29.29

(Alternator End)

30.29

Height

Width

All dimensions are in inches.

42.00

46.00

Six mounting holes 0.410" dia.

LT0143A02

24.00

26.14

Fuel Inlet Zone

3.19

(Alternator End)

29.00

AE25

30.00

Electrical Stub Up

(Alternator End)

31.25

3.19

8.12

44.50

72.00

20.94

Receiving & Installation 3-1MN2415

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.

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.

3-2 Receiving & Installation MN2415

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

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

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: 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: 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.

It is extremely important to discharge engine exhaust gasses away from the engine and out of the building. The direction of the discharged hot air and hot exhaust gases is important as they have the potential to create brown spots on the lawn. In extreme cases this extremely hot air could cause dried grass or other debris to ignite.

Guidelines for Exhaust System

1. It is extremely important that you do not allow the hot exhaust gases to re−circulate into the engine’s cooling air intake.

2. The exhaust system is subject to the engine’s vibration and it must therefore be solidly secured to reduce mechanical stress and the potential for breakage.

3. The engine’s exhaust system is the hottest component of the installation and extreme care and considerations must be given to it.

Receiving & Installation 3-3MN2415

Indoor Location

Generator

Heigh

Width

Continued

4. Keep all fuel and its associated piping away from all components of the engine exhaust system.

5. The exhaust system should be inspected on a regular basis to assure there are no toxic exhaust gas leaks. In some areas this inspection may be provided by your local public service.

6. A carbon monoxide tester may be installed to detect the presence of the deadly gas during times when you are in the building with the engine running (during testing or maintenance).

Installation The generator is completely assembled, tested and adjusted at the factory before it is shipped to

you. The procedures presented in this manual are suggestions and it is the responsibility of the Owner/Operator to arrange for these procedures to be performed by licensed contractors according to all applicable codes including local codes for your Municipality/City/County and State. Installation generally includes the following:

1. Secure Generator to concrete pad.

2. Connect Fuel Supply.

3. Electrical Connections − power wiring (optional transfer switch) and control wiring.

4. Battery (not included).

5. Ground Connection.

After installation, the post installation checks must be performed prior to starting the engine. After these checks have been performed and the system operation is verified to be good, refer to

Section 6 Maintenance for periodic checks that must be performed at scheduled intervals to ensure continued operation with minimal problems.

Secure the Generator

Refer to Table 3-1 for the dimensions and weight of each generator. Mounting bolts in the base frame secure the generator to the shipping pallet. Remove these bolts, lift the generator and remove the shipping pallet.

Secure the generator to the concrete pad using anchor hardware (not provided). See Figure 3-1. Anchor bolts must be long enough to extend through the generator mounting frame.

Table 3-1 Physical Dimensions

Generator

Model

AE8−E/O 36.75 29.00 44.5 255 lbs. 463 lbs.

AE10−E/O 36.75 29.00 44.5 316 lbs. 509 lbs.

AE11−E 30.50 30.375 46 468 lbs.

AE25−E−NG 34.00 31.5.0 72 1450 lbs.

AE25−E−LP 34.00 31.5.0 72 1450 lbs.

engt

Open Enclosed

Weight

3-4 Receiving & Installation MN2415

Fuel Connections

The AE Series generators will run on Natural Gas or LPG (Liquid Propane Gas). If natural gas supply is used, follow the “Natural Gas Connections” procedure. If LPG supply is used, follow the “LP Gas Connections” procedure. Table 3-2 defines the flow rate required for each fuel type.

Note: The AE25 must be ordered for use with Natural gas or LPG.

General Considerations

The following pamphlets are available from:

Table 3-2 Fuel Consumption Natural and LPG

Generator Model Required Flow Rate (cubic feet per hour) Pressure

Natural Gas LPG

AE8 160 64 6 oz (11) AE10 200 72 6 oz (11) AE11 200 72 4 oz. (7) AE25 400 159 6 oz (11)

oz. (inches water column)

1. A generator set needs the engine to deliver 2 hp of energy to the alternator for every 1000 watts of electric output power (example: an 8000 watt generator needs the engine to deliver 16 hp of energy to the generator end).

2. An engine needs 10,000 BTU’s of fuel energy per horsepower of engine power to provide a sufficient supply of fuel (example: a 16 Hp engine needs 160,000 BTU’s of fuel energy for it to work properly). This fuel must be supplied to the regulator on the generator set at a pressure indicated in Table 3-2. To achieve this pressure in an L.P. System, you will normally have to reduce the tank pressure by means of a primary regulator or a regulator system of 2 or more regulators.

3. There are 2,516 BTU’s in one cubic foot of Propane (LP Fuel). There are 1,096 BTU’s in one cubic foot of Natural Gas.

4. There are 36.39 cubic feet in one gallon of Propane. There are 57.75 cubic feet in one gallon of Natural Gas.

5. There are 8.58 cubic feet per pound of Propane. There are 23.56 cubic feet per pound of Natural Gas.

6. When installing the piping for the gaseous fuel supply please refer to the pipe chart in Tables 3-3 and 3-4 to be sure you are using piping of significantly large size to deliver the necessary amount of fuel.

7. If copper tubing is used, it should be “K” or “L” having a minimum wall thickness of

0.032 inches. Black Iron Pipe is recommended but follow building codes for your area.

National Fire Protection Association (NFPA) P.O. Box 9101 Quincy, MA 02269

No. 37 − Combustion Engines No. 54 − Gaseous Appliances and piping No. 58 − Storage and handling LPG

Example: Determining Pipe Size for Natural Gas

An AE8 has a 16Hp engine. For Natural Gas fuel, determine the supply pipe size for 60 feet run. 16 x 10,000 = 160,000 BTU’s / per hour for proper operation.

160, 000

1, 096

+ 146 cubic feet per hour.

From Table 3-4, a 60 foot run requires a minimum 1” pipe at full engine load.

Receiving & Installation 3-5MN2415

Natural Gas Connections

The incoming pressure must be as indicated in Table 3-2. Note: Almost all operation problems are related to the installation techniques used.

Do Not guess, be sure pipe size is adequate for required flow rate.

Table 3-3 Natural Gas Flow Rate (Cubic Feet per Hour) per Pipe Length

Pipe

Length

(Feet)

″

″ 1″ 1−

″ 1−

15 73 165 332 722 1174 2386 3704 6253 13352 37229 30 50 115 232 515 818 1712 2646 4521 9331 26330 53728 45 41 95 191 418 673 1419 2213 3752 7600 22462 43867 60 37 83 166 366 587 1241 1924 3319 6542 18595 37999 75 74 149 332 524 1077 1684 2886 5772 16652 33959

90 67 137 298 433 962 1501 2597 5291 15200 31025 105 63 126 274 433 885 1376 2357 4906 14064 28715 120 115 260 404 827 1289 2213 4618 13160 26859 150 105 233 366 750 1174 2011 4185 11775 24050 180 96 216 337 693 1077 1876 3848 10736 21934 210 89 197 308 635 991 1712 3559 9937 20298 240 183 289 596 933 1616 3357 9235 18990 270 171 274 558 875 1520 3127 8658 17903 300 164 260 524 827 1433 2886 8177 16998

Iron Pipe Size

″ 2″ 2−

″ 3″ 4″ 6″ 8″

1. Connect the proper size gas pipe at the input to the Natural Gas regulator. Connect the Natural Gas pipe line shown in Figure 3-2 using the correct size pipe for the required flow rate and length of pipe. Refer to Table 3-3 for pipe size. Be certain that all connections are sealed and no leaks are present. The installer must ensure that all gas connections comply with all building codes.

2. Verify Fuel Supply Pressure Prior to initial operation of generator, verify that fuel system pressure is as indicated in Table 3-2 and fuel pipe sizes comply with Table 3-3.

3. Proceed to Electrical Connections.

Note: Regulator shown for Natural Gas only.

For LPG, mount upside down.

Figure 3-2 Gas Line Connections

Carburetor

Gasket

Regulator

Mounting Bracket

Air Cleaner

Solenoid, Fuel Lock

Inlet Connection

3-6 Receiving & Installation MN2415

Example: Determining Pipe Size for LPG

An AE8 has a 16Hp engine. For LP fuel, determine the supply pipe size for 60 feet run. 16 x 10,000 = 160,000 BTU’s / per hour for proper operation.

160, 000

2, 516

+ 63.5 cubic feet per hour.

From Table 3-4, a 60 foot run requires a minimum 1” pipe at full engine load.

LP Gas Connections (vapor withdrawal only)

The LPG connections should only be made if your generator is setup to run on LPG. If it is setup to run on Natural Gas, contact your Baldor representative and do not continue with installation.

The incoming pressure must be as indicated in Table 3-2.

Table 3-4 LP Gas Flow Rate (Cubic Feet per Hour) per Pipe Length

Pipe

Length

(Feet)

15 48 109 218 475 772 1570 2437 4115 8786 24497 50007 30 33 76 153 339 538 1127 1741 2975 6140 17325 35353 45 27 63 126 275 443 934 1456 2469 5001 14781 28865 60 24 54 110 241 386 817 1266 2184 4304 12236 25004 75 49 98 218 345 709 1108 1899 3798 10957 22345

90 44 89 196 310 633 987 1709 3482 10001 20414 105 41 83 180 285 582 905 1551 3228 9254 18895 120 76 171 266 544 848 1456 3038 8659 17673 150 69 153 241 494 772 1323 2754 7748 15825 180 63 142 222 456 709 1234 2532 7064 14432 210 58 130 202 418 652 1127 2342 6439 13356 240 120 190 393 614 1063 2209 6077 12405 270 113 180 367 576 1000 2057 5697 11780 300 108 171 345 544 943 1899 5381 11179

″

″ 1″ 1−

″ 1−

Iron Pipe Size

″ 2″ 2−

″ 3″ 4″ 6″ 8″

Note: Almost all operation problems are related to the installation techniques used.

Do Not guess, be sure pipe size is adequate for required flow rate.

1. Connect the proper size gas pipe at the input to the LP Gas regulator. Connect the LPG pipe line shown in Figure 3-2 using the correct size pipe for the required flow rate and length of pipe. Refer to Table 3-4 for pipe size. Be certain that all connections are sealed and no leaks are present. The installer must ensure that all gas connections comply with all building codes.

2. Verify Fuel Supply Pressure Prior to initial operation of generator, verify that fuel system pressure is as indicated in Table 3-2 and fuel pipe sizes comply with Table 3-4.

3. Proceed to Electrical Connections.

Receiving & Installation 3-7MN2415

Electrical Connections

Class 1 wiring methods must be used for field wiring connections to terminals of a class 2 circuit. It is the responsibility of the owner/operator to arrange for these procedures to be performed by a licensed electrical contractor and ensure conformance to all applicable codes including local codes peculiar to your municipality/city/county and state. Wire size and insulation type should be as required by NEC (National Electrical Code) and local codes.

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

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.

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.

Intended Use The intended purpose of this generator set is to provide emergency power when the main utility

power supply is interrupted. Therefore, it is important that all the wiring that connects the generator set with your house, transfer switch, distribution box, battery charger, etc. be properly installed.

Circuit Protection Circuit protection is not provided with the generator. When connecting the generator output

to an electrical load, a UL listed circuit breaker with the appropriate ratings shall be provided within 25 feet of the genset. Use only copper wires.

enerator Rating

Catalog No.

AE8 8 120/240 120/240/480 AE10 10 120/240 120/240/480 AE11 11 120/240 120/240/480 AE25 25 120/240 120/240/480

Kilowatt (kW)

Transfer Switch Considerations

The following are general considerations for the safe use of a transfer switch:

1. The transfer switch should be located inside the building near the main breaker box or the disconnect box.

2. The transfer switch must be kept away from any location that might allow water to get on it.

3. If the transfer switch is mounted outside, it must be protected from the environment.

4. Do not mount the transfer switch on the generator set.

5. Do not mount the transfer switch where flammable liquids or vapors are present.

Battery Charger Considerations

1. Mount the battery charger on the generator or as close to the generator as possible.

2. If you mount the battery charger inside the building, mount it near the main breaker box or disconnect box.

3. If you mount the battery charger outside, you must protect it from the environment.

4. Do not mount the battery charger where flammable liquids or vapors are present.

Rating

1 Phase VAC

nput Breaker

1 Phase

Amps

3 Phase VAC

3 Phase

Amps

3-8 Receiving & Installation MN2415

General Wiring Considerations

1. Control wires and Power wires cannot be located in the same conduit (NEC Article 725).

2. When routing the interface wiring, do not route it up against anything that could cut or chafe the wiring. do not route the wire up against any hot or potentially hot object.

3. Make sure that all the electrical components (generator set, transfer switch, battery charger, etc.) share a common hardwired ground.

4. Check with your local building inspector to determine what you must do to comply with the local regulations for grounding of this type of permanent installation.

AE8 Electrical Connections Applies only to AE8 Enclosed and Open Series Generators Single Phase Power Connections

The generator has a 240V single phase AC output. These connections are made at the power terminal box shown in Figure 3-3.

Figure 3-3 Single Phase Output Power Connections

AE8 with Enclosure or Open

Generator

Output

BW0120D

Customer

AC Output Connections

(to Transfer Switch)

L1 to N L2 to N

L1 to L2

120VAC 120VAC 240VAC

Remote Start and Battery Charger Connections

Figure 3-4 shows the connections for the battery charger and the remote start contacts of the transfer switch. When the Remote Start Switch is closed, the generator will start. The unit will remain running until this connection is opened. When the Remote Start Switch is opened, the control circuits allow the engine to run for approximately 60−90 seconds before it shuts off. This time delay allows the engine to run unloaded to cool down before stopping.

AE8

with Enclosure

R2 Batt+ Batt−

BW0120D

Figure 3-4 Remote Start & Battery Connections

AE8

16AWG

Twisted Pair Wire

Note:

Customer Provided Optional Equipment

Remote Start Switch

(Close to Start)

Out+

Battery

Out−

Charger

To 120VAC

(Shore Power)

Connect DK1 and DK2 of the battery charger go to the D1 and D2 terminals of the terminal block if a Master Control Systems Inc. Battery charger is installed. DK1 and DK2 are not polarity sensitive.

Open

BW0183D

16AWG

Twisted Pair Wire

Customer Provided Optional Equipment

Remote Start Switch

(Close to Start)

Out+

+−

Battery

Out−

Battery

Charger

To 120VAC

(Shore Power)

Receiving & Installation 3-9MN2415

AE10 Electrical Connections Applies only to AE10 Enclosed and Open Series Generators Single Phase Power Connections

The generator has a 240V single phase AC output. These connections are made at the power terminal box shown in Figure 3-5.

Figure 3-5 Single Phase Output Power Connections

AE10 with Enclosure

BW0201D

Generator

Output

BW0333D

N 4

L1 to N L2 to N

L1 to L2

Customer

AC Output Connections

(to Transfer Switch)

120VAC 120VAC 240VAC

Generator

Output

To Frame

Note: G and N are internally

tied to Frame Ground.

Remote Start and Battery Charger Connections

Figure 3-6 shows the connections for the battery charger and the remote start contacts of the transfer switch. When the Remote Start Switch is closed, the generator will start. The unit will remain running until this connection is opened. When the Remote Start Switch is opened, the control circuits allow the engine to run for approximately 60−90 seconds before it shuts off. This time delay allows the engine to run unloaded to cool down before stopping.

Figure 3-6 Remote Start & Battery Connections

AE10

with Enclosure

R2 Batt+ Batt−

BW0333D

16AWG

Twisted Pair Wire

Note:

Customer Provided Optional Equipment

Remote Start Switch

(Close to Start)

Out+

Battery

Out−

Charger

To 120VAC

(Shore Power)

Connect DK1 and DK2 of the battery charger go to the D1 and D2 terminals of the terminal block if a Master Control Systems Inc. Battery charger is installed. DK1 and DK2 are not polarity sensitive.

AE10 Open

BW0201D

16AWG

Twisted Pair Wire

Customer Provided Optional Equipment

AE10 Open

L1 to N L2 to N

L1 to L2

Remote Start Switch

+−

Battery

Customer

AC Output Connections

(to Transfer Switch)

120VAC 120VAC 240VAC

(Close to Start)

Out+

Battery

Out−

Charger

To 120VAC

(Shore Power)

3-10 Receiving & Installation MN2415

AE11 Electrical Connections Applies only to AE11 Enclosed Series Generators Single Phase Power Connections

The generator has a 240V single phase AC output. These connections are made at the power terminal box shown in Figure 3-7.

Figure 3-7 Single Phase Output Power Connections

AE11 with Enclosure

TBP

Generator

Output

BW0459D

(Jumpered)

L1 L2

N N

L1 to N

L2 to N

L1 to L2

Customer

AC Output Connections

(to Transfer Switch)

120VAC 120VAC 240VAC

Remote Start and Battery Charger Connections

Figure 3-8 shows the connections for the battery charger and the remote start contacts of the transfer switch. When the Remote Start Switch is closed, the generator will start. The unit will remain running until this connection is opened. When the Remote Start Switch is opened, the control circuits allow the engine to run for approximately 60−90 seconds before it shuts off. This time delay allows the engine to run unloaded to cool down before stopping.

Figure 3-8 Remote Start & Battery Connections

AE11

with Enclosure

TBP

G Remote Start Remote Start

Fuel Jumper Fuel Jumper

Fuel Jumper IN = Natural Gas OUT = LPG

BW0459D

Note: Remove Fuel Jumper

if LP Gas is used.

16AWG

Twisted Pair Wire

Customer Provided Optional Equipment

Remote Start Switch

(Close to Start)

Out+

Battery

Out−

+−

Battery

Charger

To 120VAC

(Shore Power)

Receiving & Installation 3-11MN2415

AE25 Electrical Connections Applies only to AE25 Enclosed Series Generators Single Phase Power Connections

The generator has a 240V single phase AC output. These connections are made at the power terminal box shown in Figure 3-9.

Figure 3-9 Single Phase Output Power Connections

AE25 with Enclosure (Natural Gas or LPG)

GND

Load

AC Output Connections

Customer

(to Transfer Switch)

L1 to N L2 to N

L1 to L2

120VAC 120VAC 240VAC

Remote Start and Battery Charger Connections

Figure 3-10 shows the connections for the battery charger and the remote start contacts of the transfer switch. When the Remote Start Switch is closed, the generator will start. The unit will remain running until this connection is opened. When the Remote Start Switch is opened, the control circuits allow the engine to run for approximately 60−90 seconds before it shuts off. This time delay allows the engine to run unloaded to cool down before stopping.

Figure 3-10 Remote Start & Battery Connections

AE25 with Enclosure (Natural Gas or LPG)

TB1

16AWG

Twisted Pair Wire

Customer Provided Optional Equipment

Out+

Out−

Remote Start Switch

(Close to Start)

+−

Battery

Charger

To 120VAC

(Shore Power)

3-12 Receiving & Installation MN2415

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

It is important for safety reasons that the Generator set, transfer switch and battery charger share a common Ground and neutral.

The NEC requires that the frame and exposed metal surfaces be at local ground reference potential to avoid electrical shock hazard. A local ground reference may require a driven earth ground conductor at the generator installation site. Make the ground connection as shown in Figure 3-11. Use the appropriate size wire as required by NEC and local codes.

Figure 3-11 Frame Ground Connection

Nut

Washer

Ground Wire Lug Washer

Engine Oil Level

Coolant Level

Earth Ground

Stud

Frame

1. Open the enclosure access panel door 2 ( Figure 3-1).

2. Connect the ground wire to the “earth ground” terminal shown in Figure 3-11. This ground is the local reference ground to ground the generator frame only.

AE8, AE10, AE11, and AE25 These generators are shipped dry, which means there is no oil in the engine and no battery

installed.

1. Check the engine oil level, it should be empty.

2. See Table 3-5 and add the appropriate amount of oil to the engine crankcase.

3. Add a little at a time and check the oil level to ensure that you do not overfill the crankcase. Stop adding oil when the oil level reaches the full line.

AE25 only

1. Check the coolant level while the engine is cold, it should be full.

2. If the coolant level is low, add some coolant as recommended in the engine manual (usually a 50/50 mixture of antifreeze and water).

Receiving & Installation 3-13MN2415

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.

Battery Connections

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

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

WARNING: Do not mutilate the battery . The battery contains electrolyte solution which is caustic and

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

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

WARNING: A battery presents a risk of fire because they generate hydrogen gas. Hydrogen gas is

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

AE8, AE10, AE11, and AE25. The generator is shipped with no battery installed.

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

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.

can cause severe burns and blindness. If electrolyte contacts skin or eyes, immediately flush the area with water and seek medical attention quickly.

The following precautions are to be followed when working on batteries:

1. Remove watches, rings, necklaces and all other metal objects.

2. Use tools with insulated handles.

3. Wear rubber gloves and boots.

electrically conductive and corrosive. The following precautions are to be followed when working on batteries:

1. Wear full eye protection (safety glasses or goggles) and protective clothing.

2. Where electrolyte contacts the skin, flush the area immediately with water and wash it off using soap and water.

3. Where electrolyte contacts the eyes, immediately flush the eye thoroughly with water and seek medical attention quickly.

4. Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbonate of soda to one gallon (four liters) of water. The bicarbonate solution is to be added until evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

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. The following precautions are to be followed when working on batteries:

1. Do not smoke when near batteries.

2. Do not cause flame or spark in battery area.

3. Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

Procedure: The correct type battery must be installed in the battery compartment provided, see Table 3-5.

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.

1. Open access doors and locate battery tray.

2. Place the correct battery (see Table 3-5) on the tray.

3. Install the Battery Hold Down Bar and Rods as shown in Figure 3-12. a. Place the bent end of the Battery Hold Down Rod through the hole in the Battery Tray. b. Place the threaded end of the Battery Hold Down Rod through the hole in the

Battery Hold Down Bar and secure with flat washer, lock washer and nut.

c. Repeat steps 3a and 3b for the other Battery Hold Down Rod.

3-14 Receiving & Installation MN2415

Washers & Nut

MODEL

SUMMER

WINTER

OIL

RECOMMENDED

(AMPS) COLD

Figure 3-12 Battery Installation

The + and − terminals of your battery may be different than shown. Be sure that the Positive lead is connected to the positive (+) terminal of your battery.

Battery Hold Down Bar

(Install away from terminals)

Washers & Nut

Battery

Battery Hold Down Rod

Battery Tray

4. Connect the positive lead to the positive (+) battery terminal.

5. Connect the negative lead to the negative (−) battery terminal.

6. Do not lay tools or metal parts on top of batteries.

7. Connect charging source to the battery terminals.

8. 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.

Recommended Engine Oil and Battery Type

When replacing batteries, use only the recommended battery for your generator, see Table 3-5.

Table 3-5 Recommended Engine Oil and Battery Type

SUMMER WINTER OIL RECOMMENDED (AMPS) COLD

OIL

AE8 SAE. 30 5W/30 2.2 PTS Interstate SP−40 340 AE10 SAE. 30 5W/30 2.2 PTS Interstate SP−40 340 AE11 SAE. 30 5W/30 2.0 QTS Interstate SP−40 340 AE25 SAE. 30 5W/30 4.5 QTS BCI Group 24 750

OIL

CAPACITY

BATTERY

CRANKING

Receiving & Installation 3-15MN2415

Post Installation Checks

When the initial installation is complete, these checks must be performed before starting the engine. These checks are not required before each start, only after the initial installation.

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.

Note: These precautions are especially necessary in locations such as seaboard installations

and other high humidity areas. Some installations will be in atmospheres that are much more corrosive than others. Prevention of a failure is better than being forced to make a repair.

1. Generators that have been in transit or storage for long periods may be subjected to extreme temperature and moisture changes. This can cause excessive condensation, and the generator windings should be thoroughly dried before bringing the generator up to full nameplate voltage. If this precaution is not taken, serious damage to the generator can result.

2. Verify that the transfer switch is in Utility Power mode. No power must be present at the generator or transfer switch connections. Verify with a voltmeter.

3. Verify that the engine starting battery negative (−) lead) is disconnected so accidental starting is not possible.

4. Verify that the generator is securely mounted and anchored to its cement pad.

5. Verify that proper clearance exists on all sides and top of enclosure.

6. Verify that generator power is properly connected to the transfer switch.

7. Verify that generator and transfer switch are properly grounded.

8. Verify that the remote start wires are properly connected and tight between the generator and transfer switch terminals.

9. Assure that generator is a safe distance from any flammable or combustible material.

10. Verify that the generator and transfer switch load are voltage compatible.

11. Verify that no load is connected to the circuit breaker and/or transfer switch.

12. Inspect the engine and generator and verify that there are no loose wires or components. Tighten if necessary.

13. Verify that the ground conductor is of correct wire size and properly connected.

14. Verify engine oil level is full. Refer to engine manual if necessary.

15. Verify engine coolant level is full. Refer to engine manual if necessary.

16. Verify exhaust system to assure it is in properly connected and pointing away from combustible materials.

17. Verify that the Master Control Switch is still in the “Stop” position. Connect the engine starting battery negative (−) lead).

18. Verify the fuel source is ON and the pressure and flow rate are correct.

19. Remove all tools, rags, etc. from inside the generator enclosure. Close all enclosure doors and be sure no hands are inside the generator enclosure when it starts.

3-16 Receiving & Installation MN2415

Post Installation Checks

Continued

20. Verify all loads are disconnected.

21. Start the generator. (Refer to Section 4 Operation for details).

22. The engine should begin to crank and start when the fuel moves through the pipe to the carburetor. If the engine fails to start, refer to Section 5 Troubleshooting.

23. With the engine running, several checks must be made: a. Verify there are no fuel leaks. If a fuel leak is detected, stop the engine (move the

Master Control Switch to the “Stop” position) immediately and repair the leak before proceeding.

b. Verify there are no coolant or oil leaks. If a leak is detected, stop the engine

(move the Master Control Switch to the “Stop” position) immediately and repair the leak before proceeding.

c. Verify that operation is smooth. If belt squeals, vibrations or other sources of

noise exist, stop the engine (move the Master Control Switch to the “Stop” position) immediately and repair before proceeding.

d. Verify that the correct voltage exists (line−to−line and line−to−neutral) at the

generator and at the transfer switch.

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.

24. After the operation checks are made, stop the engine (move the Master Control Switch to the “Stop” position) and wait at least 2 hours for the engine to cool. When the engine is cool, check engine oil and coolant levels as instructed in the engine operation manual.

25. Close all enclosure covers. The post installation checks are now complete.

Receiving & Installation 3-17MN2415

3-18 Receiving & Installation MN2415

Section 4 Operation

Operator Control Panel

Each operator panel is slightly different, depending on features of the generator you purchased. The Operator Control Panel of Figure 4-1 is shown because it has most of the available features. This will be used to explain how the controls operate.

Figure 4-1 Operator Control Panel AE8 and AE10

Master Control Switch (Run Manual −Off − Remote Auto) Run Manual − Immediately energizes the crank cycle to start

the generator set and produce power.

Stop − Stops the Engine and generator set. Remote Auto − The engine can only be started by making a connection

across the remote start terminals of the control box. Allows normal automatic backup operation of the Generator Set under control of the Transfer Switch whenever utility AC power is lost.

Controller Fuse Fuse for engine controller.

Lamp This Red indicator light will come on when the engine shuts down due to a fault condition.

Circuit Breaker

Circuit Protection for AC power output. Circuit Breaker − 2 pole Circuit Protection for the generator set out-

put windings.

Master Control

Switch

Controller

Fuse

Lamp

Circuit Breaker

Figure 4-2 Operator Control Panel AE11

Under Speed Shutdown

Over Speed Shutdown

High Coolant Temperature Shutdown

Low Oil Pressure Shutdown

Stop Manual

Run

Auto Start

Hour Meter

(fuel solenoid energized

Alternator Charge Failure Warning

Failure to Start Shutdown Aux1 Input Warn/Shutdown

Aux2 Input Warn/Shutdown

Shutdown Warning Indicators

Low Oil Pressure, High Coolant Temperature, Over Speed (Engine), Under Speed (Engine), Failure to Start Engine.

Warning (or Shutdown) Indicators

Alternator Failure (to Charge Battery), Auxiliary 1 Input Active, Auxiliary 2 Input Active.

Hour Meter Displays total hours of operation based on power applied to Fuel Solenoid). Stop Stops the Engine and generator set. Manual Run Immediately energizes the crank cycle to start the generator set and produce power. Auto Start The engine can only be started by making a connection across the remote start terminals of the

control box. This allows normal automatic backup operation of the Generator Set under control of the Transfer Switch whenever utility AC power is lost.

Operation 4-1MN2415

Figure 4-3 Operator Control Panel AE25

OIL

BATTERY

MANUAL

RUN

HIGH TEMPERATURE LOW OIL PRESSURE OVERSPEED

OVERCRANK

STOP

MASTER

CONTROL

WATER

Hour Meter

DC CONTROL FUSE AC CONTROL FUSE

AUTO

START

NAT. GAS L.P. GAS

Display Lamps High Temperature − Indicates excessive engine coolant temperature.

Low Oil Pressure − Indicates low engine oil pressure. Overspeed − Indicates engine speed is greater than preset limit. Overcrank − Failure of the engine to start by the end of the crank period results in

an “overcrank” shutdown and alarm indication.

Hour Meter Displays total hours of operation based on power applied to Fuel Solenoid). Meters Water − Displays the temperature of the engine coolant.

Oil − Displays the engines oil pressure. Battery − Displays the battery voltage of the starting battery.

DC Control Fuse Fuse for engine controller. AC Control Fuse Fuse for engine controller.

Master Control

Switch Stop Stops the Engine and generator set. Manual Run Immediately energizes the crank cycle to start the generator set and produce power. Auto Start The engine can only be started by making a connection across the remote start terminals of the

control box. This allows normal automatic backup operation of the Generator Set under control of the Transfer Switch whenever utility AC power is lost.

Natural/LP Gas

Selector Switch

Selects the correct fuel source: Natural Gas or L.P. Gas.

4-2 Operation MN2415

Operating Procedures

Manual Start/Stop All models.

Automatic Start/Stop All models.

Automatic Fault Shutdown AE11 and AE25.

The engine−generator controller is designed to start and stop an engine from either a local mode “Manual Run” or remote mode “Auto Start”. When a start command is issued, the controller issues a run and crank output signal. The controller then monitors engine speed and when crank disconnect speed is reached, the crank signal is terminated. While the engine accelerates to normal speed, the controller continuously monitors the engines speed signal. Should the engine speed exceed the maximum predetermined setpoint, the Overspeed shutdown fault circuit will activate, terminating the run signal.

In addition to Overspeed shutdown, other engine functions are also monitored and the engine will automatically stop for any shutdown fault. The engine will also stop, or when the remote start signal is removed or local Stop is pressed. The engine controller operation includes time delay circuits for normal operating conditions such as start delays, cool down and cranking periods.

Push the Manual Run button to immediately initiate the engine crank cycle to start the engine and generate AC power. This mode does not require a start command from a remote device but operates immediately when the button is pushed. When pushed, the following happens:

1. The Engine Crank cycle begins.

2. When the engine starts and accelerates to nominal speed, the controllers speed sensor will terminate the Engine Crank cycle.

Manually Stop the Generator−Set at anytime by simply pushing the “Stop” button. The controllers RUN output will be immediately terminated which will initiate the engine stop sequence.

Push the “Auto−Start” push−button. The following happens:

1. The engine will automatically start upon activation of the remote start contact input. The remote device (transfer switch) initiates a start sequence when utility power fails.

2. When the remote start signal is activated, the engine will start.

3. The automatic stop sequence will be initiated by removal of the remote start signal.

4. When the start signal is removed, a cool down delay function will be initiated.

5. When the cool down time delay period expires (typically 5 minutes), the controllers RUN output will be immediately terminated which will initiate the engine to stop.

Manually Stop the Generator−Set at anytime by simply pushing the “Stop” button. The controllers RUN output will be immediately terminated which will initiate the engine stop sequence.

When a fault circuit is programmed as a Shutdown, the engine will immediately stop when the fault is activated. A specific shutdown fault can be programmed with a definite time transient delay period that must expire before the shutdown is activated. The stop sequence will cause the controllers RUN output to be immediately terminated which will cause the engine to stop.

A Warning lamp does not terminate generator set operation. It only warns that a condition exists. (alternator charge failure, etc.) but allows generator operation to continue.

Operation 4-3MN2415

AE11 Operating Procedures

The AE11 engine controller is programmable and it’s internal workings is more complex than the other AE series generators.

Auto Start Operation

This mode is activated by pressing the Auto pushbutton, see Figure 4-2. An LED indicator beside the button lights in Auto mode. The start sequence is initiated when the remote start input from the transfer switch or other device is activated. To prevent a false remote start, the Start Delay timer is initiated. If the Remote Start signal is removed during the Start Delay timer, the unit returns to stand−by. After the Start Delay, if the pre−heat output option is selected, the pre−heat timer is starts, and the corresponding auxiliary output (if configured) will energize.

After these delays, the Fuel Solenoid is energized, then one second later, the Starter Motor is engaged. The engine is cranked for a 10−second period. If the engine fails to start, the starter motor is disengaged for a 10−second rest period. Should this sequence continue beyond the 3 starting attempts, the start sequence will be terminated and Fail to Start fault will be illuminated. When the engine starts, the starter motor is disengaged and locked out at 20 Hz measured at the Alternator output. (Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for under speed or over speed detection).

When the starter motor has disengaged, the Safety On timer starts. This timer is preset to 12 seconds and allows engine speed, Oil Pressure, High Engine Temperature, Under−speed, Charge Fail and Auxiliary fault inputs to stabilize without triggering a fault. Once the engine is running, the Warm Up timer starts (if selected). This allows the engine to stabilize before the load is switched on. After the Warm Up delay, the AC output is switched on to operate the load.

When the Remote Start signal is removed, the Stop Delay timer is initiated. After which the Load Transfer output (if configured) is deactivated, and the Cool Down Period is initiated. After the Cool Down Period has elapsed, the Fuel Solenoid is de−energized, bringing the generator to a stop.

Manual Operation There is no “Start Delay” in Manual Run. This mode is activated by pressing the Manual Run pushbutton, see Figure 4-2. If the pre−heat output option is selected, the pre−heat timer is starts, and the corresponding auxiliary output (if configured) will energize. After this delay, the Fuel Solenoid is energized, then one second later, the Starter Motor is engaged. The engine is cranked for a 10−second period. If the engine fails to start, the starter motor is disengaged for a 10−second rest period. Should this sequence continue beyond the 3 starting attempts, the start sequence will be terminated and Fail to Start fault will be illuminated. When the engine starts, the starter motor is disengaged and locked out at 20 Hz measured at the Alternator output. (Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for under speed or over speed detection).

The generator will continue to run until the “Stop” or “Auto Start” mode is selected. If Auto mode is selected, the Remote Stop Delay Timer starts. After this delay, the Fuel Solenoid

is de−energized, to stop the generator. Selecting Stop de−energizes the Fuel Solenoid is de−energized, to stop the generator.

Warnings and Shutdowns

Warnings

Warnings are used to warn the operator of a problem fault. Battery Charge Failure, if the module does not detect a voltage from engine mounted alternator, the lamp will illuminate. (Either 8 Volts or 16 Volts depending on the configuration of Nominal DC Voltage). Inputs 1 and 2 can be configured as warnings or shutdowns. The lamp will be illuminated when the input is active.

Shutdowns

Shutdowns are latching and stop the Generator. The alarm must be cleared, and the fault removed to reset the module. In the event of a shutdown the appropriate lamp is illuminated. The alarm condition must be corrected before a reset will take place. If the alarm condition remains it is not possible to reset the unit (except faults that occur during the “Safety On timer” period. These are delayed alarms, like oil pressure is low with the engine at rest).

Inputs 1 and 2 can be configured as warnings or shutdowns. The relevant lamp is illuminated when the input is active.

4-4 Operation MN2415

Shutdowns

Continued

Fail To Start − if the engine does not start after 3 start cycles, a shutdown will be initiated and

the Fail to Start Shutdown lamp is On. Low Oil Pressure − if engine oil pressure is less than the low oil pressure limit (after the Safety On timer), a shutdown will occur and the Low Oil Pressure Shutdown lamp is On. High Engine Temperature − if engine coolant temperature exceeds the high engine temperature limit (after the Safety On timer), a shutdown will occur and the High Engine Temperature Shutdown lamp is On. Overspeed − if engine speed exceeds the pre−set limit (14% above the nominal frequency), a shutdown will occur and the Overspeed Shutdown lamp is On. The Overspeed shutdown is not delayed, shutdown is immediate.

Note: During start−up the Overspeed trip level is extended to 24% above the normal frequency

for the duration of the safety timer to allow an extra trip level margin. This prevents nuisance tripping during start−up.

Underspeed − if engine speed goes below the pre−set trip (20% of the nominal frequency) after the Safety On timer delay, a shutdown will occur and the Underspeed Shutdown lamp is On.

Inputs 1 and 2 can be configured as warnings or shutdowns. The relevant lamp is illuminated when the input is active.

Editing the Configuration

The 4110 engine controller is fully configurable from the front panel. There is no requirement for a computer or software.

Access Configuration Editor Figure 4-4.

With the unit is in Stop mode, Configuration Mode is selected by a small switch on the rear, bottom edge of the printed circuit board. This is partially hidden to prevent accidental operation. When Configuration Mode is selected, the “Auto” LED will flash rapidly, and all normal operations are suspended.

Figure 4-4 Configuration Editor Access

Editing The Configuration

The Stop pushbutton is pressed to select the LED “code“ that corresponds to the function. The first is the “Pre−Heat Timer”. Pressing Stop again displays “Start Delay” etc. The 5 LED’s on the left display the code for each function. See Table 4-1.

The Manual pushbutton is pressed to change the value. The 3 LED’s on the right display the present value. See Table 4-1.

When the correct parameter value is displayed, press the Auto Start button to save the new setting. Repeat the process for each function value you want to change. When configuration is complete, return the Configuration Mode Selector Switch to the “Normal Mode” position.

Note: When configuration is complete, return the Configuration Mode Selector Switch to the

“Normal Mode” position to resume normal operation.

Table 4-1 shows the programmable functions and values for this engine controller.

Switch in Normal Mode Switch in Configuration Mode

Operation 4-5MN2415

Table 4-1 Programmable Functions and Values

ffffF

fffFf

fffFF

ffFff

ffFfF

Function

Pre−Heat Timer

f f f f F f f f

!!!! 1 !!!! 2

f f F f F f f F F F f f F f F F F f F F F

Used to pre−heat the engine prior to cranking. The output is active for the duration of the setting, prior to cranking.

Start Delay

f f f F f f f f

f f F f F f f F F F f f F f F F F f F F F

Provides a delay between activating the remote start input, or a mains failure, and actually starting the engine.

Stop Delay

f f f F F f f f

f f F f F f f F F F f f F f F F F f F F F

Provides a delay between deactivating the remote start input and actually stopping the engine.

Energize to Stop Hold Timer

f f F f f f f f

f f F f F f f F F F f f F f F F F f F F F

Controls of the engine stop solenoid. When the engine is to be stopped, the Energize To Stop output becomes active, closing the stop solenoid (fuel valve). When the engine comes to rest, the stop solenoid will remain energized for the period of the Energize To Stop Timer, to ensure the engine has come to a complete stop.

Value (Preset in Bold) 0 Seconds

5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds

0 Seconds

5 Seconds

10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds

0 Seconds 5 Seconds 10 Seconds 15 Seconds 20 Seconds

30 Seconds

60 Seconds 180 Seconds

0 Seconds 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds

Warm−up Timer

f f F f F f f f

f f F f F f f F F F f f F f F F F f F F F

0 Seconds 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds

Delay between the engine being available for use, and the closure of the generator load−switching device to allow time for the engine to warm before being loaded. This occurs after the 12 second safety on timer.

4-6 Operation MN2415

Function

ffFFf

fFfff

fFffF

fFfFf

fFfFF

fFFff

fFFfF

Fffff

FfffF

Cooling Timer

Table 4-1 Programmable Functions and Values

f f F F f f f f

f f F f F f f F F F f f F f F F F f F F F

!!!!1 !!!!2

Continued

Value (Preset in Bold) 0 Seconds 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds

Delay between opening the generator load−switching device and stopping the engine to allow time for the engine to cool down before being stopped. This is particularly useful when used in conjunction with turbo−charged engines.

Nominal Frequency

f F f f f f f f

f f F

The nominal line frequency. Either 50 Hz or 60 Hz

Nominal DC Voltage

f F f f F f f f

f f F

The generator battery voltage. Either 12 Volts or 24 Volts. It is used for the charge alternator failure level.

LOP Switch Contact

f F f F f f f f

f f F

Configuration for the oil pressure switch. Either to close to battery negative on a fault, or open on a fault.

HET Switch Contact

f F f F F f f f

f f F

Configuration for the coolant temperature switch. Either to close to battery negative on a fault, or open on a fault.

Crank Disconnect on Oil Pressure

f F F f f f f f

f f F

If this is enabled, the starter motor will disconnect 2 seconds after the oil pressure switch detects oil pressure. NOTE:− Not suitable for all generators, due to the different monitoring points on lubrication systems.

Under Speed Detection

f F F f F f f f

f f F

If this is enabled, the unit will shut down the generator if the frequency falls below 20% of the nominal frequency.

Auxiliary Input 1

F f f f f f f f

f f F f F f f F F F f f F f F F F f F F F

See Note 1

50Hz (O/S +14%) Overshoot 24%

60Hz (O/S +14%) Overshoot 24%

12VDC (CF 8VDC)

24VDC (CF 16VDC)

Close on Fault

Open on Fault

Close on Fault

Open on Fault

Disabled

Enabled (2 second delay)

Disabled

Enabled (U/S 20%)

Immediate Warning Close on Fault

Immediate Warning Open on Fault Immediate Shutdown Close on Fault Immediate Shutdown Open on Fault Delayed Warning Close on Fault Delayed Warning Open on Fault Delayed Shutdown Close on Fault Delayed Shutdown Open on Fault

Auxiliary Input 2

See Note 1

F f f f F f f f

f f F f F f f F F F f f F f F F F f F F F

Immediate Warning Close on Fault

Operation 4-7MN2415

Note 1:

FffFf

FffFF

Programmable input, can be configured to on of the following:

S Immediate warning close on fault − If the input is activated at any time the unit will alarm and energize the common warning and common alarm output. S Immediate warning open on fault − If the input is deactivated at any time the unit will alarm and energize the common warning and common alarm output. S Immediate shutdown close on fault − If the input is activated at any time the generator will be shutdown and energize the common warning and common shutdown output. The

generator can not be started.

S Immediate shutdown open on fault − If the input is deactivated at any time the generator will be shutdown and energize the common warning and common shutdown output.

The generator can not be started.

S Delayed warning close on fault − If the input is activated and the safety time has elapsed the unit will alarm and energize the common warning and common alarm output. S Delayed warning open on fault − If the input is deactivated and the safety time has elapsed the unit will alarm and energize the common warning and common alarm output. S Delayed shutdown close on fault − If the input is activated and the safety time has elapsed the generator will be shutdown and energize the common warning and common

shutdown output.

S Delayed shutdown open on fault − If the input is deactivated and the safety time has elapsed the generator will be shutdown and energize the common warning and common

shutdown output.

Table 4-1 Programmable Functions and Values Continued

Auxiliary Output 1

F f f F f f f f

f f F f F f f F F F f f F f F F F f F F F

Not Used Pre−heat Load Transfer Common Warning Common Shutdown System in Auto Common Alarm Energize to Stop

See Note 2

Auxiliary Output 2

F f f F F f f f

f f F f F f f F F F f f F f F F F f F F F

Not Used Pre−heat Load Transfer Common Warning Common Shutdown System in Auto Common Alarm Energize to Stop

See Note 2

Note 2: Outputs are solid state, rated at 1.2 Amps and switch to battery negative Programmable output can be configured to one of the following:

S Pre−heat. − The output is energized for the period of pre−heat time prior to cranking, and between the cranking attempts. S Load Transfer. − The output is active after the safety timer has elapsed. S Common warning. − The output is active if there are any warning alarm active. S Common shutdown − The output is active if there are any shutdown alarms active. S System in auto. − The output is active when the system is in automatic mode. S Common Alarm. − The output is active if there is any alarm condition. S Energize to stop. − The output is energized when the engine is required to stop (normal or fault conditions), and will remain energized for the period of the Energize To Stop.

Timer, to ensure the engine has come to a complete stop.

when active.

4-8 Operation MN2415

Electrical Connections

The engine controller is installed into the AE11 from the factory. The information provided here will help you connect external devices to the Auxiliary inputs and outputs.

Table 4-2 Engine Controller Terminal Identification

Pin No Description Cable Size Notes

1 DC Plant Supply Input (−ve) 1.0mm Connected to plant battery negative 2 DC Plant Supply Input (+ve) 1.0mm Connected to plant battery positive (Recommended Fuse 2A) 3 Fuel Solid State Output 1.0mm Used to operate the fuel relay. 4 Start Solid State Output 1.0mm Used to operate the cranking relay. 5 Auxiliary Solid State Output 11.0mm Configurable output. 6 Auxiliary Solid State Output 21.0mm Configurable output. 7 Charge Fail Input/ Excitation Output 1.0mm Must NOT be connected to plant supply negative if not used. 8 Low Oil Pressure Input 0.5mm Switch to negative.

9 High Engine Temp Input 0.5mm Switch to negative. 10 Auxiliary Input 10.5mm Switch to negative. 11 Auxiliary Input 20.5mm Switch to negative. 12 Automatic start Input 0.5mm Switch to negative. 13 Not used 14 Not used 15 Functional Earth 1.0mm Connect to a good clean earth point. 16 Not used 17 Not used 18 Not used 19 Not used 20 Alternator Input L1 1.0mm Do not connect if not used. (2A Fuse) 21 Alternator Input N 1.0mm Do not connect if not used.

Garretson Model KN Fuel Valve Considerations

General

The KN is designed for sensitivity and simple operation. It is used with low−pressure vaporized gaseous fuels, where dependable starting is a requirement. Because of its extreme sensitivity, the KN offers excellent results in most remote starting applications (Standby power generators, etc.). With proper installation and maintenance, the KN will provide years of trouble−free service.

Operation

The KN is an atmospheric zero governor which acts like the float and needle valve in a gasoline carburetor. Air−flow through a venturi in the carburetor creates a vacuum, which acts through the outlet of the KN on the diaphragm. Atmospheric pressure then forces the diaphragm toward the vacuum, depressing the lever and pulling the valve seat away from the orifice, which allows fuel to flow as long as the demand persists. When the vacuum ceases, a spring force pushes on the lever and forces the valve seat against the orifice shutting off the fuel flow. It is important to remember that fuel should not flow through the KN when the engine is not running.

A properly adjusted KN requires a vacuum of only 0.25” to 0.35” of water column to start the opening sequence. Due to this sensitivity, most installations do not need priming to start unless low cranking speeds or restricted and lengthy piping are required. If priming is necessary and a manual primer is installed, use only 1 or 2 second bursts of fuel and immediately try to start the engine. If there is a choke on the carburetor, do not use it as this will probably cause flooding and hard starting. As you can see, the operation of this unit is simple and basic. If you are having trouble operating the engine, in most cases the fuel controller is not malfunctioning. There is generally a problem with the engine or fuel supply. so do not make adjustments or attempt to service the KN until you are sure it is needed.

Operation 4-9MN2415

Figure 4-5 Garretson KN Fuel Valve

Outlet

Mount

Primer (Optional)

Lock−Off Adjustment

Inlet

Mount

Service

The KN should be periodically checked for leakage past the valve seat and the vents on the cover kept clean and free of obstructions. If the KN needs service we suggest you take it to a qualified serviceman. If that help is not available Garretson will furnish you a list of repair shops with the proper service information.

Installation

The KN should be mounted as close to the carburetor as possible with the arrow on the cover pointing up and the diaphragm in a vertical position. This helps to minimize the effects of gravity on diaphragm travel. This unit should also be placed for easy access to the primer if provided. There are two sets of mounting holes provided. either set of mounts will adequately support the KN. The bottom set of holes has a 1 3/4” bolt spacing for use with all Garretson universal mounting brackets. The mounting bosses on the cover are spaced (5 3/4”) for 5/16 bolts.

Before installing the fuel supply line, be sure that the gas pressure is no more than the maximum inlet pressure shown on the front of the KN. If the pressure is greater, leakage could result in a fire hazard and or hard starting. The piping to the inlet should be of sufficient size to allow full flow to the KN. This is very important in natural gas installations as any restrictions can affect engine performance. If a solenoid is used ahead of the KN in the low− pressure line, it should have an orifice at least as big as the orifice in the KN. Flexible piping to the inlet should be used to prevent cracking from vibration if the KN is mounted on the engine or other vibrating surface.

Note: Thread sealing compound should be used on all pipe thread fittings between the KN and

the fuel supply tank, being careful not to get any inside the inlet or fittings. Excess compound could collect on the seat and orifice and cause hazardous leakage, resulting in poor performance. After piping is complete, turn on the gas and use a soap solution to check all fittings for leaks.

If an electric solenoid primer is used, follow the wiring and adjusting instructions furnished separately. kit by connecting into a pressure line at a reduced pressure, call us. The KN outlet is 3/8 NPT and if an outlet fitting has not been provided, select and insert a suitable vapor fitting taking care not to allow any chips or dirt to enter the outlet. Use of street ells or conventional pipe fittings in the fuel line between the KN and the carburetor is not recommended as they may restrict the flow of fuel.

When installation of a properly sized fuel hose between the KN and carburetor is completed, if you are installing a complete conversion return to the instructions. For field replacement applications the unit is ready for service.

4-10 Operation MN2415

Section 5 Troubleshooting and Maintenance

Maintenance

This manual contains only very minimal engine maintenance instructions. Refer to the engine manufacturer’s owner’s manual for specific engine maintenance instructions for your generator set. Any maintenance instructions or recommendations in the engine owner’s manual take precedence over any of the following general recommendations.

General:

1. Inspect the fuel system for leaks. Replace all defective components immediately.

2. Inspect and replace any fuel line that shows signs of deterioration.

3. Inspect all the fuel clamps to ensure they are tight.

4. Inspect and clean the battery posts and the associated battery cable terminals.

5. Inspect the external wire cables and connectors used with the generator set for cuts, fraying, or loose connections. Repair or replace any problems prior to using the unit.

Engine:

1. Clean and/or replace any fuel, oil, and/or air filters per the engine manufacturers’ guidelines.

2. Check oil level regularly; at least every 5 to 8 operating hours. Maintain the proper oil level.

3. Change the oil as is recommended in the engine manufacturer’s owner’s manual.

4. Replace the spark plug(s) as is recommended by the engine manufacturer.

5. Clean the cooling fins on the engine to keep the engine’s heat dissipation potential at it’s maximum.

6. Inspect and clean all governor and carburetor linkages so they operate properly.

Alternator:

This generator set must be run at its proper speed to obtain the correct electrical power at its output. All engines have a tendency to slow down when a load is applied to it. The engine governor is designed to hold the operating speed as nearly constant as possible. When the electrical load is increased, the engine is more heavily loaded and engine speed drops slightly. This slight decrease in engine speed results in a slight decrease in generator voltage and frequency output. This voltage and frequency variation has no appreciable effect in the operation of motors, lights, and most appliances and tools. However, timing devices and clocks will not keep perfect time when used on this generator.

( also called Generator End)

1. Clean the generator set and remove any and all dust, dirt, or other foreign material.

2. Inspect and clean the cooling air intake and exhaust louvers of the generator end. Make sure they are clean. Remove dirt or any buildup that may restrict the cooling air flow.

3. Clean the generator set and its components with a damp cloth or sponge. Never use a water hose or pressure washer as this may damage electrical components.

4. Inspect and replace any control panel components that are broken or not working properly (receptacles, circuit breakers, switches, etc.)

Troubleshooting and Maintenance 5-1MN2415

Problems and Solutions

Some of the more common problems are listed in Table 5-1. This information is intended to be a check or verification that simple causes can be located and fixed. It is not an exhaustive “how to” for all types of problems. Procedures that require in depth knowledge or skills should be referred to the Baldor Generator Service Department by calling (920) 236−4200.

Table 5-1 General Troubleshooting Guide

Problem Possible Cause Remedy

Engine cranks but will not start

Engine will not crank (electric start) Dead battery.

Engine starts but will not run smoothly Fuel or ignition problem Refer to engine manual. Engine overheats Excessive load

No output voltage Ciruit Breaker tripped or failed.

Output voltage varies Irregular speed (fixed speed mode)

Low output voltage Low engine speed

High output voltage Excessive speed (fixed speed mode) Check engine for malfunction. Verify engine RPM. Electrical shock when frame is touched Static charge.

Mechanical noise Internal failure of Alternator

No fuel. Low Oil Level Restricted air flow. No spark.

No engine speed during crank

Emergency Stop LED is ON

Debris or dirt buildup on engine

Internal failure of Alternator

Fluctuating speed (fixed speed mode)

Loose terminal or load connections

Excessive load High resistance connections −

connections will be warm or hot Internal failure of Alternator Low power factor

Grounded armature or field coil.

Loose or misaligned coupling

Check that fuel valves are ON. Check fuel level in fuel tank. Low Oil Pressure Sutdown activated. Replensih oil to full. Check/replace air filter. Check/replace spark plug(s). Check that engine switch is in Start position.

The magnetic pickup must be correctly adjusted and operating. Remove battery and trickle charge or replace with new battery.

Never Jump Start. Reset controller after an Emergency Stop.

Remove one or more electrical loads. Remove debris. Clean engine surfaces to allow cooling.

Reset circuit breaker or replace if required. Return to factory for repair.

Check engine for malfunction or load for fluctuation Stabilize load. The addition of a lamp load (resistance load) may

compensate partially for load changes caused by intermittent motor operation. Do not overload.

Verify all connections and terminal tighness. Verify engine RPM.

Check engine for malfunction or system for overload. Reduce load. Verify all connections and terminal tighness.

Return to factory for repair. Reduce inductive (motor) load. Some AC motors use about the

same current regardless of load. Do not use motors of greater horsepower rating than is necessary to move the mechanical load.

Ground generator frame at local reference ground (see Section 3). Return to factory for repair

Return to factory for repair Tighten; align coupling and alternator shaft to engine shaft.

5-2 Troubleshooting and Maintenance MN2415

Table 5-2 Troubleshooting Guide (Digital Controller Only)

Problem Possible Cause Remedy

Controller does not power up even with correct DC power applied

Low Oil Pressure fault Low Oil Pressure

High Engine Temperature fault Excessive Temperature

Shutdown fault Fault Trip

Fail to Start is activated after pre−set number of attempts to start

Continuous starting of generator in AUTO Remote Start circuit fault Check that there is no signal present on the Automatic start" input. Generator fails to start at remote start

command Pre−heat inoperative Check wiring to engine heater plugs.

Starter motor inoperative Check wiring to starter solenoid.

Fuel solenoid inoperative Check wiring to fuel solenoid.

Wiring Mistake Loss of DC Supply

Defect in sender or wiring

Failed switch or wiring

No fuel

No starting current to starter motor Engine fault

No Remote Start Signal Wrong generator mode

Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse.

Check DC supply voltage is not above 35 Volts or below 9 Volts. Check the operating temperature is not above 70 °C.

Check engine oil pressure. Check oil pressure switch and wiring. Check switch polarity (i.e. Normally Open or Normally Closed).

Check engine temperature. Check switch and wiring. Check switch polarity (i.e. Normally Open or Normally Closed).

Clear trip condition and reset controller. Check switch and wiring of fault indicated by the LED. Check configuration of input.

Check fuel solenoid is on and battery supply is present at solenoid. Check fuel. Check battery supply. Refer to engine manual.

Check the Remote Start" input signal. Check that the Auto Start" mode is selected.

Check battery supply is present at the Pre−heat output of module. Check pre−heat has been selected in your configuration. NB all the outputs are negative switching.

Check battery supply. Check battery supply is present on the Starter output of module. NB all the outputs are negativeswitching.

Check battery supply. Check battery supply is present on the fuel output of module. NB all the outputs are negativeswitching.

Note: Table 5-2 is provided as a guide check−list only. It is possible for the module to be

configured to provide a wide range of different features always refer to the source of your module configuration if in doubt.

Note: All the outputs are solid state, rated at 1.2 Amps and switch to battery negative when

active.

Troubleshooting and Maintenance 5-3MN2415

Note: See Engine Controller manual for additional information.

Table 5-3 Troubleshooting Guide (Analog Controller Only)

Problem Possible Cause Remedy

Controller cannot be Reset"

Engine alarms are ON for high engine temperature or low oil pressure when engine is operating properly

Overspeed shutdown occurs at normal speed

Engine not stopped Controller not in OFF mode

Sending unit is disconnected (open circuit)

Defective sending unit

Controller has failed or input from Magnetic pickup is incorrect.

Verify the engine is at a complete stop before trying to reset. Set the controller to the OFF mode before trying to reset.

Verify the sending units wiring to controller terminals is not open or shorted.

Verify the engine mounted senders have correct resistance values for corresponding input temperature or pressure.

Verify the adjustments. Replace controller if failed.

Service Service for your generator can be obtained from Baldor Generators. Please have the following

information available prior to contacting the factory:

The model number and serial number of the generator set. A complete and accurate description of the problem.

Parts Parts for your generator can be obtained from Baldor Generators. Please have the following

information available prior to contacting the factory:

The model number and serial number of the generator set. A complete and accurate description of the part (part number if known).

Note: Engine parts can usually be obtained from a local distributor by using the information in

the engine manufacturer’s owner’s manual.

5-4 Troubleshooting and Maintenance MN2415

Appendix A Series AE8

Information in this Appendix applies to the AE8 Generator.

Operator Panel Configuration

Master Control

Switch

Figure A-1 AE8 Operator Panel

RUN

MANUAL

Controller

Fuse

Lamp

Master Control Switch − A three position switch allows choice of automatic or manual operating mode.

Run Manual − In this position the controller immediately energizes the crank cycle to start the generator set and produce power. Off − off position, prevents engine from stating. Remote Auto − The engine can only be started by making a connection across the remote start terminals of the control box. This allows normal

automatic backup operation of the Generator Set under control of the Transfer Switch.

Controller Fuse − This fuse provides overload protection for the controller circuit board. Lamp − This Red indicator light will come on when the engine shuts down due to a fault condition. Circuit Breaker − The 2 pole Circuit Breakers provide overload protection (excessive AC current) for the generator set output windings.

OFF REMOTE

CONTROLLER

FUSE

AUTO

Circuit Breaker

Series AE8 A-1MN2415

Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure A-2 and A-3.

Parts information is provided in Table A-1. Engine parts are identified in the engine manual that was provided with your generator set.

Figure A-2 Alternator Assembly

RM1088A01

RM1088A06 RM1088A07

HB6150A00

HB6150A01

Figure A-3 Frame Assembly

Table A-1 Generator Set Parts List

Ref No. Part No. Description Open Enclosed

1 HA9139A01 Adaptor, Engine X X 2 61FN3000 Fan X X 3 61RA0016A00 Rotor Assembly X X 4 BG6204H03 Rotor Bearing X X 5 61SA0015A03 Stator Assembly X 5 61SA0015A04 Stator Assembly X 6 61EP3204A01 Bearing Bracket X 6 61EP3204A07 Bearing Bracket X 7 EH0321A00 Cover X

8 HA1037A00 C" Washer X X 15 RM1088A01 Isolator, Control Box X 16 RM1088A06 Isolator, Generator end X 16 RM1088A07 Isolator, Engine end X X 20 BA0191A00 Base Frame X 20 BA5000A00 Base Frame X 21 HB7025A00 Engine Mounting Foot X X 22 HB7002A07 Engine end frame cross member X 22 HB7002A08 Engine end frame cross member X 23 HB6150A00 Alternator end frame cross member X 23 HB6150A01 Alternator end frame cross member X

A-2 Series AE8 MN2415

Table A-1 Generator Set Parts List Continued

Ref No. Part No. Description Open Enclosed

Not Shown EH0279A00 Enclosure, Top X Not Shown EH0280A00 Enclosure, Door X Not Shown EH0281A00 Enclosure, End Cap X Not Shown EH0290A00 Enclosure, Right Side X Not Shown EH0291A00 Enclosure, Left Side X Not Shown HB2400A00 Enclosure, Latch X Not Shown EH0308A00 Control Box X Not Shown EB1243A00 Circuit Board, ARSS−3 X Not Shown EH0296A00 Control Box X Not Shown SP9094 Toggle Switch, Master Control X X Not Shown DI0181A00 Glo−Light X X Not Shown DI0176A00 Diode X X Not Shown OC6030F11 Capacitor, 30MFD / 370V, 90 degree X X Not Shown CK0070A04 Circuit Breaker 40Amp X Not Shown CK0070A27 Circuit Breaker 35Amp X Not Shown FU066A02 Fuse, AGC1 X X Not Shown EA5009A00 Muffler X Not Shown EA0008A08 Muffler X Not Shown EA0008A08 Muffler Silencer X Not Shown HB6116A00 Battery Tie Down X X Not Shown HA3187A12 Battery Tie Down Bolt X X Not Shown EA0010A04 Battery Charger, 12V, 2AMP X X Not Shown HB6146A00 Fuel Load Block, K−N X X Not Shown HB6147A00 Carburetor Adapter X X Not Shown EA0000A00 Regulator, K−N, Manual Prime X X Not Shown SE0052A00 Solenoid, Low Pressure X X

Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix.

Series AE8 A-3MN2415

Figure A-4 AE8 Customer Connection Diagram

A-4 Series AE8 MN2415

Figure A-5 AE8 Open Frame Wiring Diagram

Series AE8 A-5MN2415

Figure A-6 AE8 Enclosed Wiring Diagram

A-6 Series AE8 MN2415

Appendix B Series AE10

Information in this Appendix applies to the AE10 Generator.

Operator Panel Configuration

Master Control

Switch

Figure B-1 AE10 Operator Panel

RUN

MANUAL

Controller

Fuse

Lamp

Master Control Switch − A three position switch allows choice of automatic or manual operating mode.

automatic backup operation of the Generator Set under control of the Transfer Switch.

OFF REMOTE

CONTROLLER

FUSE

AUTO

Circuit Breaker

Series AE10 B-1MN2415

Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure B-2 and B-3.

Parts information is provided in Table B-1. Engine parts are identified in the engine manual that was provided with your generator set.

Figure B-2 Alternator Assembly

RM1088A07

Figure B-3 Frame Assembly

Table B-1 Generator Set Parts List

Ref No. Part No. Description Open Enclosed

1 HB6177A01 Adaptor, Engine X X

2 62FN4002 Fan X X

3 62RA014A00 Rotor Assembly X X

4 BG6207H03 Rotor Bearing X X

5 62SA0006A00 Stator Assembly X X

6 62EX5001A01 Exciter Assembly X X

7 62EP3202A01 Bearing Bracket X X

8 HA3188A00 Rotor Bolt (Rotor to Engine) X X

Not Shown HB7023A00 Rotor End Plate X

15 RM1088A07 Isolator X X 20 BA0198A00 Base Frame X 20 BA5000A00 Base Frame X 21 HB7025A00 Engine Mounting Foot X X 22 HB7002A08 Engine end frame cross member X X 23 HB6068A00 Alternator end frame cross member X X

B-2 Series AE10 MN2415

Table B-1 Generator Set Parts List Continued

Ref No. Part No. Description Open Enclosed

Not Shown EH0279A00 Enclosure, Top X Not Shown EH0280A00 Enclosure, Door X Not Shown EH0281A00 Enclosure, End Cap X Not Shown EH0290A00 Enclosure, Right Side X Not Shown EH0291A00 Enclosure, Left Side X Not Shown HB2400A00 Enclosure, Latch X Not Shown BE0364A17 Control Box X Not Shown EH0296A02 Control Box X Not Shown SP9094 Toggle Switch, Master Control X X Not Shown DI0181A00 Glo−Light X X Not Shown DI0176A00 Diode X Not Shown CK0070A05 Circuit Breaker 50Amp X Not Shown CK0070A29 Circuit Breaker 50Amp X Not Shown EB1243A00 Control Circuit Board X X Not Shown FU066A02 Fuse, AGC1 X X Not Shown FU066A00 Fuse, MTH−5 X Not Shown EA5009A00 Muffler X Not Shown EA0008A08 Muffler Silencer X Not Shown HB6116A00 Battery Tie Down X X Not Shown HA3187A12 Battery Tie Down Bolt X X Not Shown EA0010A04 Battery Charger, 12V, 2AMP X X Not Shown HB6146A00 Fuel Load Block, K−N X X Not Shown HB6147A00 Carburetor Adapter X X Not Shown EA0000A00 Regulator, K−N, Manual Prime X X Not Shown SE0052A00 Solenoid, Low Pressure X X

Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix.

Series AE10 B-3MN2415

Figure B-4 AE10 Customer Connection Diagram

B-4 Series AE10 MN2415

Figure B-5 AE10 Open Frame Wiring Diagram

Series AE10 B-5MN2415

Figure B-6 AE10 Enclosed Wiring Diagram

B-6 Series AE10 MN2415

Appendix C Series AE11

Information in this Appendix applies to the AE11 Generator.

Operator Panel Configuration

Under Speed Shutdown

Over Speed Shutdown

High Coolant Temperature Shutdown

Low Oil Pressure Shutdown

Figure C-1 AE11 Operator Panel

Alternator Charge Failure Warning

Failure to Start Shutdown Aux1 Input Warn/Shutdown

Aux2 Input Warn/Shutdown

Stop Manual

Run

Auto Start

Hour Meter

(fuel solenoid energized

Shutdown Warning Indicators

Low Oil Pressure, High Coolant Temperature, Over Speed (Engine), Under Speed (Engine), Failure to Start Engine.

Warning (or Shutdown) Indicators

Alternator Failure (to Charge Battery), Auxiliary 1 Input Active, Auxiliary 2 Input Active.

control box. This allows normal automatic backup operation of the Generator Set under control of the Transfer Switch whenever utility AC power is lost.

Series AE11 C-1MN2415

Replacement Parts

Replacement parts assembly views for the Generator set are shown in Figure C-2 and C-3. Parts information is provided in Table C-1. Engine parts are identified in the engine manual that was provided with your generator set.

Figure C-2 Alternator Assembly

RM1088A15

Figure C-3 Frame Assembly

Table C-1 Generator Set Parts List

Ref No. Part No. Description

1 HB6177A02 Adaptor, Engine

2 62FN4002 Fan

3 62RA0016A00 Rotor Assembly

4 BG6207H03 Rotor Bearing

5 62SA0025A00 Stator Assembly

6 62EX5001A01 Exciter Assembly

7 62EP3202A01 Bearing Bracket

8 HA3188A00 Rotor Bolt (Rotor to Engine)

Not Shown HB7023A00 Rotor End Plate

15 RM1088A15 Isolator 20 EH0491A09 Base Frame 21 HB6068A02 Engine Mount (Kohler CP23) 22 HB6068A16 Engine/Alternator Mount 23 HB6068A03 Alternator Mount

C-2 Series AE11 MN2415

Table C-1 Generator Set Parts List Continued

Ref No. Part No. Description

Not Shown EH0491A02 Enclosure, Top Not Shown EH0491A11 Enclosure, Access Panel Not Shown EH0491A01 Enclosure, Front Not Shown EH0491A10 Enclosure, Right Side (Hinge) & Rear Not Shown EH0491A13 Enclosure, Left Side (Latch) & Front Not Shown HB2414A05 Latch Not Shown HW2409A21 Hinge, Nylon Not Shown HW2409A22 Hinge, Nylon Not Shown HW2410A02 Gas Spring, 30 lb. Not Shown EH0309A02 Control Box Not Shown EM0046A00 Engine Controller, 4110 Auto Start Not Shown RE5031A01 Relay Not Shown EM0027A01 Voltage Regulator (AVC63−20.) Not Shown CK0070A29 Circuit Breaker 50Amp Not Shown FU066A02 Fuse, AGC1 Not Shown FU066A00 Fuse, MTH−5 Not Shown SE0057A02 Solenoid, Engine Starting 12V Not Shown EA5038A00 Muffler Not Shown HB6116A00 Battery Tie Down Not Shown HA3187A12 Battery Tie Down Bolt Not Shown EA0010A04 Battery Charger, 12V, 2AMP Not Shown EA0000A00 Regulator, K−N, Manual Prime Not Shown SE0071A00 Solenoid, Automatic Gas Valve

Conversion from LPG to Natural Gas Optional Procedure

If this is a new installation, begin with step 5. If the generator has been installed, ensure that the following steps are performed:

1. Place the controller in the OFF position.

2. Place the circuit breaker in the OPEN position.

3. Turn off the LPG supply. Disconnect and remove the LPG equipment and hoses.

4. Disconnect the negative terminal from the starting battery.

Figure C-4

90° Elbow

K−N Regulator

Insert

5. Open the lid and remove the front panel by removing the two 7/16” bolts along the top edge of the front panel.

6. Remove the hose that connects to the 90° elbow at the top of the demand (K−N) regulator, Figure C-4.

Series AE11 C-3MN2415

7. Remove the insert from the 90° elbow, Figure C-5.

8. Connect the hose and hose clamp to the 90° elbow.

Figure C-5

90° Elbow with LPG

Insert removed.

Hose (fuel line) and clamp installed

Insert

9. Remove the control box cover by removing the six 7/16” bolts. to gain access to the customer connection terminal strips.

10. Remove the jumper assembly attached to the demand regulator.

11. Locate the two terminals labeled FUEL JUMPER and connect the jumper assembly between them.

12. Install the control box cover and the front panel.

The unit has now been converted to operate on Natural Gas.

Figure C-6

L1 BAT Charger

N BAT Charger

G BAT Charger

Remote Start

Fuel Jumper

Jumper attached to K−N Regulator

L1 GEN

L2 GEN

L3 GEN

N GEN

G GEN Grounding

Electrode Terminal

Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix.

C-4 Series AE11 MN2415

Figure C-7 AE11 Customer Connection Diagram

Series AE11 C-5MN2415

Figure C-8 AE11 Generator Connection Diagram

C-6 Series AE11 MN2415

Figure C-9 AE11 Engine Connection Diagram

Series AE11 C-7MN2415

Figure C-10 AE11 Connection Diagram

Notes:

1. Remove jumper if LP fuel is used.

2. Remove bullet connector from BLK/WHT wire.

Substitute WD1000F23.

3. No Bonding wire.

4. (GRN) wires have green colored insulation.

(Red) wires have Red colored insulation.

C-8 Series AE11 MN2415

Figure C-11 AE11 Customer Wiring Interface Diagram

Series AE11 C-9MN2415

C-10 Series AE11 MN2415

Appendix D Series AE25

Information in this Appendix applies to the AE25 Generator.

Operator Panel Configuration

Figure D-1 AE25 Operator Panel

OIL

BATTERY

MANUAL

RUN

HIGH TEMPERATURE LOW OIL PRESSURE OVERSPEED

OVERCRANK

STOP

AUTO

START

MASTER

CONTROL

WATER

Hour Meter

DC CONTROL FUSE AC CONTROL FUSE

NAT. GAS L.P. GAS

Display Lamps High Temperature − Indicates excessive engine coolant temperature.

an “overcrank” shutdown and alarm indication.

Hour Meter Displays total hours of operation based on power applied to Fuel Solenoid). Meters Water − Displays the temperature of the engine coolant.

Oil − Displays the engines oil pressure. Battery − Displays the battery voltage of the starting battery.

DC Control Fuse Fuse for engine controller. AC Control Fuse Fuse for engine controller.

Master Control

control box. This allows normal automatic backup operation of the Generator Set under control of the Transfer Switch whenever utility AC power is lost.

Natural/LP Gas

Selector Switch

Selects the correct fuel source: Natural Gas or L.P. Gas.

Series AE25 D-1MN2415

Replacement Parts

Replacement parts assembly views for the Generator set are shown in Figure D-2 and D-3. Parts information is provided in Table D-1. Engine parts are identified in the engine manual that was provided with your generator set.

Figure D-2 Alternator Assembly

Figure D-3 Frame Assembly

Table D-1 Generator Set Parts List

Ref No. Part No. Description

1 HB6179A00 Adaptor, Engine 2 62FN2000A02 Fan 3 62RA0025A00 Rotor Assembly 4 BG6207H03 Rotor Bearing 5 62SA0017A00 Stator Assembly 6 62EX5002A04 Exciter Assembly 7 62EP3200A02 Bearing Bracket 8 HB7023A00 Rotor End Plate 9 HA2444A02 Rotor Bolt (Rotor to Engine)

Not Shown EM0027A01 Voltage Regulator, AVC63−2.0

15 RM1088A11 Isolator 20 BA0232A03 Base Frame 21 HB6072A04 Engine Mounting Foot, Right 22 HB6072A05 Engine Mounting Foot, Left

RM1088A11 (TS25−Green)

RM1088A12 (TS45−Red) RM1088A13 (TS80−White) RM1088A25 (TS45−Green)

HB6072A04

21 22

HB6072A05

D-2 Series AE25 MN2415

Table D-1 Generator Set Parts List Continued

Ref No. Part No. Description

Not Shown EH0278A78 Enclosure, Top Not Shown EH0278B72 Enclosure, Door Not Shown EH0386A02 Enclosure, Front Not Shown EH0386A03 Enclosure, Rear Not Shown EA0006A08 Radiator Not Shown FN0027A00 Fan, Radiator Cooling Not Shown EA0005A08 Upper Radiator Hose Not Shown EA0005A38 Lower Radiator Hose Not Shown TA0000A07 Coolant Recovery Tank Not Shown TA0002A07 Cap, Coolant Recovery Tank Not Shown EA0044A07 Valve, Fumoto F−107−N Not Shown EA0044A00 Valve, Fumoto T−202N Not Shown EA0001A01 Sender, Water Temperature Not Shown EA0001A02 Sender, Oil Pressure Not Shown EA0007A05 Magnetic Pickup Assembly Not Shown EA0029A02 Fuel Actuator, Ford 2.5L Not Shown SE0052A00 Fuel Lock Solenoid Not Shown EA0000A02 Fuel Regulator Not Shown EA0015A08 Air FIlter Not Shown EA0029A03 Fuel Mixer, Ford 2.5L Not Shown EA0030A02 Diaphragm, Natural Gas Not Shown GS0091A00 Gasket, Throttle Not Shown GS0091A01 Gasket, Actuator to Mixer Not Shown BE0412A00 Control Box Not Shown EM0045A01 Engine Controller, Memory 09, 132 Tooth Not Shown EM0039A02 Controller LRG423 for Ford 2.5L Not Shown CK0070A59 Circuit Breaker, w/o shunt trip Not Shown RE5031A09 Relay, VF7−41F11 Not Shown EA5034A02 Diode Kit with #10 & 1/4" Ring Terminals Not Shown HB6116A00 Battery Tie Down Not Shown HA3187A12 Battery Tie Down Bolt Not Shown EA0010A02 Battery Charger, 12VDC, 6AMP Not Shown SP9094 Switch, DPDT Not Shown SP9113 Switch, Nat. Gas/L.P. Gas Not Shown WD3203A00 Oil Pressure Gauge Not Shown WD3204A00 Water Temperature Gauge Not Shown WD3201A11 Volt Meter Not Shown WD3201A00 Elapsed Time Meter Not Shown FU066A07 Fuse, AGC15 Not Shown FU066A00 Fuse, MTH−5 Not Shown LB0094B19 Decal, Control Panel AE25 Not Shown LB0100A22 Decal, Baldor Auto Emergency 20" Not Shown LB0100A02 Decal, Baldor Auto Emergency 12" Not Shown LB0100A03 Decal, Baldor Auto Emergency 39" (split) Not Shown LB0094A11 Decal, Danger−High Voltage Not Shown LB0094A30 Decal, Warning, Auto Start Not Shown LB0095A07 Placard, Line" Not Shown LB0095A08 Placard, Load" Not Shown LB0095A15 Placard, Neutral" Not Shown LB0095A16 Placard, L1" Not Shown LB0095A17 Placard, L2" Not Shown LB0095A42 Placard, Remote Start" Not Shown LB0095A51 Placard, A.C. Connection" Not Shown LB0094A36 Decal, Danger Hot Not Shown LB0095A37 Placard, Ground"

Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix.

Series AE25 D-3MN2415

Figure D-4 AE25 Receptacle Connection Diagram

D-4 Series AE25 MN2415

Figure D-5 AE25 Engine Compartment Connection Diagram

Series AE25 D-5MN2415

Figure D-6 AE25 Control Box Connection Diagram

D-6 Series AE25 MN2415

UNITED STATES

ARIZONA

PHOENIX 4211 S 43RD PLACE PHOENIX, AZ 85040 PHONE: 602−470−0407 FAX: 602−470−0464

CALIFORNIA

LOS ANGELES 6480 FLOTILLA COMMERCE, CA 90040 PHONE: 323−724−6771 FAX: 323−721−5859

HAYWARD 21056 FORBES STREET HAYWARD, CA 94545 PHONE: 510−785−9900 FAX: 510−785−9910

COLORADO

DENVER 2520 W BARBERRY PLACE DENVER, CO 80204 PHONE: 303−623−0127 FAX: 303−595−3772

CONNECTICUT

WALLINGFORD 65 SOUTH TURNPIKE ROAD WALLINGFORD, CT 06492 PHONE: 203−269−1354 FAX: 203−269−5485

FLORIDA

TAMPA/PUERTO RICO/ VIRGIN ISLANDS 3906 EAST 11TH AVENUE TAMPA, FL 33605 PHONE: 813−248−5078 FAX: 813−247−2984

GEORGIA

ATLANTA 62 TECHNOLOGY DR. ALPHARETTA, GA 30005 PHONE: 770−772−7000 FAX: 770−772−7200

ILLINOIS

CHICAGO 1601 FRONTENAC ROAD NAPERVILLE, IL 60563 PHONE: 630−848−5100 FAX: 630−848−5110

INDIANA

INDIANAPOLIS 5525 W. MINNESOTA STREET INDIANAPOLIS, IN 46241 PHONE: 317−246−5100 FAX: 317−246−5110 800−428−4141

IOWA

DES MOINES 1800 DIXON STREET, SUITE C DES MOINES, IA 50316 PHONE: 515−263−6929 FAX: 515−263−6515

MARYLAND

BALTIMORE 6660 SANTA BARBARA RD. SUITE 22−24 ELKRIDGE, MD 21075 PHONE: 410−579−2135 FAX: 410−579−2677

MASSACHUSETTS

BOSTON 6 PULLMAN STREET WORCESTER, MA 01606 PHONE: 508−854−0708 FAX: 508−854−0291

MICHIGAN

DETROIT 33782 STERLING PONDS BLVD. STERLING HEIGHTS, MI 48312 PHONE: 586−978−9800

FAX: 586−978−9969

MICHIGAN Continued

GAND RAPIDS 668 3 MILE ROAD NW GRAND RAPIDS, MI 49504 PHONE: 616−785−1784 FAX: 616−785−1788

MINNESOTA

MINNEAPOLIS 21080 134TH AVE. NORTH ROGERS, MN 55374 PHONE: 763−428−3633 FAX: 763−428−4551

MISSOURI

ST LOUIS 422 INDUSTRIAL DRIVE MARYLAND HEIGHTS, MO 63043 PHONE: 314−298−1800 FAX: 314−298−7660

KANSAS CITY 915 N W PLATTE VALLEY DR RIVERSIDE, MO 64150 PHONE: 816−587−0272 FAX: 816−587−3735

NEW YORK

AUBURN ONE ELLIS DRIVE AUBURN, NY 13021 PHONE: 315−255−3403 FAX: 315−253−9923

NORTH CAROLINA

GREENSBORO 1220 ROTHERWOOD ROAD GREENSBORO, NC 27406 P O BOX 16500 GREENSBORO, NC 27416 PHONE: 336−272−6104 FAX: 336−273−6628

OHIO

CINCINNATI 2929 CRESCENTVILLE ROAD WEST CHESTER, OH 45069 PHONE: 513−771−2600 FAX: 513−772−2219

CLEVELAND 8929 FREEWAY DRIVE MACEDONIA, OH 44056 PHONE: 330−468−4777 FAX: 330−468−4778

OKLAHOMA

TULSA 2 EAST DAWES BIXBY, OK 74008 PHONE: 918−366−9320 FAX: 918−366−9338

OREGON

PORTLAND 20393 SW AVERY COURT TUALATIN, OR 97062 PHONE: 503−691−9010 FAX: 503−691−9012

PENNSYLVANIA

PHILADELPHIA 1035 THOMAS BUSCH MEMORIAL HIGHWAY PENNSAUKEN, NJ 08110 PHONE: 856−661−1442 FAX: 856−663−6363

PITTSBURGH 616H BEATTY ROAD MONROEVILLE, PA 15146 PHONE: 412−380−7244 FAX: 412−380−7250

TENNESSEE

MEMPHIS 4000 WINCHESTER ROAD MEMPHIS, TN 38118 PHONE: 901−365−2020 FAX: 901−365−3914

Baldor District Offices

TEXAS

HOUSTON 4647 PINE TIMBERS SUITE # 135 HOUSTON, TX 77041 PHONE: 713−895−7062 FAX: 713−690−4540

DALLAS

3040 QUEBEC DALLAS, TX 75247 PHONE: 214−634−7271 FAX: 214−634−8874

UTAH

SALT LAKE CITY 2230 SOUTH MAIN STREET SALT LAKE CITY, UT 84115 PHONE: 801−832−0127 FAX: 801−832−8911

WISCONSIN

MILWAUKEE 2725 SOUTH 163RD STREET NEW BERLIN, WI 53151 PHONE: 262−784−5940 FAX: 262−784−1215

INTERNATIONAL SALES

FORT SMITH, AR P.O. BOX 2400 FORT SMITH, AR 72902 PHONE: 479−646−4711 FAX: 479−648−5895

CANADA

EDMONTON, ALBERTA 4053−92 STREET EDMONTON, ALBERTA T6E 6R8 PHONE: 780−434−4900 FAX: 780−438−2600

OAKVILLE, ONTARIO 2750 COVENTRY ROAD OAKVILLE, ONTARIO L6H 6R1 PHONE: 905−829−3301 FAX: 905−829−3302

MONTREAL, QUEBEC 1844 WILLIAM STREET MONTREAL, QUEBEC H3J 1R5 PHONE: 514−933−2711 FAX: 514−933−8639

VANCOUVER, BRITISH COLUMBIA 1538 KEBET WAY PORT COQUITLAM, BC V3C 5M5 PHONE 604−421−2822 FAX: 604−421−3113

WINNIPEG, MANITOBA 54 PRINCESS STREET WINNIPEG, MANITOBA R3B 1K2 PHONE: 204−942−5205 FAX: 204−956−4251

AUSTRALIA

UNIT 3, 6 STANTON ROAD SEVEN HILLS, NSW 2147, AUSTRALIA PHONE: (61) (2) 9674 5455 FAX: (61) (2) 9674 2495

UNIT 8, 5 KELLETTS ROAD ROWVILLE, VICTORIA, 3178 AUSTRALIA PHONE: (61) (3) 9753 4355 FAX: (61) (3) 9753 4366

BALDOR CENTROAMERICA

RESIDENCIAL PINARES DE SUIZA POL. 15 #44, NVA. SAN SALVADOR EL SALVADOR, CENTRO AMERICA PHONE: (503) 288−1519 FAX: (503) 288−1518

BALDOR SUDAMERICA

CALLE F, EL CANGREJO CONDOMINIO P.H. CONDADO PLAZA APT. 11D, BELLA VISTA PANAMÁ CITY, REP. DE PANAMÁ PHONE: (507) 265−6041

CHINA

SHANGHAI JIAHUA BUSINESS CENTER ROOM NO. A−8421 808 HONG QIAO ROAD SHANGHAI 200030 PHONE: 86−21−64473060 FAX: 86−21−64078620

GERMANY

DIESELSTRASSE 22 D−85551 KIRCHHEIM MUNICH, GERMANY PHONE: (49) (89) 90508 − 0 FAX: (49) (89) 90508 − 492

INDIA

14, COMMERCE AVENUE MAHAGANESH COLONY PAUD ROAD PUNE − 411 038 MAHARASHTRA, INDIA PHONE: 91 20 25 45 95 31/32 FAX: 91 20 24 55 95 30

ITALY

BALDOR ASR AG SUCCURSALE DI MENDRISIO VIA BORROMINI, 20A CH−6850 MENDRISIO SWITZERLAND PHONE: 41 91 640 9952 FAX: 41 91 630 2633

JAPAN

DIA BLDG 802, 2−21−1 TSURUYA−CHO, KANAGAWA−KU YOKOHAMA, 221−0835, JAPAN PHONE: 81−45−412−4506 FAX: 81−45−412−4507

KOREA

ROOM 210 BUPYEONG INDUSTRIAL COMMERCIAL COOPERATIVE 396−16 CHEONGCHEON 2−DONG, BUPYEONG−GU INCHEON, KOREA, 403−858 PHONE: 82 32 508 3252 FAX: 82 32 508 3253

MÉXICO

KM. 2.0 BLVD. AL AEROPUERTO LEÓN 37545, GUANAJUATO, MÉXICO PHONE: 52 477 761 2030 FAX: 52 477 761 2010

MIDDLE EAST & NORTH AFRICA

VSE INTERNATIONAL CORP. 3233 NORTH ARLINGTON HEIGHTS SUITE 100W ARLINGTON HEIGHTS, IL 60004 PHONE: 847 590 5547

SINGAPORE

51 KAKI BUKIT ROAD 2 K B WAREHOUSE COMPLEX SINGAPORE 417863 PHONE: (65) 6 744 2572 FAX: (65) 6 747 1708

SWITZERLAND

POSTFACH 73 SCHUTZENSTRASSE 59 CH−8245 FEUERTHALEN SWITZERLAND PHONE: (41) (52) 6474700 FAX: (41) (52) 6592394

TAIWAN

4F, NO. 25, SEC. 1, TUNHUA S ROAD, TAIPEI 10557, TAIWAN, R.O.C. PHONE: (886−2) 2577−4352 FAX: (886−2) 2577−4157

UNITED KINGDOM

6 BRISTOL DISTRIBUTION PARK HAWKLEY DRIVE BRISTOL BS32 0BF U.K. PHONE: 44 1454 850000 FAX: 44 1454 859001

WARNING:

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.

WARNING:

CALIFORNIA PROPOSITION 65 WARNING:

Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm.

BALDOR ELECTRIC COMPANY

P.O. Box 2400

Ft. Smith, AR 72901--2400

(479) 646--4711

Fax (479) 648--5792

PrintedinUSA

5/05

Baldor AE25, AE11, AE8, AE10 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual