Diesel POW’R Products
Generator
DG3E and DG6E
Installation & Operating Manual
5/05 |
MN2414 |
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
Owner’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Section 3
Receiving & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lifting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Physical Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Frame Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Use of Electric Motor Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Optional Wheel Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Recommended Engine Oil and Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Section 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Pre−Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Start−Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Electric Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Section 5
Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Appendix A
DG Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Operator Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
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Table of Contents i |
ii Table of Contents |
MN2414 |
Section 1
Product Safety Information
Safety Notice |
Be sure that you are completely familiar with the safe operation of this equipment. This |
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equipment may be connected to other machines that have rotating parts or parts that are |
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controlled by this equipment. Improper use can cause serious or fatal injury. Always |
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disconnect all electrical loads before starting or stopping the generator. |
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Installation and repair procedures require specialized skills with electrical generating equipment. |
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Any person that installs or repairs this generator must have these specialized skills to ensure that |
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this generating unit is safe to operate. Contact Baldor for repairs or for any questions you may |
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have about the safe installation and operation of this system. |
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The precaution statements are general guidelines for the safe use and operation of this |
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generator. It is not practical to list all unsafe conditions. Therefore, if you use a procedure that is |
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not recommended in this manual, you must determine if it is safe for the operator and all |
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personnel in the proximity to the generator and connected loads. If there is any question of the |
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safety of a procedure please, contact Baldor before starting or stopping the generator. |
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This equipment contains high voltages. Electrical shock can cause serious or fatal injury. Only |
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qualified personnel should attempt the start−up procedure or troubleshoot this equipment. |
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This equipment may be connected to other machines that have rotating parts or parts that are |
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driven by this equipment. Improper use can cause serious or fatal injury. Only qualified |
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personnel should attempt the start−up procedure or troubleshoot this equipment. |
−System documentation must be available to anyone that operates this equipment at all times.
−Keep non-qualified personnel at a safe distance from this equipment.
−Only qualified personnel familiar with the safe installation, operation and maintenance of this device should attempt start-up or operating procedures.
−Always stop engine before making or removing any connections.
−Always stop engine and allow it to cool before refueling.
Responsibility When your generator is delivered, it becomes the responsibility of the owner/operator of the generator set to prevent unsafe conditions and operation of the equipment. Some responsibilities include (but are not limited to) the following:
1.It is the responsibility of the owner/operator of this generator to ensure that this equipment is correctly and safely installed.
2.It is the responsibility of the owner/operator of this generator to ensure that this equipment, when installed fully complies with all federal, state and local codes.
3.It is the responsibility of the owner/operator of this generator to ensure that any person operating this equipment has been properly trained.
4.It is the responsibility of the owner/operator of this generator to ensure that any person operating this equipment has access to all manuals and information required for the safe use and operation of this equipment.
5.It is the responsibility of the owner/operator of this generator to ensure that it is properly maintained and safety inspected at regular scheduled intervals.
6.It is the responsibility of the owner/operator of this generator to ensure that any person who has not been trained on the safe use of this equipment does not have access to this equipment.
Read This Manual Thoroughly
If you do not understand any concept, any procedure, any safety warning statement, any safety caution statement or any portion of this manual, contact Baldor or your nearest authorized Baldor representative. We are happy to make sure you understand the information in this manual so that you can safely enjoy the full use of this generator.
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Product Safety Information 1-1 |
Precaution Statements Used In This Manual
There are three classifications of precautionary statements used in this manual. The most critical is a WARNING statement, then the Caution statement and the least critical is the Note statement. The usage of each statement is as follows:
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in injury or death.
Caution: |
Indicates a potentially hazardous situation which, if not avoided, could result in damage to |
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property. |
Note: |
Additional information that is not critical to the installation or operation. |
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains important instructions for the generator that should be followed during installation, operation and maintenance of the generator.
For ease of reading, the Warning statements are divided into four categories: Operation, Burn, Installation, and Maintenance.
Operation
WARNING: Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death. For storage or refueling handle fuel with care and only in clean, approved, properly marked safety fuel containers.
WARNING: Do not overfill the fuel tank. Only fill the tank to within 1/2, of the top of the tank to allow space for fuel expansion. Overfilling of tank may cause fuel to spill out onto engine and cause fire or explosion.
WARNING: Clean up fuel spills by wiping completely dry before starting engine. Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death.
WARNING: Make sure the fuel cap is completely and securely closed after refueling to prevent spillage. Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death.
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 battery terminals 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 |
MN2414 |
Operation Warning Statements Continued
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 while refueling. Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death.
WARNING: Stop engine and allow engine to cool before refueling. Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death.
WARNING: Never store the generator with fuel in the tank. Never store the generator indoors or in an enclosed area or in a poorly ventilated enclosure where fumes may reach an open flame, electrical spark or pilot light as on a furnace, water heater, clothes dryer, etc. Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death.
WARNING: Allow generator to cool before transporting it or storing it. Always drain fuel from tank after generator has cooled.
WARNING: When transporting the generator (especially over rough roads) always drain the fuel tank to prevent leakage or spillage of fuel. Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death.
WARNING: Operate the generator only on a level surface. If the generator is tilted during operation, fuel spillage may result. Gasoline and diesel fuel 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.
Continued on next page.
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Product Safety Information 1-3 |
Warning Statements Continued
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 of the engine. In addition to a severe burn, the 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.
Installation
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: 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: When transporting a generator (especially if it has wheel option installed) secure the unit to prevent movement during transport.
WARNING: Never connect this generator to any buildings electrical system 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 so as 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. Gasoline and diesel fuel 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 etc.
WARNING: Have electrical circuits and wiring installed and checked by licensed electrician or qualified technician. Electrical shock can cause serious or fatal injury.
WARNING: Incorrect installation of this generator set could result in property damage, injury or death. Connection of the generator to its fuel source must be done by a qualified professional technician or contractor.
Continued on next page.
1-4 Product Safety Information |
MN2414 |
Warning Statements Continued
Maintenance
WARNING: Before servicing the generator set, be sure to disconnect the battery terminals to prevent accidental engine rotation or starting.
WARNING: Before cleaning, inspecting, repairing, refueling 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.
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 tanks, supply piping, and their connections monthly for fuel leaks. Diesel fuel is flammable and can cause fire, explosions, injury or death. If a leak is found, replace only with approved pipe or components.
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: The capacitor used in this generator can store and discharge a high voltage charge. Before working with or in the area of the capacitor, discharge the capacitor by shorting its leads together with a screwdriver with an insulated handle or insulated jumper wire.
WARNING: Be extremely careful when flashing the generator. When the alternator cover is removed rotating parts and high voltage are present. Electrical shock can cause serious or fatal injury. Rotating parts can present extreme danger if clothing or body extremities are caught by the rotating part and can cause serious or fatal injury.
WARNING: Never store an engine with fuel in its tank indoors or in an enclosed, poorly ventilated area where diesel fumes could reach an ignition source and cause an explosion.
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Product Safety Information 1-5 |
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