Baldor MN2412 User Manual

PowerchiefR POW’R Products

Generator

Series PC

Installation & Operating Manual

4/04 MN2412

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recoil Start 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping Procedure 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5

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

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

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

Appendix A

Powerchief[ Series A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

. . . . . . . . . . . . . .

Table of Contents iMN2412

ii Table of Contents MN2412

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
service department 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 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.

Baldor Generators
3815 Oregon Street
Oshkosh, WI 54902
(920) 236–4200 (voice); or (920) 236–4219 (fax); or www.baldor.com

Product Safety Information 1-1MN2412

Precaution Statements Used In This Manual

There are three classifications of precautionary statements used in this manual. The most critical
is a WARNING statement, then the Caution statement and the least critical is the Note
statement. The usage of each statement is as follows:

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

death.

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

property.

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

IMPORTANT SAFETY INSTRUCTIONS

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

be followed during installation, operation and maintenance of the generator.
For ease of reading, the Warning statements are divided into four categories: Operation, Burn, Installation,
and Maintenance.

Operation
WARNING: 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 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 MN2412

Operation Warning Statements
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

Continued on next page.

Product Safety Information 1-3MN2412

Warning Statements
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.
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

Continued on next page.

1-4 Product Safety Information MN2412

Warning Statements
Maintenance
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. 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 tanks, supply piping, and their connections monthly for fuel leaks. Gasoline

and diesel fuel are 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 gasoline fumes could reach an ignition source and cause an explosion.

Continued

Continued on next page.

Product Safety Information 1-5MN2412

Caution Statements

Caution: The brass connecting tab on some 120VAC duplex receptacles have been removed. Each

receptacle is powered by a separate generator winding. When replacing a receptacle, inspect

the brass tab that normally links both receptacles. If it is removed, be sure to remove the

brass tab from the replacement receptacle before it is installed. Failure to remove the tab will

cause a direct short to the generator windings and cause possible generator damage.
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 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 wrap frame.
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: Operate the generator only on a level surface. Operation of the generator on an incline or

slope may degrade engine lubrication and result in engine failure.
Caution: Always fill fuel tank with clean fresh fuel before use. Never leave fuel in tank for long storage

periods. Old fuel becomes stale and can damage the fuel system causing the engine not to

start. Always drain the fuel tank after use before storage.
Caution: For electric start models, do not place the key switch in the start position when engine is

running. This causes the starting motor to engauge and may damage the starter and engine.

1-6 Product Safety Information MN2412

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
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

Portable Products

(Premier, Powerchief, DG Series, K Series)

Towable Products (TS) 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

*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.

Labor* Parts

1 Year 3 Years

Whichever comes first
1 Year or 1,000 Hours

Whichever comes first
1 Year or 3,000 Hours

Whichever comes first

Whichever comes first

Whichever comes first

Whichever comes first

3 Years or 3,000 Hours

Whichever comes first

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
1 Year or 1,000 Hours

Whichever comes first

General Information 2-1MN2412

2-2 General Information MN2412

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.
(Refer to Section 9 of this manual).

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 weighs between 100 and 300 lbs.
Use proper lift equipment and methods to avoid injury. Lift only by the tubular metal frame.

Figure 3-1 PowerchiefR Generators

Storage If you will not be using the generator set for a significant amount of time (3 months or longer) you

should store the generator to prevent any problems that could arise from sitting idle. Please fully
read the following guidelines prior to storing the unit.

1. Remove all fuel from the engine’s fuel tank.

2. Start the generator set and allow it to run out of fuel.

3. Close all the fuel valves.

Note: An alternative to draining the fuel from a gasoline engine is adding a fuel stabilizer, to

minimize the formation of fuel gum deposits during storage (Follow the manufacturer’s
directions). After the fuel stabilizer is added, run the generator set for 5 minutes to get the
stabilizer into the carburetor. After shutting the engine off, be sure to close all the fuel
valves.

4. Disconnect and remove the battery if your generator set is so equipped.

5. Drain the used oil from the engine’s crankcase and refill it with clean oil.

6. Remove the spark plugs and pour1 oz. of clean engine oil into each cylinder. Put a rag
over each spark plug port and turn the engine over approximately 5 times to distribute
the oil in the cylinder.

7. Replace the spark plug(s) but do not connect the plug wires. This will help prevent
accidental or unauthorized starting.

8. Provide maintenance to the engine and generator set as described in the engine and
generator maintenance sections of this manual.

9. Cover any bare metal spots with paint or another type of rust preventative.

WARNING: Never store an engine with fuel in its tank indoors or in an enclosed, poorly ventilated area

where gasoline fumes could reach an ignition source and cause an explosion.

Receiving & Installation 3-1MN2412

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 can
only be installed in an outdoor location so the exhaust fumes are vented to the atmosphere. This
system must never be installed inside an enclosed building, home, shop or garage etc.

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

1. For effective cooling and maintenance, the generator should be mounted on a flat, smooth,
non-flammable level surface. A concrete pad is ideal and provides a secure installation.

2. The location for the generator must be dry. Never operate a generator in an area that
has standing water or puddles.

3. Installation should prevent obstructions by buildup of leaves, grass, sand, snow, etc. It
is important that the unit be operated in a reasonably clean environment.

4 All engines give off considerable heat when running. The engine in your generator set

uses air to keep it cool so it is important that the ambient temperature is cool and does
not exceed 100"F (even while it is running). Where natural ventilation is inadequate a
fan to boost circulation should be used.

5. Exhaust gases from internal combustion engines are extremely poisonous. Never
operate an engine indoors.

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.

6. All electrical equipment should be protected from excessive moisture. Failure to do so
will result in deterioration of the insulation and may result in short circuits and a
possible electrocution hazard.

Installation

Electrical Connections All load connections are made at the panel using electrical cords with the proper

WARNING: Never connect this generator to any buildings electrical system unless a licensed electrician

The generator is completely assembled, tested and adjusted at the factory before it is shipped to
you. External connections required at the time of installation are:

Note: The generator is shipped dry. This means no oil is in the engine crankcase and no battery

is installed. You must refer to the engine manual and obtain the correct type and quantity
of engine motor oil and the correct battery (if equipped for electric start).

1. Electrical Connections.

2. 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.

mating plug for the receptacle being used. More than one receptacle can be used as long as the
total load does not exceed the continuous rating of the generator.

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.

Use correct size insulated wire to connect the generator to the load. The gauge of the wire will
depend on the distance to the load, the permissible voltage drop at the load, and the current
required by the load. If you are not sure of the gauge wire needed for your application, consult a
competent electrician. Using wire that is too small can result in fire hazard. Also, be sure the
wire has the appropriate ratings for insulation and environment conditions.

The correct mating connector must be used to fit the connectors provided on the operator panel
of your generator. Table 3-1 describes the connector types provided (receptacles) and the load
characteristics to help you choose the correct size wire. Figure 3-2 shows the receptacles.

3-2 Receiving & Installation MN2412

Electrical Connections Continued

Table 3-1 Single Phase Power Receptacle Description

Model Electrical Connection Information (Receptacle Provided at Panel)

Straight 120VAC

(20Amp)

PC30H 3- 15AMP 120VAC 3000 / (22.5/-)
PC40H 2- 5-20R GFCI 120VAC 1- L5-30R 120VAC 1- L14-30R 120/240VAC 4000 / (33.3/16.7)
PC50H 2- 5-20R GFCI 120VAC 1- L5-30R 120VAC 1- L14-30R 120/240VAC 5000 / (33.3/16.7)
PC60H 2- 5-20R GFCI 120VAC 1- L5-30R 120VAC 1- L14-30R 120/240VAC 6000 / (45.8/22.9)

PC90VE 2- 5-20R GFCI 120VAC 1- L5-30R 120VAC 1- L14-30R 120/240VAC 9000 / (66.7/33.4)

Twist Lock 120VAC

(30Amp)

Twist Lock 120/240VAC

(30Amp)

Rated Watts/

(Full load Amps

120/240)

Note: GFCI is Ground Fault Protected power.

Class 1 wiring methods must be used for field wiring connections to terminals of a Class 2 circuit.

Figure 3-2 Receptacle Connections

W

(SILVER)

G

(GOLD)

X

NEMA 5-20R

125V 20A

NEMA

L5-30R

125V

30A

G

X

(GOLD)

Y

(GOLD)

NEMA
L14-30R
125/250V

30A

W

(SILVER)

Frame Ground Connection
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.

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 3-3. Use the appropriate size wire (normally 6 AWG) as required by NEC and local
codes. The local reference ground is normally a copper clad earth ground rod driven into the
earth at least 8 feet.

WARNING: Do not connect the generator output neutral to the frame or local ground. The generator

output is isolated from ground. NEC and local codes require that the generator output remain
isolated from local ground reference.

Receiving & Installation 3-3MN2412

Frame Ground Connection Continued

Figure 3-3 Frame Ground Connection

Nut
Washer

Ground Wire Lug
Washer

Stud

Frame

Earth Ground

Engine Oil Refer to the engine manual that was provided with your generator. Determine the correct type of

engine oil and the amount specified by the engine manufacturer. Add the required amount of oil
to bring the oil level to full.

Battery Connections

Applies to 12VDC Electric Start models only.

Note: PC90VE units that have an electronic governor must have a battery installed before the

Genset can be started (even with the pull starter). If no battery is present or the battery is
discharged, the electronic governor will not operate and the generator set will not run.

The generator is shipped with no battery installed.

WARNING: Do not dispose of battery or batteries 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: Do not mutilate the battery . The battery contains electrolyte solution which 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. 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.

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

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.

WARNING: A battery presents a risk of fire 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. 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.

3-4 Receiving & Installation MN2412

Battery Connections Continued

Note: PC90VE units that have an electronic governor must have a battery installed before the

Genset can be started (even with the pull starter). If no battery is present or the battery is
discharged, the electronic governor will not operate and the generator set will not run.

Procedure: The correct type battery must be purchased and installed in the battery compartment provided.

1. Remove the bag containing the battery box components.

2. Set the battery on the battery tray.

3. Install the battery hold down rods as shown in Figure 3-4.
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 a and b for the other battery hold down rod.

4. Connect the battery cables to the battery, be sure the Positive lead is connected to the
positive (+) battery terminal and the negative lead is connected to the positive (–)
battery terminal.

Figure 3-4 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.

Washers & Nut

Battery Tie Down

Use of Electric Motor Loads

Electric motors require much more current (amperes) to start them than to keep them running.
Some motors, particularly split–phase motors are very difficult to start and require 5 to 7 times
more current to start them. Repulsion–induction type motors are the easiest to start and normally
only require 2 to 3 times as much current to start them.

Most fractional horsepower motors take about the same amount of current to start them and
keep them running. This is true whether they are the repulsion–induction type motor, capacitor
type motor, or the split–phase type motor.

Other factors that influence the amount of current needed to start a motor are:

1. The type of load connected to the motor. If the electric motor is connected to a hard

2. The brand or design of the electric motor. The expected starting current for a

3. The condition of the electric motor. A clean motor with free turning bearings will

Battery

Washers & Nut

Battery Tie Down Bolt

Battery Rack

starting load such as an air compressor it will require more starting current. If the same
electric motor is connected to a light load such as a heater or power saw it will require
less starting current.

particular size motor will vary depending on the brand of the electric motor as well as
the type of electric motor (Split Phase, capacitor, Repulsion–induction type, etc.)

require less starting currents than a similar type motor that is dirty and the bearings are
not as free turning as they used to be.

Receiving & Installation 3-5MN2412

Optional Wheel Kit

MODEL

SUMMER

WINTER

OIL

RECOMMENDED

(AMPS) COLD

PDG2 – 2 Wheel Dolly Kit; and PDG4 – 4 Wheel Dolly Kit

An optional 2 or 4 wheel dolly kit is available for Powerchief portable generators. If you have
purchased one of these kits, refer to MN2409 for the installation instructions.

Recommended Engine Oil and Battery Type

Series PC

SUMMER WINTER OIL RECOMMENDED (AMPS) COLD

OIL

PC30H-17.10030 SAE. 30 5W/30 .85 PTS N/A N/A
PC50H-01,17.20050-01 SAE. 30 5W/30 1.90 PTS N/A N/A
PC60H-17.20060 SAE. 30 5W/30 2.0 PTS N/A N/A
PC60H-04, 17.20060-04 SAE. 30 5W/30 2.0 PTS N/A N/A
PC60HE-04, 17.20062-04 SAE. 30 5W/30 2.0 PTS Interstate SP-40 340
PC90VE - 17.10090 SAE. 30 5W/30 2.0 PTS Interstate SP-40 340

OIL

CAPACITY

BATTERY

CRANKING

3-6 Receiving & Installation MN2412

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 Panels

Press to Reset

120 VOLTS

120 VOLTS

CIRCUIT BREAKERS

Press to Reset

120/240 VOLTS

AC Circuit Breakers Provide overcurrent protection for the generator output. When tripped, the plunger (in

center of breaker) will extend out about 3/8 inch. Remove the loads, push the plunger
into the breaker to reset the breaker the restore the loads.

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 elastical 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.

Receptacles – Receptacles are provided to allow easy connection of electrical loads. Never connect this

generator to any buildings electrical system unless a licensed electrician has installed an
approved transfer switch. Multiple receptacles may be used at the same time provided the total
electrical load does not exceed the generators rated output.

120Volts – PC30H has no GFCI protection, 3 outlets rated 125VAC at 15 Amperes.

All others have NEMA 5–20R GFCI Duplex receptacle provides ground fault

protection. Rated 125VAC at 20 Amperes.
30 Amps 120 Volts – Twist lock NEMA L5–30R receptacle, rated 125 Volts at 30 Amperes.
30 Amps 120/240 Volts – Twist lock NEMA L14–30R receptacle rated 250Volts at 30 Amperes.

Note: The nominal voltage produced by the generator at each receptacle is 120VAC or 240VAC.

Operation 4-1MN2412

Pre–Start Checks

Start–Up Procedure

Electric Start

Recoil Start

Before the engine is started, several things must first be checked.

1. Place the generator set in an open, dry, well ventilated and reasonably level location.

2. If grounding is required for your application, check to make sure your unit is grounded
properly (see Section3).

3. Check the engine’s oil level and add oil if necessary to bring it to the level
recommended by the engine manufacturer.

4. Check the fuel level and add fuel to within 1/2 inch of the fill tube if necessary.

5. Open the fuel valve on the fuel tank.

6. Check the fuel system for fuel leaks and repair them prior to starting the engine. Wipe
up any fuel spills before starting the engine.

7. Disconnect or “turn off” all external loads.

8. Make sure all circuit breakers are set (pushed in).

9. Tighten any bolts or nuts that may have loosened due to vibration.

10. Be sure all extension cords are in good condition before starting the generator.
Use only U.L. listed extension cords.

1. Move the engine’s choke lever to the “Choke/Start” position. If the engine is warm or if
the ambient air temperature is high; try starting the engine without choking it.

2. Move the Control Panel Engine “ON/OFF” switch to “ON” (if equipped).

3. Engage the electric start motor.
(Push the engine’s start switch or turn the key switch fully clockwise).

4. Do not allow the starter motor to crank for more than 10 seconds at a time.

5. Allow 20 seconds between starter motor cranking attempts.

6. Once the engine has started, release the start switch and do not re–engage it.

Note: If the engine does not start after a few attempts, smell for fuel near the air cleaner. If there

is a significant gasoline smell, turn the choke lever off and attempt to start the engine.

7. When the engine starts, turn the engine’s choke lever to the “OFF” position.

8. Power is now present at the receptacles.
Connect or “turn on” the loads you wish to operate.

1. Move the engine’s choke lever to the “Choke/Start” position. If the engine is warm or if
the ambient air temperature is high; try starting the engine without choking it.

2. Move the Control Panel Engine “ON/OFF” switch to “ON” (if equipped).

3. Pull lightly on the recoil grip until you feel significant resistance, then pull sharply. Allow
the recoil to gently rewind into the recoil housing. See your engine manual for
instructions specific to your unit. Do not allow the recoil rope to “snap back” into the
recoil housing.

Note: If the engine does not start after turning the engine over a few times, smell for fuel near

the air cleaner. If there is a significant gasoline smell coming from the air cleaner, turn the
choke lever off and attempt to start the engine with the choke off.

4. When the engine starts, turn the engine’s choke lever to the “OFF” position.

5. Power is now present at the receptacles.
Connect or “turn on” the loads you wish to operate.

Stopping Procedure

1. Disconnect or “Turn Off” all loads connected to the generator set.

2. Move the Control Panel Engine “ON/OFF” switch to “OFF” (if equipped).

3. Push the engine stop switch if so equipped.
OR
Turn the engine key switch to the “OFF” position.

4. Turn all fuel valves off.

4-2 Operation MN2412

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 fuel clamps to ensure they are tight.

4. Make sure the fuel cap fits snugly on the fuel tank and that the fuel tank does not leak.

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

6. Inspect the external wire cables and connectors used with the generator set for cuts,
frayed insulation, or loose connections. Repair or replace damaged parts before use.

7. The engine should be checked for proper speed setting(s).
Prior to adjusting the engine speed, turn the auto idler switch to “OFF” (if present).
Make sure that the auto idler magnet does not touch the throttle lever of the engine
when running.

a. Disconnect all electrical loads and start the engine.
b. Adjust the engine speed to 3720 RPM (62 Hz) with no load speed.
c. Adjust the auto idler speed after you have accomplished the above adjustment.
d. Adjust the auto idler speed by moving the electro–magnet back and forth in the

magnet bracket to achieve an engine RPM of 2500–2900 with the auto idler switch
“ON”.

8. Test all GFCI receptacles monthly by pressing the test button on the receptacle and
making sure that the GFCI trips and and no voltage is present at the receptacle.
Replace any GFCI receptacle that fails the test.

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.

7. Inspect the recoil starting rope for any damage and replace it if necessary (if
applicable).

8. Clean the trash screen around the recoil starter or other cooling air intake.

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 5-1MN2412

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 (like flashing the
field) should be referred to the Baldor Generator Service Department by calling (920) 236–4200.

Table 5-1 Troubleshooting Guide

Problem Possible Cause Remedy

Engine will not start

Engine will not crank (electric start) Dead battery. Remove battery and trickle charge or replace with new 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 defective.

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
Electrical shock when frame is touched Static charge.

Mechanical noise Defective bearing

No fuel.
Restricted air flow.
No spark.

Debris or dirt buildup on engine

Loss of residual magnetism in exciter
field poles.

Open in stator windings
Defective exciter circuit.

Fluctuating speed (fixed speed mode)

Loose terminal or load connections
Defective bearing (uneven air gap)

Excessive load
High resistance connections -

connections will be warm or hot
Shorted field

Low power factor

Grounded armature or field coil.

Rotor rubbing on stator

Loose or misaligned coupling

Check that fuel valves are ON. Check fuel level in fuel tank.
Check/replace air filter.
Check/replace spark plug(s). Check that engine switch is in Start
position.

Never Jump Start.

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

Reset circuit breaker or replace if required.
Flash field.

Check for continuity in windings. Return to factory for repair if open.
Check/replace diode and capacitor and flash the field.

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 are proper and check tighness torque of
terminals.

Replace worn bearing
Check that the Auto Idle switch is in OFF position.

Check engine for malfunction or system for overload. Reduce load.
Verify all connections are proper and check tighness torque of

terminals.
Test field coils for possible short by checking resistance with an

ohmmeter or resistancebridge. Return rotor assembly to factory
forrepair if alternator field coils are shorted.

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

Replace bearing
Bad bearing - replace.

Bent shaft - return to factory.
Loose end bell - tighten;
Loose drive Discs - tighten

Tighten; align coupling and alternator shaft to engine shaft.

Service Service for your generator can be obtained from the service department at Baldor Generators by

calling (920) 236–4200. 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 the service department at Baldor Generators by

calling (920) 236–4200. 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.

5-2 Troubleshooting and Maintenance MN2412

Appendix A
PowerchiefR Series

Information in this Appendix applies to the following Baldor Generators:

PC30H, PC40H, PC50H, PC60H, PC90VE

Caution: The brass connecting tab on some 120VAC duplex receptacles have been removed. Each

receptacle is powered by a separate generator winding. When replacing a receptacle, inspect
the brass tab that normally links both receptacles. If it is removed, be sure to remove the
brass tab from the replacement receptacle before it is installed. Failure to remove the tab will
cause a direct short to the generator windings and cause possible generator damage.

Operator Panel Configuration

Figure A-1 PC30H Operator Panel

Duplex Receptacle.
Duplex receptacle is rated at 125VAC, 15 Amps.

Press to Reset

Receptacle. Single style receptacle rated for 125VAC, 15 Amps.

Circuit Breaker.

Provide overload protection for the generator set.

120 VOLTS

CIRCUIT BREAKERS

Press to Reset

Figure A-2 PC40H, PC50H, PC60H, PC90VE Operator Panel

NEMA 5-20R GFCI Receptacle.
This ground fault circuit interrupter duplex receptacle is rated at 125VAC, 20 Amps.

NEMA L5-30R Receptacle. Twist-lock style receptacle rated for 125VAC, 30 Amps.

120 VOLTS

120/240 VOLTS

NEMA L14-30R Receptacle. Twist-lock style receptacle rated for 125/250VAC, 30 Am

Circuit Breakers.

Provide overload protection for the generator set.

MN2412

PowerchiefR Series A-1

Replacement Parts

1

2

3

Replacement parts assembly views for the Generator set are shown in Figure A-3 and A-4.
Parts information is provided in Table A-1. Parts information for the engine is provided in the
engine manual that was provided with your generator set. Please refer to the engine manual for
replacement parts information.

Figure A-3 Alternator Assembly

5

6

10 11 12

7

4

Figure A-4 Frame Assembly

22

23

HB7002A07

OR

HB7002A08

21

20

Table A-1 Generator Set Parts List

Ref No. Part No. Description PC30H PC40H PC50H PC60H PC90VE

1 HA9139A00 Adaptor X
1 HA9139A01 Adaptor X X X X
2 HA1037A00 C" Washer X X X X X
3 61FN3000 Fan X X X X X
4 61RA0011A00 Rotor Assembly (includes bearing) X
4 61RA0013A00 Rotor Assembly (includes bearing) X X
4 61RA0015A00 Rotor Assembly (includes bearing) X
4 61RA0016A00 Rotor Assembly (includes bearing) X
5 61SA0019A02 Stator Assembly X
5 61SA0010A04 Stator Assembly X X
5 61SA0013A07 Stator Assembly X
5 61SA0022A00 Stator Assembly X
6 61EP3204A01 Bearing Bracket (bearing included with rotor) X X X X X
7 EH0320A00 Cover X X X
7 EH0321A00 Cover X
7 EH0322A00 Cover X

21

A-2 PowerchiefR Series

MN2412

Table A-1 Generator Set Parts List

Ref No. Part No. Description PC30H PC40H PC50H PC60H PC90VE

10 WD1541A00 Receptacle, 125VAC at 15 Amps X
10 WD1541A03 Receptacle, 125VAC at 15 Amps X
10 WD1541A33 GFCI Duplex Receptacle, 250VAC at 20 Amps, NEMA 5-20R X X X X X
11 WD1541A10 Receptacle, 125VAC at 30 Amps, NEMA L5-30R X X X X X

12 WD1541A14 Receptacle, 125/250VAC at 30 Amps, NEMA L14-30R X X X X
Not Shown EH0301A00 Control Box (Operator Panel) X X X
Not Shown HB6040A01 Control Panel Cover (Operator Panel) X X X
Not Shown EH0315A00 Control Box (Operator Panel) X
Not Shown EH0330A00 Control Panel Cover (Operator Panel) X
Not Shown DI0176A01 Diode X X X X X
Not Shown RR0244A00 Varistor X X X X
Not Shown OC3020F12 Capacitor, 20MFD / 370V X
Not Shown OC6030F11 Capacitor, 30MFD / 370V, 90 degree X X X X
Not Shown CK0070A01 Circuit Breaker 15Amp X
Not Shown CK0070A03 Circuit Breaker 30Amp X X
Not Shown CK0070A04 Circuit Breaker 40Amp X X X
Not Shown CK0070A05 Circuit Breaker 50Amp X
Not Shown CK0070A06 Circuit Breaker 25Amp X
Not Shown TA0002A03 Fuel Cap (with-out Gauge) X X X X
Not Shown TA0000A03 Fuel Tank X X X X
Not Shown EA0011A00 Fuel Filter, in-line X X X X
Not Shown EA0035A00 Spark Deflector X
Not Shown EA0022A01 Spark Arrestor Screen X

20 BA0188A00L2B Base Frame X X X

20 BA0203A00L2B Base Frame X

20 BA209A00L2B Base Frame X

21 HB7025A00Z Engine Mounting Foot X X X X

22 HB7002A07 Engine end frame cross member X X X

22 HB7002A08 Engine end frame cross member X

23 HB6150A01 Alternator end frame cross member X X X X
Not Shown RM1088A05 Isolator, Engine end and generator end X
Not Shown RM1088A06 Isolator, Generator end X X X X
Not Shown RM1088A07 Isolator, Generator end X X X X
Not Shown HB6116A00 Battery Tie Down X
Not Shown HA3187A12 Battery Tie Down Bolt X
Not Shown LB0094B15 Decal, 120V X
Not Shown LB0094B23 Decal, Press to Reset" X
Not Shown LB0094A35 Decal, Warning X X X X
Not Shown LB0094A56 Decal, X
Not Shown LB0094A92 Decal, PC Series X X X X
Not Shown LB9606A02 Decal, Baldor Logo, 6.35" X X X X X
Not Shown LB9606A04 Decal, Baldor Logo, 5.65" X X X X
Not Shown LB9606A01 Decal, Baldor Logo, 4" X X X X
Not Shown LB9606A05 Decal, Baldor Logo, 7.53" X
Not Shown LB9636A00 Decal, PC30H X
Not Shown LB96 Decal, PC40H X
Not Shown LB96 Decal, PC50H X
Not Shown LB96 Decal, PC60H X
Not Shown LB96 Decal, PC90VE X

Continued

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

MN2412

PowerchiefR Series A-3

Figure A-5 PC30H Wiring Diagram

A-4 PowerchiefR Series

MN2412

Figure A-6 PC40H Wiring Diagram

MN2412

PowerchiefR Series A-5

Figure A-7 PC50H Wiring Diagram

A-6 PowerchiefR Series

MN2412

Figure A-8 PC60H Wiring Diagram

MN2412

PowerchiefR Series A-7

Figure A-9 PC90VE Wiring Diagram

A-8 PowerchiefR Series

MN2412

UNITED STATES

ARIZONA

PHOENIX
4211 S 43RD PLACE
PHOENIX, AZ 85040
PHONE: [phone]
FAX: [phone]

CALIFORNIA

LOS ANGELES
6480 FLOTILLA
COMMERCE, CA 90040
PHONE: [phone]
FAX: [phone]

HAYWARD
21056 FORBES STREET
HAYWARD, CA 94545
PHONE: [phone]
FAX: [phone]

COLORADO

DENVER
2520 W BARBERRY PLACE
DENVER, CO 80204
PHONE: [phone]
FAX: [phone]

CONNECTICUT

WALLINGFORD
65 SOUTH TURNPIKE ROAD
WALLINGFORD, CT 06492
PHONE: [phone]
FAX: [phone]

FLORIDA

TAMPA/PUERTO RICO/
VIRGIN ISLANDS
3906 EAST 11TH AVENUE
TAMPA, FL 33605
PHONE: [phone]
FAX: [phone]

GEORGIA

ATLANTA
62 TECHNOLOGY DR.
ALPHARETTA, GA 30005
PHONE: [phone]
FAX: [phone]

ILLINOIS

CHICAGO
795 MITTEL DRIVE
WOOD DALE, IL 60191
PHONE: [phone]
FAX: [phone]

INDIANA

INDIANAPOLIS
5525 W. MINNESOTA ST.
INDIANAPOLIS, IN 46241
PHONE: [phone]
FAX: [phone]
800-428-4141

IOWA

DES MOINES
1901 BELL AVE., SUITE 7
DES MOINES, IA 50315
PHONE: [phone]
FAX: [phone]

MARYLAND

BALTIMORE
6660 SANTA BARBARA RD
SUITE 22-24
ELKRIDGE, MD. 21075
PHONE: [phone]
FAX: [phone]

MASSACHUSETTS

BOSTON
317 BROOKS ST.
WORCESTER, MA 01606
PHONE: [phone]
FAX: [phone]

MICHIGAN

DETROIT
33782 STERLING PONDS BLVD.
STERLING HEIGHTS, MI 48312
PHONE: [phone]
FAX: [phone]

GRAND RAPIDS
668 3 MILE ROAD NW
GRAND RAPIDS, MI 49504
PHONE: [phone]
FAX: [phone]

MINNESOTA

MINNEAPOLIS
21080 134TH AVE. NORTH
ROGERS, MN 55374
PHONE: [phone]
FAX: [phone]

MISSOURI

ST LOUIS
422 INDUSTRIAL DRIVE
MARYLAND HEIGHTS, MO 63043
PHONE: [phone]
FAX: [phone]

KANSAS CITY
915 N W PLATTE VALLEY DR
RIVERSIDE, MO 64150
PHONE: [phone]
FAX: [phone]

NEW YORK

AUBURN
ONE ELLIS DRIVE
AUBURN, NY 13021
PHONE: [phone]
FAX: [phone]

NORTH CAROLINA

GREENSBORO
1220 ROTHERWOOD ROAD
GREENSBORO, NC 27406
P O BOX 16500
GREENSBORO, NC 27416
PHONE: [phone]
FAX: [phone]

OHIO

CINCINNATI
2900 EARHART COURT
SUITE 200
HEBRON, KY 41048
PHONE: [phone]
FAX: [phone]

CLEVELAND

8929 FREEWAY DRIVE
MACEDONIA, OH 44056
PHONE: [phone]
FAX: [phone]

OKLAHOMA
TULSA

2 EAST DAWES
BIXBY, OK 74008
PHONE: [phone]
FAX: [phone]

OREGON

PORTLAND
20393 SW AVERY COURT
TUALATIN, OR 97062
PHONE: [phone]
FAX: [phone]

PENNSYLVANIA

PHILADELPHIA
1035 THOMAS BUSCH
MEMORIAL HIGHWAY
PENNSAUKEN, NJ 08110
PHONE: [phone]
FAX: [phone]

PITTSBURGH
616H BEATTY ROAD
MONROEVILLE, PA 15146
PHONE: [phone]
FAX: [phone]

Baldor District Offices

TENNESSEE

MEMPHIS
4000 WINCHESTER ROAD
MEMPHIS, TN 38118
PHONE: [phone]
FAX: [phone]

TEXAS

HOUSTON
4647 PINE TIMBERS
SUITE # 135
HOUSTON, TX 77041
PHONE: [phone]
FAX: [phone]

DALLAS
3040 QUEBEC
DALLAS, TX 75247
PHONE: [phone]
FAX: [phone]

ODESSA
6968 EAST COMMERCE
ODESSA, TX 79762
PHONE: [phone]
FAX: [phone]

UTAH

SALT LAKE CITY
2230 SOUTH MAIN STREET
SALT LAKE CITY, UT 84115
PHONE: [phone]
FAX: [phone]

WISCONSIN

MILWAUKEE
2725 SOUTH 163RD STREET
NEW BERLIN, WI 53151
PHONE: [phone]
FAX: [phone]

INTERNATIONAL SALES

FORT SMITH, AR
BALDOR ELECTRIC CO
FORT SMITH, AR 72902
PHONE: [phone]
FAX: [phone]

CANADA
EDMONTON, ALBERTA

4053-92 STREET
EDMONTON, ALBERTA T6E6R8
PHONE: [phone]
FAX: [phone]

OAKVILLE, ONTARIO
2750 COVENTRY ROAD
OAKVILLE, ONTARIO L6H6R1
PHONE: [phone]
FAX: [phone]

MONTREAL, QUEBEC
1844 WILLIAM STREET
MONTREAL, QUEBEC H3J1R5
PHONE: [phone]
FAX: [phone]

VANCOUVER,
BRITISH COLUMBIA
1538 KEBET WAY
PORT COQUITLAM, BC V3C 5M5
PHONE [phone]
FAX: [phone]

WINNIPEG, MANITOBA
54 PRINCESS STREET
WINNIPEG, MANITOBA R3B1K2
PHONE: [phone]
FAX: [phone]

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: [phone]
FAX: [phone]

CHINA

SHANGHAI JIAHUA BUSINESS CENTER
ROOM NO. C-203
808 HONG QIAO ROAD
SHANGHAI 200021
PHONE: [phone]
FAX: [phone]

EL SALVADOR

BALDOR CENTROAMERICA
RESIDENCIAL PINARES DE SUIZA
POL. 15 #44, NVA. SAN SALVADOR
EL SALVADOR, CENTRO AMERICA
PHONE: [phone]
FAX: [phone]

FRANCE

2, RUE DU VALLON
94440 MAROLLES EN BRIE
PHONE: [phone]
FAX: [phone]

GERMANY

DIESELSTRASSE 22
D-85551 KIRCHHEIM
MUNICH, GERMANY
PHONE: (49) (89) 90508 - 0
FAX: (49) (89) 90508 - 491

ITALY

Baldor ASR AG
Mendrisio Office
Via Borromini, 20A
6850 Mendrisio
Switzerland
PHONE: [phone]
FAX: [phone]

JAPAN

NEO MIME 501
2-5 DAIMACHI,
KANAGAWA-KU
YOKOHAMA, 221-0834, JAPAN
PHONE: [phone]
FAX: [phone]

MÉXICO

BLVD. AL AEROPUERTO, KM. 2
LEÓN 37545, GUANAJUATO,
MÉXICO
PHONE: [phone]
FAX: [phone]

PANAMA

BALDOR SUDAMERICA
9109 0818, ZONA 6 BETHANIA
PANAMÁ CITY, REP. DE PANAMÁ
PHONE: [phone]
FAX: [phone]

SINGAPORE

51 KAKI BUKIT ROAD 2
K B WAREHOUSE COMPLEX
SINGAPORE 417863
PHONE: [phone]
FAX: [phone]

SWITZERLAND

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

TAIWAN

ROOM R, 2F, NO. 124
CHUNG CHENG ROAD, SHIHLIN DIST.
TAIPEI 11141
PHONE: [phone] EXT. 802
FAX: [phone]

UNITED KINGDOM

6 BRISTOL DISTRIBUTION PARK
HAWKLEY DRIVE
BRISTOL BS32 0BF U.K.
PHONE: [phone]
FAX: [phone]

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
MN2412

BALDOR GENERATORS

3815 Oregon Street

Oshkosh, WI 54902

(920) 236–4200 or (800) 872–7697

Fax [phone]

www.baldor.com

Printed in USA

4/04 C&J1500