Baldor TS175, TS80, TS45, TS25, TS130 User Manual 2
PRESENTS YOUR
BALDOR GENERATORS
3815 OREGON STREET OSHKOSH WI 54902
PHONE: 920–236–4200 FAX: 920–236–4219
REVISED/EFFECTIVE MAY 1, 2003 C:\ISO9001\FORMS\SPSG–002–48msw
FORM#: S–PSG–002–48
TOWABLES
OPERATOR’S MANUAL
Table of Contents
ACCESSORIES AND EQUIPMENT WITH THIS GENERATOR SET INCLUDES:
ITEM PAGE
SAFETY RECOMMENDATIONS: These recommendations must be read and followed 1
to safely operate your generator set.
VOLTAGE RATINGS: This informational page describes features and specifications for 7
all Towable Units.
ELECTRICAL CONNECTION INFORMATION: This information explains how to interface 9
your generator with the AC loads and other standard and optional accessories.
CONTROL PANEL: This includes a drawing of the control panel and a description of 11
the components associated with it.
PRE–START PROCEDURE: This described a pre–start check that should be performed 14
prior to initial start–up.
OPERATION GUIDE: Information on how to start, stop, and operate the generator set 15
is included here. Included also is information in regards to the operation of the
genset/ engine control device and the different fault shutdown circuits designed to
protect the generator set from potential engine operational problems.
TROUBLESHOOTING GUIDE: Included in this guide are basic instructions to help 18
troubleshoot most problems with your generator set. For more troubleshooting
help please contact the service department at Baldor Generators
HIGHWAY TRAILER: This includes information in regards to safe operation, proper 23
utilization, and recommended guidelines for using and operating the trailer.
BALDOR GENERATORS W ARRANTIES: this details the warranty provided by Baldor 27
Generators for coverage for electrical generator end of the generator set.
OTHER MANUALS AND ACCESSORIES THAT SHOULD ACCOMPANY YOUR TOWABLE
GENERATOR:
ENGINE OPERATOR’S MANUAL: This operator’s manual includes information in regards to
the operation and maintenance of the engine utilized in this generator set.
AC GENERATOR, ACCESSORIES, AND LOAD CONNECTION DIAGRAMS / ENGINE
CONTROLS, ACCESSORIES, AND REMOTE CONNECTION DIAGRAMS: These diagrams contain in-
formation in regards to the internal wiring of the generator set, specifically the AC and
Engine Control circuits. These diagrams will also include information for any optional AC
or DC powered accessories that are included.
PARTS LIST: This is a listing of all parts used by Baldor Generators to build this specific generator set.
SAFETY WARNINGS
z Place protective covers and guards over the rotating parts, if rotating parts such as the drive shaft, pulley,
belt, etc. are left exposed, they are potentially hazardous.
z When cleaning, repairing or inspecting, make sure all moving parts have stopped.
z Prior to working on the generator set, disconnect the spark plug and battery to prevent accidental starting.
z Use only original equipment or authorized replacement parts. Use of correct parts will assure the operator
of the safety integrity that was designed into the unit.
z Unauthorized modifications to the generator set may impair the function and/or safety of the unit.
z Do not operate the generator set without a muffler. Inspect periodically and replace if necessary.
z Do not touch the hot exhaust components or the high voltage spark plug and coil terminals. While Spark
Plug Voltages are not normally lethal, an involuntary jerk of the hand caused by a hot surface or by
an electrical shock can result in injury.
z Repair of electrical generating equipment requires specialized skills. Repair personnel must have a
thorough understanding of generator and small engine repair procedures.
z Never inhale exhaust gases. They contain carbon monoxide; a colorless, odorless and extremely
dangerous gas that can cause unconsciousness or death. Symptoms of carbon monoxide poisoning
can include: dizziness, nausea, headaches, sleepiness, vomiting or incoherency. If you or anyone else
experiences any of these symptoms, get out into the fresh air immediately. Shut the unit down and
do not operate it until it has been inspected and, if necessary, repaired.
z Never Operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave.
z CALIFORNIA PROPOSITION 65 WARNING: engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects or other reproductive harm.
z Know how to stop the engine quickly and understand the operation of all controls.
Revised: 8/13/02 Page 1 of 4 FORM#: S–PSG–001–3
Effective: 2/27/98 C:\ISO9001\FORMS\SPSG0013.msw.bbk
1
SAFETY WARNINGS
z Never permit anyone to operate the generator set without proper instructions.
z Never allow children to operate the generator set.
z Children and pets must be kept away from the area of operation due to the possibility of burns from hot
engine components or injury from any equipment the generator set is powering.
z Always wear eye protection and Hearing protection when working near the generator set.
z Operate the generator set only with the guards, shields and other safety items in place and working
properly.
z Do not put hands, feet, tools or other objects near rotating parts.
z Use reasonable care when moving or lifting the unit. The generator set may move around inside the wrap
frame creating ”Pinch Points”.
z Do not run the generator set while it is being moved.
z Do not support the generator set from the top of the wrap frame.
z Do not operate the generator set while under the influence of alcohol, drugs or medication.
z When transporting or using a generator set with the wheel option, secure the unit to prevent it from moving
around.
z Do not tamper with or change the engine speed as it has been preset at the factory for proper operation.
z Keep hands and face away from the carburetor when the air cleaner is being moved. A sudden backfire
can cause serious burns.
z Be careful of hot parts. The muffler and other generator parts become very hot while the engine is running.
z Do not ”jump start” the generator set.
z Sulfuric acid can cause severe injury and can give off gases, which are corrosive and potentially explosive.
Avoid contact with skin, eyes, and clothing. In case of contact, flush area immediately with water.
z When transporting a generator set, secure it to prevent it from moving or shifting.
z Know how to stop the engine quickly and understand the operation of all controls.
z Do not operate electrical equipment while standing in water, on wet ground or with wet hands or shoes.
z Use extreme caution when working on electrical components. Potentially dangerous voltage is present
when the engine is running.
Revised: 8/13/02 Page 2 of 4 FORM#: S–PSG–001–3
Effective: 2/27/98 C:\ISO9001\FORMS\SPSG0013.msw.bbk
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SAFETY WARNINGS
z Always treat the electrical circuits as if they were energized.
z Disconnect all leads plugged into the unit Prior to working on it.
z Have the electrical circuits serviced only by qualified technicians.
z Inspect wiring frequently and replace frayed, broken or poor leads.
z Do not connect this unit to any building’s electrical system unless you utilize an approved transfer switch or
the main service entrance switch has been disconnected and locked open.
z Circuit overload protection must be provided in accordance with national electrical codes and local
regulations.
z Check GFCI Receptacles monthly by using the ”Test” and ”Reset” buttons designed into them.
z Depending on your application it may be mandatory to ground or not ground this unit to earth ground.
Comply with local electrical codes.
```` FOR GASOLINE OR DIESEL POWERED GENERATOR SETS ````
z Operate the generator set on a level surface. If the generator set is tilted, fuel spillage may result.
z Handle fuel with care. It is highly flammable. Use only clean, properly marked and approved safety
containers for refueling and storing fuel.
z Stop the engine and allow it to cool before refueling.
z 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.
z If fuel is spilled, wipe it up carefully and wait until the fuel has dried before starting the engine.
z Make sure the fuel cap is properly closed after refueling.
z Never operate the generator set while smoking.
z Never operate the generator set near an open flame.
z Never store the generator set with fuel in the tank indoors or in an enclosed, poorly ventilated enclosure
where fuel fumes may reach an open flame, electrical spark or pilot light as on a furnace, water heater,
clothes dryer, etc.
z When transporting over long distances or rough roads, drain the fuel tank to prevent leakage and spillage.
Revised: 8/13/02 Page 3 of 4 FORM#: S–PSG–001–3
Effective: 2/27/98 C:\ISO9001\FORMS\SPSG0013.msw.bbk
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SAFETY WARNINGS
```` FOR GASOLINE OR DIESEL POWERED GENERATOR SETS ````
z Check all fuel supply piping and their connections on a monthly basis for fuel leaks.
z Use only approved piping and componentry in your fuel supply system.
z A professional, experienced technician should only install the fuel supply system.
z Do not run the fuel line up against any sharp objects.
z Comply with NFPA regulations and your local codes in regard to shut–off valves, regulators, etc. and any
other recommendations or requirements they may have.
z Keep the generator set at least three feet away from buildings or other structures.
z Keep the generator set away from flammable and other hazardous materials (trash, rags, lubricants,
explosives, paints, etc.)
z Keep the generator set free of grass, leaves and excessive grease and oils.
z Allow the generator set to cool before transporting it or storing it indoors.
z Have fire extinguisher accessible and nearby while operating the generator set.
z This generator set 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 arrester and it must be maintained
in effective working order by the operator.
z Operation inside an enclosed compartment or building is a potential fire hazard and should not be done
unless approval is obtained from Baldor Generators. Engine/Generator overheating can cause severe
damage due to restricted, obstructed or improper air–flow that is necessary for the proper cooling of the
unit.
z Hot exhaust gases being discharged by the engine must never be directed toward anything that could
catch fire or explode.
Revised: 8/13/02 Page 4 of 4 FORM#: S–PSG–001–3
Effective: 2/27/98 C:\ISO9001\FORMS\SPSG0013.msw.bbk
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FORWARD
This manual contains the information you need to safely and efficiently operate your generator
set. During the preparation of this manual every effort was made to ensure the accuracy of its
contents.
Never operate this generator set without first carefully reading this manual and observing all the
safety warnings it presents. While safety is built into every Baldor Pow’R Gard generator set,
careless or improper operation could possibly result in mechanical failure, property damage, severe injury or death.
Note that this manual covers only very basic information in regards to the engine. A separate
owner’s manual for the engine is supplied with this unit for your use. Please refer to this manual
for information relative to engine operation, maintenance, recommendations and additional
safety warnings.
As soon as you receive your generator set, inspect it closely for shipping damage. If you find
some damage, notify the transportation company immediately and file a freight damage claim.
Think of this manual as a tool to help you get the most out of your generator set. We strongly
suggest that you keep this manual with your generator set and refer to it when questions arise
in regards to its operation.
Baldor Generators, formerly Pow’R Gard Generator Corporation has been in business since
1965. The generator sets we manufacture have earned the reputation of being of high quality
and a dependable product. 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.
Thank you for purchasing your Baldor Pow’R Gard Generator Set.
Effective: February 26, 1998
Revised 2/01/02
Form#: S–CSD–003–7 C:\ISO9001\FORMS\SCSD0037.MSW
5
Effective: February 26, 1998
Revised 2/01/02
Form#: S–CSD–003–7 C:\ISO9001\FORMS\SCSD0037.MSW
6
Features & Specifications
Model TS25 TS45 TS80 TS130 TS175
Standby output– 1500C Rise
G
G
E
(KVA/KW):
3 PH @ 480 Volt 25/20 48/38 81/65 134/107 175/140
3 PH @ 208/240 Volt 25/20 46/37 72/58 131/105 169/135
1 PH @ 240 Volt 18/18 27/27 45/45 70/70 80/80
Continuous Output–
1250C Rise (KVA/KW):
3 PH @ 480 Volt 23/18 44/35 75/60 121/97 169/135
3 PH @ 208/240 Volt 23/18 44/35 69/55 119/95 156/125
1 PH @ 240 Volt 18/18 25/25 43/43 66/66 75/75
Voltage – 3 PH Adjustable 208/220/240/
N
E
Voltage – 1 PH Adjustable 120/127/139/
R
A
T
O
R
E
N
G
I
N
E
Amperage (Continuous):
3 PH 480 Volt 27.1 52.6 90.2 145.8 203.0
3 PH 208 Volt 62.5 121.4 190.8 329.6 433.7
3 PH 240 Volt 54.1 105.3 165.4 285.7 375.9
1 PH 240 Volt/120 Volt 75.0/150.0 104.2/208.3 179.2/358.3 275/550 312.5/625.0
Receptacles:
120 Volt, 15 Amp GFCI 4 6 6 6 6
120/240 Volt, 50 Amp,
CS6369 Twistlock
Voltage Regulation 1/2% 1/2% 1/2% 1/2% 1/2% 1/2%
Power Factor – 3 Phase 0.8 0.8 0.8 .08 .08
Total Harmonic Distortion <5% <5% <5% <5% <5%
Engine Make/Model Isuzu
Fuel Consumption (GPH):
Approx. Run Time (Hrs.):
Battery Recommendation Min. Cold
(Battery not included)
Frequency 50 or 60 Hertz 50 or 60 Hertz 50 or 60 Hertz 50 or 60 Hertz 50 or 60 Hertz
Insulation Class F Class F Class F Class F Class F
Design Water Cooled
Starting System 12 VDC 12 VDC 12 VDC 12 VDC 12 VDC
Displacement (cid) 133.0 264.2 276.0 414.0 498.0
Cylinders 4 4 4 6 6
HP @ Rated Speed 34.5 64.0 100.0 166.0 211.0
RPM 1800 1800 1800 1800 1800
Safety Shutdowns:
High Temperature Std. Std. Std. Std. Std.
Low Oil Std. Std. Std. Std. Std.
Overspeed Std. Std. Std. Std. Std.
Overcrank Std. Std. Std. Std. Std.
Fuel Capacity 50 80 80 160 160
1/2 Load 1.3 2.0 2.7 4.2 5.6
Full Load 2.0 3.4 4.9 8.1 10.5
1/2 Load 38 40 30 38 29
Full Load 25 24 16 20 15
Cranking Amps
416/440/460/480
240/254/277
2 3 3 3 3
4LE
4 Cycle Diesel
750 900 900 (2) 750 (2) 750
208/220/240/
416/440/460/480
120/127/139/
240/254/277
Isuzu
4BG1
Water Cooled
4 Cycle Diesel
208/220/240/
416/440/460/480
120/127/139/
240/254/277
John Deere
TO4045T
Water Cooled
4 Cycle Diesel
208/220/240/
416/440/460/480
120/127/139/
240/254/277
John Deere
TO6068
Water Cooled
4 Cycle Diesel
208/220/240/
416/440/460/480
120/127/139/
240/254/277
John Deere
RG6081T
Water Cooled
4 Cycle Diesel
Dimensions (L x W x H):
With Trailer 123” x 62” x 70” 139” x 60” x 81” 139” x 60” x 81” 163” x 66” x 94” 163” x 66” x 94”
Without Trailer 74” x 38” x 52” 84” x 38” x 61” 84” x 38” x 61” 108” x 42” x 74” 108” x 42” x 74”
Weight (Lbs.):
Without Fuel 2265 3540 3848 5600 6200
Without Fuel & Trailer 1790 2829 3053 4610 5205
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8
SWITCHABLE
ELECTRICAL CONNECTION INFORMATION
WARNING: High voltage may be present at receptacles and load studs while engine is
operating – DANGER of electrical shock is present. Use extreme care.
LOAD RECEPTACLES
1. Voltage is present in 120/240 volt switch position only.
2. Load wires may be brought into receptacle compartment through access door at control station.
HARD WIRE LOAD TERMINAL BLOCK
1. Voltage available at load block is outlined in chart below.
2. Cables must be brought into load block compartment through access hole in base of trailer.
3. Opening load block door will cause load disconnect to trip.
4. Do not start engine with load turned “on”. Allow engine to come up to speed and warm up (1).
5. If left unattended, lock all doors to prevent tampering or injury.
AVAILABLE VOLTAGE:
SWITCH POSITION
277/480 1–2–3 = 480 VAC, 3 Phase
1–N, 2–N, 3–N = 277 VAC, 1 Phase
120/240 1–2–3 = 240 VAC, 3 Phase
2–3 = 240 VAC, 1 Phase
2–N, 3–N = 120 VAC, 1 Phase
1–N = 180 – 200 VAC, Wild Leg
120/208 1–2–3 = 208 VAC, 3 Phase
2–3 = 208 VAC, 1 Phase
1–N, 2–N, 3–N = 120 VAC, 1 Phase
STUD
NOTE: To prevent damage to loads and generator, select voltage switch position prior to starting
engine.
NOTE: Upon switching voltage selector switch, adjust voltage and adjust rheostat (located on engine
control panel) for proper voltage.
Revised: October 3, 2002 D:\ISO9001\FORMS\MSW’98bbk
Effective: April 23, 1999
Form#: S–PSG–001–15
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CONNECTION INFORMATION
Your new Baldor Generator has all interconnecting wiring terminated at a junction box. All wiring will be
clearly labeled as being load; remote start contacts and AC input terminals and are to be connected as
described below.
Load – These connections are rated and sized according to the KW of the generator. Proper lead
wire from these points to the automatic transfer switch (or load switching device) is mandatory.
See enclosed transfer switch information for corresponding generator input terminals.
Remote Start Contacts – This two–wire connection, once connected to an appropriate switch,
will start the generator and perform as described in the remote start/stop literature. These
contacts are connected to the “Engine Start Contacts” of the automatic transfer switch.
A Two Pole normally open, closed to operate switch may also be used to start the generator.
AC Input – These connections are for units with float type battery chargers or engine block
heater combinations. A Constant supply of 120 volts AC (or as specified) is needed at these
terminals to power these devices.
NOTE: Power is not required when the unit is in operation. Internal battery charging and radiant heat
during operation eliminate the need for these devices.
NOTE: It is recommended that units utilizing an automatic transfer switch with adjustable time delays
have the initial adjustments made prior to start–up.
Factory recommendations are; allow a 2 second delay on start–up, 15–second delay on emergency to
normal.
Revised: March 20,2001 D:\ISO9001\FORMS\MSW’98bbk
Effective: April 23, 1999
Form#: S–PSG–001–19
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CONTROL PANEL OPERATION
AND FUNCTION
A. MASTER CONTROL SWITCH – This switch controls the starting and stopping of the engine via
the engine control logic circuitry.
With this switch in the “Manual” mode, the engine will start and run immediately after a
10 – 20 second time delay.
CAUTION: Please note that once the engine has been told to start, the gen set
should be treated as though it is operational, even though the start
delay has not yet allowed the engine to crank.
With this switch in the “Automatic” mode, the engine can be started and stopped from a remote
contact. (Standard switch, transfer switch, etc.) There is a time delay, to cool down, of 60–90
seconds when the unit is shut down from the remote contacts while the Master Control Switch is in
the “Automatic Mode.
With this switch in the “Off” position, the engine will immediately stop. The position must also be
utilized to clear fault shut–down conditions.
B. PANEL LIGHTS – By turning on the panel light switch, the panel lights will be energized and will
illuminate the control panel. The fuse next to the switch is to protect this circuit from damage due to
excessive current.
C. FIELD AND CONTROLLER FUSES – These fuses protect the internal workings of the generator
set.
D. GAUGES – These gauges monitor some of the more critical operating parameters of the engine as
well as the run time of the generator set.
The Voltmeter displays the charging rate that is currently being produced by the engine’s alternator to
facilitate the charging of the battery. This gauge should normally be above 12.5V whenever the unit is
running. If you ever notice the gauge is reading below 12V while the engine is running please contact
the service department at Baldor Generators.
The Temperature Gauge monitors and displays the operating temperature of the engines coolant. The
point at which a fault shut–down will occur is approximately 230°F.
The Oil Pressure Gauge displays and monitors the current operating pressure of the engine’s oil
system. The trip point at which a fault shutdown will occur is approximately 15 PSI or below.
Fuel level is checked by the owner or is usually a separately supplied fuel tank.
The Hour Meter accumulates and displays the total running time of the generator set.
11
E. VOLTAGE ADJUST – The rheostat allows the user to “fine tune” the generator set’s voltage
output. It is normally used to adjust output voltage after switching the output of the generator set to a
different voltage.
F. METERS – These meters monitor and display the current operating parameters of the generator set.
The Voltmeter monitors and displays the current operating AC output of the generator set.
The Hertz Meter monitors and displays the current operating frequency of the generator set.
The ammeter monitors and displays the amount of current that is being delivered by the generator set.
This meter works in conjunction with the Voltmeter Switch (Item G) in determining which output leg
to monitor.
G. AMMETER SWITCH – The switch allows the user to switch between L1, L2 and L3 to monitor the
current in each output leg of the generator.
H. PANEL LIGHT – By turning on the panel light switch, the panel lights (Not pictured on diagram)
will be energized and will illuminate the control panel.
I – SYSTEM FAULT INDICATORS – These lights will come on when a fault condition or a warning
condition develops.
The “Low Oil Pressure” light will come on when the engine’s oil pressure drops below 15 PSI. This
condition will trigger a fault shut–down and the unit will stop.
The “Over–crank” light will come on when the engine has failed to start after four attempted crank
cycles. Each crank cycle consists of a 12 second time period followed by a 12 second rest time
period.
The “Over–speed” light will come on when the engine’s operating speed rises above it’s normal
operating parameters. This condition will trigger a fault shut–down and the engine will stop.
High Temperature light will come on when the engine’s operating temperature exceeds the safety
set–point.
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OPERATION – PRE–START PROCEDURE
1. Fill system fuel tank with clean, fresh diesel fuel.
CAUTION: Wipe up any and all fuel spillage.
2. Fill engine crankcase to full mark with clean, fresh lubricating oil per attached engine operating guide.
3. Radiator coolant should be checked at the beginning of each day and filled in compliance with the engine
manufacturer’s guidelines.
4. Secure the generator for operation.
Skid mounted – the power generating system should be mounted to a smooth,
hard surface suitable for supporting the system under all stress conditions.
Trailer mounted – block wheels to prevent accidental movement.
Adequate clearance must be provided for access doors to fully open.
NOTE: The generating system exhaust also exits radiator end. When
positioning a generator system ensure position does not cause a
concentration of toxic emissions.
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