Baldor TS35, TS45, TS60, TS400, TS80, TS175, TS130, TS250 manual General, Engine

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Section 5

Troubleshooting and Maintenance

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.

Caution: If a dead battery is suspected charge battery (or replace), and then attempting starting. Damage to engine control may result from jump starting.

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

General:

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

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

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

4.Make sure the fuel cap fits snugly on the fuel tank and that the fuel tank contains no leaks.

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, fraying, or loose connections. Repair or replace any problems prior to using the unit.

Engine:

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

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

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

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

5.Inspect and clean all governor and fuel supply linkages so they operate properly.

Alternator: ( also called Generator End)

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 may not keep perfect time.

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.)

MN2417

Troubleshooting and Maintenance 5-1

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Contents Tier 2/3 Towable Generators Trailer and Skid Mounted California Proposition 65 Warning Table of Contents Ii Table of Contents MN2417 Read This Manual Thoroughly Section Product Safety InformationProperty Precaution Statements Used In This ManualOperation Statements On next MN2417 Product Safety Information Operation Statements Burn Statements Installation Statements Installation Statements Maintenance Statements Product Safety Information MN2417 Labor Parts Limited WarrantyGeneral Information MN2417 Section Receiving & Installation Generator Mounting Skid Hot Exhaust Gasses InstallationFuel Connections Prime Power Ratings Standby Power RatingsProtection Receptacle Panel Single Phase Single Phase ConnectionsGeneral Wiring Considerations Three Phase ConnectionsTransfer Switch Considerations Battery Charger ConsiderationsFrame Ground Connection Battery Installation Oil & Battery Recommendations Recommended Engine Oil and Battery TypePost Installation Checks Post Installation Checks Selecting the Proper Towing Equipment Towing the GeneratorTow Vehicle Tow Hitch Capacity Towing Heavy Trailer Loads Trailer Component Identification Lug Nut Tightening Specifications Page Receptacle Panel Load Connections, see Figure Three/Single Phase OperationOperator Control Panel Components Voltage Reconnect and AdjustmentManual Stop Procedure Manual Start ProcedureAuto Start Procedure Digital Engine Controller Description EM0046A21 MRS17 Alarm & Warning ConditionsMeasurement Menu OFF ModeMAN Mode AUT ModeAlarm List Adjustment MenuECU Alarm List Shut down SD see Table Sensor fail FLS see TablePossible Warnings Binary Inputs Inputs and OutputsBinary outputs Set points Basic Setpoints Analog Inputs10 Engine Setpoints Stabil Time11 Engine Protect Setpoints 10Engine Setpoints12 Generator Protect Setpoints 14 IOM/PTM Module Setpoints 13 Sensor Spec Setpoints+ D+ Jdic Engine GeneralTroubleshooting Guide Problems and SolutionsLoad too large for unit 1Troubleshooting GuideTroubleshooting and Maintenance MN2417 Part number Appendix a Wiring DiagramsFigure A-1 TS25 Connection Diagram Figure A-2 TS25 Connection Diagram Figure A-3 TS25 Connection Diagram Figure A-4 TS25 Connection Diagram Figure A-5 TS25 Connection Diagram Figure A-6 TS25 Connection Diagram Figure A-7 TS35 Connection Diagram Figure A-8 TS35 Connection Diagram Figure A-9 TS35 Connection Diagram Figure A-10 TS35 Connection Diagram Figure A-11 TS35 Connection Diagram Figure A-12 TS35 Connection Diagram Figure A-13 TS35 Power Connection Diagram Figure A-14 TS60 Connection Diagram Figure A-15 TS60 Connection Diagram Figure A-16 TS60 Connection Diagram Figure A-17 TS60 Connection Diagram Figure A-18 TS60 Connection Diagram Figure A-19 TS60 Connection Diagram Figure A-20 TS60 Connection Diagram Figure A-21 TS80 Connection Diagram Figure A-22 TS80 Connection Diagram Figure A-23 TS80 Connection Diagram Figure A-24 TS80 Connection Diagram Figure A-25 TS80 Connection Diagram Figure A-26 TS80 Connection Diagram Figure A-27 TS80 Connection Diagram Figure A-28 TS80 Connection Diagram Figure A-29 TS80 Connection Diagram Figure A-30 TS80 Connection Diagram Figure A-31 TS400 Connection Diagram Figure A-32 TS400 Connection Diagram Figure A-33 TS400 Connection Diagram Figure A-34 TS400 Connection Diagram Figure A-35 TS400 Connection Diagram Figure A-36 TS400 Connection Diagram Figure A-37 TS400 Connection Diagram Figure A-38 TS400 Connection Diagram Figure A-39 TS400 Connection Diagram Baldor District Offices Baldor Electric Company
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