Baldor DG3E, DG6E manual Problems and Solutions, Troubleshooting Guide, Service

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	No fuel.	Check that fuel valves are ON. Check fuel level in fuel tank.
	Restricted air flow.	Check/replace air filter.
		Check that engine switch is in Start position.
Engine will not crank (electric start)	Dead battery.	Remove battery and trickle charge or replace with new battery.
		Never Jump Start.
Engine starts but will not run smoothly	Fuel or ignition problem	Refer to engine manual.
Engine overheats	Excessive load	Remove one or more electrical loads.
	Debris or dirt buildup on engine	Remove debris. Clean engine surfaces to allow cooling.
No output voltage	Ciruit Breaker tripped or defective.	Reset circuit breaker or replace if required.
	Loss of residual magnetism in exciter	Flash field.
	field poles.	Check for continuity in windings. Return to factory for repair if open.
	Open in stator windings
	Defective exciter circuit.	Check/replace diode and capacitor and flash the field.
Output voltage varies	Irregular speed (fixed speed mode)	Check engine for malfunction or load for fluctuation
	Fluctuating speed (fixed speed mode)	Stabilize load. The addition of a lamp load (resistance load) may
		compensate partially for load changes caused by intermittent motor
		operation. Do not overload.

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

Verify all connections are proper and check tighness torque of terminals.

Replace worn bearing

Low output voltage	Low engine speed
	Excessive load
	High resistance connections −
	connections will be warm or hot
	Shorted field
	Low power factor

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.

High output voltage	Excessive speed (fixed speed mode)	Check engine for malfunction
Electrical shock when frame is touched	Static charge.	Ground generator frame at local reference ground (see Section 3).
	Grounded armature or field coil.	Return to factory for repair
Mechanical noise	Defective bearing	Replace bearing
	Rotor rubbing on stator	Bad bearing − replace.
		Bent shaft − return to factory.
		Loose end bell − tighten;
	Loose or misaligned coupling	Loose drive Discs − tighten
		Tighten; align coupling and alternator shaft to engine shaft.

Service	Service for your generator can be obtained from Baldor Generators. Please have the following
	information available prior to contacting the factory:
	The model number and serial number of the generator set.
	A complete and accurate description of the problem.
Parts	Parts for your generator can be obtained from Baldor Generators. Please have the following
	information available prior to contacting the factory:
	The model number and serial number of the generator set.
	A complete and accurate description of the part (part number if known).
	Note: Engine parts can usually be obtained from a local distributor by using the information in
	the engine manufacturer’s owner’s manual.

5-2 Troubleshooting and Maintenance MN2414