Baldor DG3E, Installation & Operating Manual

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5-2 Troubleshooting and Maintenance MN2414
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.
Restricted air flow. Check that fuel valves are ON. Check fuel level in fuel tank.
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
Debris or dirt buildup on engine Remove one or more electrical loads.
Remove debris. Clean engine surfaces to allow cooling.
No output voltage Ciruit Breaker tripped or defective.
Loss of residual magnetism in exciter
field poles.
Open in stator windings
Defective exciter circuit. 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.
Output voltage varies Irregular speed (fixed speed mode)
Fluctuating speed (fixed speed mode)
Loose terminal or load connections
Defective bearing (uneven air gap)
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
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.
Grounded armature or field coil. Ground generator frame at local reference ground (see Section 3).
Return to factory for repair
Mechanical noise Defective bearing
Rotor rubbing on stator
Loose or misaligned coupling
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 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.