Towable Generators and Light Tower (Diesel Liquid Cooled) TG8LT TG10T, 15T, 20T and 25T Installation & Operating Manual 8/12 MN2423
Any trademarks used in this manual are the property of their respective owners. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Table of Contents MN2423
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 equipment. Installation and repair procedures require specialized skills with electrical generating equipment and liquid cooled engine systems.
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.
Operation Statements Continued 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.
Operation Statements Continued WARNING: Never “jump start” equipment 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: Do not smoke near equipment during operation or when close to fuel source. Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death.
Installation Statements Continued 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 equipment set is safe to operate. Seek expert advise for installation or repairs. WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that grounds are connected.
Maintenance Statements Continued 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.
Section 2 General Information Thank you for purchasing your Baldor Generator Set/Light Tower. This manual contains information you need to safely and efficiently install and operate your equipment. 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.
2-2 General Information MN2423
Section 3 Receiving & Installation Receiving & Inspection When you receive your equipment, there are several things you should do immediately. 1. Observe the condition of the equipment and report any damage immediately to the 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.
Light Tower Checks Trailer Stabilization Checks Consists of 2 rear mounted outrigger assemblies and the jack on the trailer tongue. 1. Verify that the jack rotates and locks into position. 2. Ensure that all bolts, nuts and other hardware are tight and not missing. 3. Verify that the rear outriggers extend and rotate into position. 4. Ensure that the lock mechanisms operate correctly. Light Mast Checks A 4 section 30 foot mast can be rotated 360 degrees. 1.
Equipment Checks These checks should be performed before first service, after 25 hours of operation and every 100 operating hours thereafter. Trailer Checks Single axle trailer with leaf springs and two tires. 1. Verify that the hitch mechanism on the trailer opens and closes freely and is securely fastened to the trailer tongue. 2. Verify that the safety chains are securely fastened to the trailer tongue. 3.
Single Phase Connections Single Phase connections are made at load receptacles located near the operator control panel side of the equipment, Figure 3-3. Figure 3-3 G Test Reset X CS6369 125/250V 50A Y W NEMA L1430R 125/250V 30A CS6365N G Three Phase Connections (TG25T Only) Refer to Figure 3-4. For power to be applied to these terminals, the output voltage selector switch must be in the 120/208V or 277/480V positions.
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.
3-6 Receiving & Installation MN2423
Section 4 Operation Towing the Equipment WARNING: Never allow a person to ride in or on a trailer that is being towed. All states prohibit passengers in towed vehicles. A person can fall off and be struck be another vehicle or run over by the towed trailer. Failure to observe this warning can result in death. WARNING: Before using a tow vehicle, verify that the vehicle is designed for the load. Using a vehicle that is too small is very dangerous. Be certain that it can handle the M.G.V.W.
Light Tower Setup See Figure 3-1 for component identification. WARNING: When erecting or stowing the mast assembly, be aware of the pinch points such as where the tower structures join or where the cable and winch are located. Careless operation can result in injury. Keep extremities away from moving parts to avoid injury. WARNING: Before erecting the mast assembly, be certain that the outriggers are properly set to stabilize the unit and that they are secure and are not damaged.
Light Tower Setup for Towing 1. Adjust the two rear jacks to their shortest length. 2. Pull the Jack Lock Pin for the right jack and rotate the jack to the horizontal position. Lock the jack in this position using the Jack Lock Pin. 3. Pull the Outrigger Lock for the right jack and push the right outrigger fully in. Lock the outrigger using the Outrigger Lock. 4. Repeat steps 2 and 3 for the left outrigger and jack. 5. Shut all doors on the engine compartment housing and latch the locks.
5. Move the Coupler Handle to the vertical position to release the ball hitch. OR Release the Pintle hook. 6. Use the jack to raise the trailer coupler from the ball hitch of the tow vehicle. 7. The tow vehicle can now be moved away from the equipment. 8. Use the jack to level the trailer for operation. Lug Nut Tightness Be sure to use only the fasteners matched to the cone angle of your wheel (usually 60 or 90 degrees.) The proper procedure for attaching your wheel is as follows, see Figure 4-1: 1.
4. L1, L2, L3, Neutral and Ground cables must be brought into load block compartment through access hole in base of enclosure. 5. Ensure that wires are properly connected and connections are secure. 6. Use disconnect at the load to turn off the load. Do not start engine with load switched “on”. Allow engine to come up to speed and warm up before load is switched on. Note: When the generator is running, opening load block door will cause load disconnect to trip. 7.
Pre−Start Procedure Before attempting to start the equipment, several things must first be verified or performed. These are: 1. Fill system fuel tank with clean, fresh diesel fuel. 2. Fill engine crankcase to full mark with clean, fresh lubricating oil per engine manufacturer 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 equipment for operation. a.
Flood Light Operation: 1. When the engine reaches operating speed and is operating smoothly, turn on one light and wait one second turn on another light and wait one second etc. until the flood lights are all on. 2. Observe the operation of each flood light and replace defective bulbs if required. To change a bulb, refer to Section 5 of this manual. Note: Vaporous flood lights may require 5 to 15 minutes to warm up and produce full light output. Operating Checks: 3.
Digital Engine Controller Description EM0046A68 (MRS) Figure 4-5 Operator Control Panel UP (Increase) Display Down (Decrease) LED Indicators Stop LED Indicators X X X X X X X X Auto Y and B Setup Mode 4-8 Operation Start Note: The operator control panel LCD display operating temperature range is −20C to 70C (not the entire equipment, see generator specifications). Alarm (red) − The LED will blink when there is one or more active warnings or shutdowns.
Operating Mode Use the AUTO button to select AUTO or MANUAL mode. AUTO − Green LED above AUTO will be on. Start and Stop buttons are ignored. MAN − Green LED above AUTO will be off. Press Start to manually start the equipment immediately. Press STOP to stop the equipment immediately. Inputs and Outputs Any Binary input or output can be configured to any controller terminal. Inputs are T07,T11−T15; Outputs are T04−T06, T07. They can be changed to different functions by NanoEdit software.
Set points Table 4-8 Basic Setpoints B01 Nominal Voltage Ph−N B02 Nominal Voltage Ph−Ph B03 Nominal Frequency B04 Connection Type B05 Units Format B07 Zero Power Mode Delay B08 Light Tower Mode E01 Prestart Time E02 Maximum Cranking Time E03 Cooling Time E06 Battery Undervoltage E07 Warning Maintenance E08 Oil Pressure Starter Disengage E09 Choking Time E10 Minimal Stabilization Time Nominal system voltage (phase to neutral).
Figure 4-6 Wiring Diagram MN2423 Operation 4-11
4-12 Operation MN2423
Section 5 Troubleshooting and Maintenance WARNING: Never “jump start” a equipment 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 attempt starting. Damage to engine control may result from jump starting.
Cleaning Keeping your equipment clean is an important part of good operation. If dirt buildup is not removed, the equipment will run hotter than normal and it’s life is reduced. The following are general guidelines for cleaning.
Equipment Troubleshooting Guide Table 5-1 Light Mast Troubleshooting Guide Problem Mast will not raise to operating position. Possible Cause Mast Lock Pin still in place. Defective winch or cable. Mast will not telescope to desired height. Defective winch or broken cable. Mast will not rotate. Bolt/nut on bottom of mast may be too tight. Mast rotation collar needs to be greased. Remedy Remove pin. Have winch and cable examined by a qualified mechanic. Replace if required.
Table 5-2 Generator Troubleshooting Guide Continued Problem Genset will not pull load Possible Cause Incorrect Engine Speed Load not connected properly Load too large for unit Electrical shock when frame is touched Mechanical noise (alternator) Trailer lights inoperable Static charge. Grounded armature or field coil.
Appendix A Wiring Diagrams Replacement Parts Engine parts are identified in the engine manual that was provided with your generator set. IMPORTANT: Fuses are installed in the control box to protect the engine controller and associated control circuits. When replacing fuses, use the exact replacement fuse (manufacturer and part number). Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix.
Figure A-1 TG8LT A-2 Wiring Diagrams MN2423
Figure A-2 TG8LT MN2423 Wiring Diagrams A-3
Figure A-3 TG8LT A-4 Wiring Diagrams MN2423
Figure A-4 TG10T MN2423 Wiring Diagrams A-5
Figure A-5 TG10T A-6 Wiring Diagrams MN2423
Figure A-6 TG15T MN2423 Wiring Diagrams A-7
Figure A-7 TG15T A-8 Wiring Diagrams MN2423
Figure A-8 TG20T MN2423 Wiring Diagrams A-9
Figure A-9 TG20T A-10 Wiring Diagrams MN2423
Figure A-10 TG25T MN2423 Wiring Diagrams A-11
Figure A-11 TG25T A-12 Wiring Diagrams MN2423
Baldor District Offices
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. P.O. Box 2400 Fort Smith, AR 72902-2400 USA Ph: (1) 479.646.4711, Fax: (1) 479.648.5792 www.baldor.
