Baumalight KR Series User manual

QC and KR Series Generators
OPERATORS MANUAL
Issue Date: January 2023

TABLE OF CONTENTS
1 INTRODUCTION ���������������������������������������������������������������������������������������������������������������������������������1
1�1 Overview��������������������������������������������������������������������������������������������������������������������������������������1
1�2 Harmonic Distortion Values�������������������������������������������������������������������������������������������������������1
2 SAFETY������������������������������������������������������������������������������������������������������������������������������������������������2
2�1 Safety Alert Symbol And Safety Words������������������������������������������������������������������������������������2
2�2 Operational Hazards�������������������������������������������������������������������������������������������������������������������3
Prepare For Emergencies ����������������������������������������������������������������������������������������������������������4
Replace Safety Signs �����������������������������������������������������������������������������������������������������������������4
Do Not Allow Riders �������������������������������������������������������������������������������������������������������������������4
Lower Operating Speed �������������������������������������������������������������������������������������������������������������4
Avoid Rollover ����������������������������������������������������������������������������������������������������������������������������4
Hazards From Modifying Equipment ����������������������������������������������������������������������������������������5
2�3 Maintenance Hazards Maintenance ������������������������������������������������������������������������������������������6
3 SAFETY SIGNS�����������������������������������������������������������������������������������������������������������������������������������6
4 ASSEMBLY������������������������������������������������������������������������������������������������������������������������������������������8
4�1 Remove Shipping Dunnage And Parts �������������������������������������������������������������������������������������8
4�2 Remove Generator From Pallet�������������������������������������������������������������������������������������������������8
4�3 Driveline Dimension �������������������������������������������������������������������������������������������������������������������8
5 OPERATION �������������������������������������������������������������������������������������������������������������������������������������� 10
5�1 Preparation For Use �����������������������������������������������������������������������������������������������������������������10
5�2 Machine Components ��������������������������������������������������������������������������������������������������������������10
5�3 Attaching Generator To Tractor����������������������������������������������������������������������������������������������� 11
5�4 Detaching Generator From Tractor�����������������������������������������������������������������������������������������13
5�5 Transporting������������������������������������������������������������������������������������������������������������������������������13
5�6 Operating The Generator ���������������������������������������������������������������������������������������������������������14
5�6�1 Initial Start-Up ������������������������������������������������������������������������������������������������������������������14
5�6�2 Monitoring The Load ��������������������������������������������������������������������������������������������������������16
5�6�3 Shutting Down The Generator�����������������������������������������������������������������������������������������16
5�6�4 Storing The Generator �����������������������������������������������������������������������������������������������������17
6 SERVICE AND MAINTENANCE������������������������������������������������������������������������������������������������������18
6�1 Service���������������������������������������������������������������������������������������������������������������������������������������18
6�1�1 Electrical Tests �����������������������������������������������������������������������������������������������������������������18
6�1�2 Automatic Voltage Regulator Operational Test ������������������������������������������������������������� 19
6�1�3 Voltage Regulator Adjustment ���������������������������������������������������������������������������������������20
6�2 Maintenance������������������������������������������������������������������������������������������������������������������������������21
6�2�1 Lubrication Symbol ����������������������������������������������������������������������������������������������������������22
6�2�2 Every 250 Hours ���������������������������������������������������������������������������������������������������������������22
6�2�3 Every 1000 Hours �������������������������������������������������������������������������������������������������������������23
6�2�4 Severe Service Recommendations��������������������������������������������������������������������������������� 23
6�2�5 Maintaining The Permanent Magnets �����������������������������������������������������������������������������24
6�2�6 Restoring Residual Magnetism ���������������������������������������������������������������������������������������24
7 TROUBLESHOOTING ����������������������������������������������������������������������������������������������������������������������25
BAUMALIGHT GENERATOR WARRANTY���������������������������������������������������������������������������������������29
ii

1 INTRODUCTION
Congratulations on your choice of a Baumalight QC or KR Series Generator. This equipment has been
designed and manufactured to meet the needs of a discriminating buyer for efcient auxiliary power.
The Generator is powered by the Power Take Off (PTO) on your tractor.
Safe, efcient and trouble free operation of your Generator requires that you and anyone else who will
be operating or maintaining the Generator, read and understand the Safety, Operation, Maintenance and
Troubleshooting information contained within the Operators Manual.
This manual covers the Baumalight QC and KR Series Generators. Use the Table of Contents as a guide
to locate required information.
Keep this manual handy for frequent reference and to pass on to new operators or owners. Call your
Baumalight dealer, distributor or the factory if you need assistance, information or additional copies of
the manuals.
When this machine is worn out and no longer in use, it should be returned to the retailer or other party
for recycling.
OPERATOR ORIENTATION - The directions left, right, front and rear, as mentioned throughout this
manual, are as seen from the tractor drivers seat and facing in the direction of travel.
1�2 Harmonic Distortion Values
No Load - 4.1%
Loaded - 4.6%
1�1 Overview
1

2 SAFETY
You must read, understand and follow the
instructions given by the operating unit
manufacturers, as well as the instructions in this
manual.
The safety information in this manual is denoted
by the safety alert symbol:
^
This symbol means ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
The level of risk is indicated by the following signal
words:
^DANGER
DANGER - Indicates a hazardous
situation, which, if not avoided, WILL
result in death or serious injury�
^WARNING
WARNING - Indicates a hazardous
situation, which, if not avoided, could
result in death or serious injury�
^CAUTION
CAUTION - Indicates a hazardous
situation, which, if not avoided, could
result in minor or moderate injury�
NOTICE
NOTICE - Indicates a situation that could
result in damage to the equipment or
other property.
2�1 Safety Alert Symbol And Safety
Words
2

2�2 Operational Hazards
^WARNING
Prevent serious injury or death�
Read and understand this manual before
operating generator�
Never allow anyone near the generator
and tractor during operation�
Travel at a safe speed�
^WARNING
Prevent serious injury or death from
moving parts�
Moving parts can crush and dismember�
Do not operate without guards and
shields in place�
Disconnect and lock out power source
before adjusting or servicing�
^WARNING
Use generator only for the designed
applications�
Any other use may result in personal
injury, damage to equipment and may
void the warranty�
^WARNING
Prevent serious injury or death�
Verify generator is connected to tractor
before operation or transport�
Verify generator driveline is attached to
tractor�
Carefully read all safety messages in this manual
and on equipment safety signs. Keep safety signs
in good condition and replace missing or damaged
safety signs.
New equipment components and repair parts must
include the current safety decal.
Learn how to properly operate equipment.
NEVER operate or work around this equipment
without proper instruction, while fatigued or under
the inuence of alcohol, prescription or non-
prescription medication or if feeling ill.
Keep your equipment in proper working condition.
Know the regulations and laws that apply to you
and your industry. This manual is not to replace
any regulations or laws. Additional information
may be found at: www.asae.org or www.osha.gov.
If you do not understand any part of this manual,
contact Baumalight at 866-820-7603.
3

Prepare For Emergencies
• Be prepared in case of emergencies.
• Keep a re extinguisher and rst aid kit close
to the machine.
• Keep emergency phone numbers close to your
phone.
• Know your address so emergency services
can locate you if an emergency arises.
Replace Safety Signs
• Replace missing or damaged safety signs.
• Safety signs are identied in Section 3 of this
manual.
• Replacement safety signs are available from
your Baumalight dealer.
Do Not Allow Riders
• NEVER carry anyone with generator.
• NEVER use generator as a work platform.
• NEVER allow passengers on generator.
Lower Operating Speed
• Lower operating speed while loading,
unloading or performing heavy operations.
• Keep load low and move at slow speeds on
rough or uneven terrain.
Avoid Rollover
The equipment may rollover, resulting in death or
serious injury. To help prevent rollover:
• Travel at a slow speed.
• Avoid sharp turns & sudden movement on
slopes.
• Avoid holes, ditches and other obstructions
which may cause equipment to rollover.
• Use caution when operating on slopes and do
not operate on excessively steep slopes.
^WARNING
Risk of electrocution� High voltages
are present at the generators terminals
when the unit is running�
Additionally, accessory equipment
such as space heaters can be energized
from an outside power source when the
unit is at rest� Be sure to disconnect all
sources of power before working on
equipment�
4

Detach Generator Safely
Detach generator on a rm and level surface.
Generator may roll away if detached on sloping
or soft surface. Be sure people, livestock and pets
are clear of machinery.
Hazards From Modifying Equipment
Do not make any alterations to your generator.
Altering the equipment may cause unsafe
conditions and may void the manufacturers
warranty.
Stay Clear Of Rotating Drivelines
^WARNING
Entanglement in a rotating driveline can
cause serious injury or death�
Keep tractor shields and driveline
shields in place at all times� DO NOT
operate without driveline guards�
DO NOT wear loose tting clothing.
2�3 Maintenance Hazards
Maintenance
Before servicing, park machine on a rm and
level surface, chock wheels, and place a “Do
Not Operate” tag on control panel. Read and
understand this manual. If you do not understand
any part of the manual, contact Baumalight at 866-
820-7603.
Always wear face and/or eye protection, safety
shoes, and other protective equipment appropriate
for the job.
Do not make unauthorized modications. Contact
Baumalight at 866-820-7603 before you weld, cut/
drill holes, or make any other modications.
Always use Baumalight replacement parts.
^WARNING
Moving parts can crush and cut�
Keep clear of moving components�
Follow lockout procedure before
servicing�
^WARNING
Crushing hazard�
Before performing inspections, service
or maintenance:
• Park machine on rm, level surface.
• Turn engine off and remove key�
• Place “Do Not Operate” tag on
control panel�
5

^WARNING
Entanglement hazard�
Keep clear of moving components�
Wear proper protective equipment
appropriate for the job�
3 SAFETY SIGNS
KR Series Generator Shown
6

A. MTB-021
B. MTB-111 - On QC series generators, this will
be on the opposite side panel.
C. MTB-050
D005261 - *The French decal will be on the
opposite side of frame.
NE PAS INSTALLER SUR UNE
SURFACE SOLIDE.
(ex. Bloc de Béton)
UTILISER DES SUPPORTS DE
CAOUTCHOUC
D005261
D. MTB-186
7

^WARNING
Depending on model, approximate
weight of the generator is 269 - 674 kg
(592 - 1485 lbs)
Do not position feet around or under
pallet�
1. Remove crate material from pallet.
2. Remove all shipping bands, wires and loose
parts from around generator.
4 Assembly
4�1 Remove Shipping Dunnage And
Parts
4�2 Remove Generator From Pallet
1. Attach hitch to generator frame.
2. Roll generator off of pallet.
3. Install PTO driveline.
4�3 Driveline Dimension
A PTO driveline is supplied with the machine.
To accompany the variety of hitch geometry
available today, the driveline can be too long for
most machines or too short for others. It is very
important that the driveline be free to telescope
but not to bottom out when going through its
working range. If the driveline bottoms out, the
bearings on both the machine and tractor PTO
shaft will be overloaded and fail in a short time.
1. To determine the proper length of the
driveline, follow this procedure:
a. Clear the area of all bystanders.
b. Attach generator to tractor (see section
5.3) but do not attach driveline.
c. Measure dimension between locking
grooves on tractor PTO shaft and
machine input shaft.
d. Measure the same dimensions on the
compressed driveline.
e. If compressed driveline dimension
exceeds the machine dimension,
driveline will have to be cut.
2. When cutting the driveline, follow this
procedure:
a. Subtract machine dimension (A) from
uncut driveline dimension (B) or (B-A).
This dimension determines how much
too long the driveline is.
b. Add another 1 inch (25 mm) to the
dimension to be sure it doesn’t bottom out,
to determine (C) the cut off dimension.
c. Use a hacksaw to cut dimension (C) from
both ends. Cut both plastic tubes and
metal cores.
d. Use a le to remove burrs from edges
that were cut.
8

e. Assemble the 2 ends of the shaft.
f. Make sure shaft can telescope freely. If it
does not, separate the 2 parts and inspect
for burrs or cuttings on shaft ends. Be sure
it telescopes freely before installing.
9

A. PTO Driveline
B. Display
C. Power Panel
D. Generator
E. Gear Box
F. PTO Driveline Guard
G. PTO Driveline Support
H. Trailer Tongue
5�2 Machine Components
Although the generator has been carefully
inspected and checked prior to shipment from
manufacturer, it is recommended that the unit be
thoroughly inspected.
Check all bolts for tightness and remove all
shipping tags, bags, skids, and blocking. Remove
any masking materials afxed during painting.
Inspect the tractor and any accessory equipment
to verify that nameplates and all safety warning,
caution signs and decals provided with the
equipment are in place and clearly visible.
Visually inspect the unit before each start up.
Check for loose or missing parts and any damage
that may have occurred during moving or shipping.
Review all tractor pre-start instructions, and ensure
that all recommended steps and procedures have
been followed.
5�1�1 Neutral Bond To Ground
All units are shipped with neutral bonded to ground
inside alternator. Only a qualied electrician may
relocate neutral bond to a remote location within
electrical service. Electrical connections must
comply with federal, state, provincial and local
electrical codes.
^WARNING
Prevent injury and machine damage�
Units are shipped with neutral bonded
to ground inside alternator�
Only a qualied electrician may relocate
neutral bond to a remote location within
electrical service�
5 OPERATION
5�1 Preparation For Use
10

5�3 Attaching Generator To Tractor
A
B
^WARNING
To prevent injury or machine damage
put transmission in “Park” and check
for PTO driveline binding or separation�
Only experienced and properly trained
operators should operate the tractor
and generator�
1. Back up tractor to generator.
2. Engage tractor park brake and/or place
transmission in “Park”.
3. Shut off engine and remove key.
4. Lift up on trailer tongue and slide onto tractor
hitch.
5. Install pin and retaining pin.
6. Pull collar (A) back toward the generator. Align
splines on tractor PTO shaft and driveline by
rotating generator driveline. Push driveline
onto PTO shaft until it snaps into place.
7. Pull back on driveline to make sure it is locked
on shaft.
8. Attach safety shield chain (B) as shown.
NOTICE
A misaligned PTO shaft on the generator
end can cause shuddering and
bouncing on the tires which may lead
to transmission damage and potentially
void the warranty. Be sure PTO shaft
is properly aligned with generator
transmission.
11

9. If necessary, remove bolt (E) and adjust the
trailer tongue (D) so that the PTO driveline (C) is
perpendicular with the generator transmission
(F). The shaft must be straight with no bend
in the universal joint on the generator side. A
bend is allowable at the tractors PTO drive end.
D
C
90°
90°
E
F
INCORRECT
90°
CORRECT
CORRECT
INCORRECT
90°
A misaligned PTO shaft on the generator end can
cause generator to shudder and bounce on the
tires. This may lead to transmission damage and
potentially void the warranty.
If shaft is straight and generator bounce persists,
reducing generator tire air pressure may help
reduce bouncing.
12

1. Park tractor on a level surface.
2. Shut off engine and remove key.
3. Disconnect driveline safety chain (B).
4. Support driveline with your hand.
5. Pull collar (A) back toward generator and slide
off shaft. Place PTO driveline on driveline
support.
6. Remove retaining pin and pin from trailer
tongue.
7. Lower tongue to ground.
5�4 Detaching Generator
From Tractor
^WARNING
Prevent serious injury or death caused
by unexpected movement:
1� Park tractor on a level surface�
2� Engage tractor park brake�
3� Disengage PTO�
4� Shut off engine and remove key�
1. Verify all reectors and Slow Moving Vehicle
(SMV) sign are visible.
2. Verify trailer tongue is pinned to tractor hitch.
3. Verify tractor PTO is disengaged.
4. Travel at a reasonable and safe speed.
A
B
NOTICE
Do not engage the PTO when towing
the generator to a location or generator
damage could result.
The generator trailer does not have a
suspension. Limit speeds to less than
20 kph (12 mph) to minimize the risk of
rollover.
5�5 Transporting
13

5�6 Operating The Generator
^WARNING
Entanglement in a rotating driveline can
cause serious injury or death�
Keep tractor shields and driveline
shields in place at all times� DO NOT
operate without driveline guards�
DO NOT wear loose tting clothing.
^WARNING
Never operate tractor when other people
are in the vicinity�
Do not allow riders on tractor�
^WARNING
Prevent serious injury or death caused
by unexpected movement:
1� Park tractor on a level surface�
2� Engage tractor park brake�
3� Disengage PTO�
4� Shut off engine and remove key�
5�6�1 Initial Start-Up
1. Connect the power cable to the generator and
to the transfer switch.
2. Start the tractor and allow it to warm up.
3. With the engine idling, engage the PTO drive.
4. Adjust throttle until the volts on DisplayMaster1
display 120 VAC (single phase).
5. Turn on the main breaker on the generator.
6. Operate the transfer switch so that the load is
transferred to the generator.
14

15

5�6�2 Monitoring The Load
NOTICE
Follow the shut down sequence to
minimize the risk of damage to the
generator or associated equipment.
1. Switch off the electrical load or allow it to drop
to minimum.
2. If possible, operate the transfer switch to
transfer the load back to utility power.
3. Turn generator main breaker off.
4. Drop the tractor speed to idle.
5. Disengage the PTO drive. Allow the PTO shaft
to gradually come to a stop.
6. Shut off tractor engine and remove key.
7. Disconnect the PTO driveline from tractor.
8. Place the mount on the trailer tongue in the
upright position and place PTO driveline on
support.
9. Tow unit back to storage.
10. See Storing Generator in this section if
generator will not be used for some time.
5�6�3 Shutting Down The Generator
Plan when to change over to generator power.
Ideally, the transfer should take place when the
system demand is at its lowest. If a big motor can
come on stream, change over to generator power
before it does so when the load is lesser.
The generator has sufcient capacity to handle
rush current (higher demand) during motor start
up, so it is permissible to operate temporarily at
overload. However, only allow the generator to do
so for short periods of time (less than a minute).
Carefully monitor the tractor speed settings when
the load changes and adjust the throttle to keep
the generator operating at 120 VAC (single phase).
NOTICE
Risk of generator damage.Avoid running
the generator at overload for excessive
periods of time. Doing so can damage
the generator and void the warranty.
16

5�6�4 Storing The Generator
1. Wipe down the unit using a clean rag and
water, or a cleaning solvent.
2. Inspect the air louvers and make sure that they
are not obstructed. The generator requires a
ow of cooling air. Clean them as necessary.
3. With a rag soaked in cleaning solvent, clean
the splines on both ends of the connecting
drive shaft, on the generator driveline, and on
the tractor.
4. Inspect all splines on the driveshaft, the
generator, and the tractor for signs of damage
or wear. Repair any damage or wear as soon
as possible.
5. Apply a light coat of lithium waterproof grease
to the surfaces of the connecting driveshaft
splines.
6. Examine the universal joints for signs of wear
or damage. Repair or replace any worn or
damaged part.
7. Using the grease gun, lubricate each universal
joint.
8. Inspect the level of the lubricant in the gearcase.
Top off as needed with gear lubricant.
9. Verify the tire pressure and adjust as
necessary. Check the sidewall of the tires for
the recommended pressure.
10. Inspect the generator to look for damage to the
generator. If any damage is found, avoid using
the generator and report the damage to your
Baumalight representative.
11. Check all fasteners and make sure they are
properly tightened. This includes the bolts that
attach the generator to the trailer, the bolts that
attach the guard to the gearcase, and the bolts
that attach the tongue to the trailer.
12. Cover generator and store in a clean, dry place.
17

6 SERVICE AND
MAINTENANCE
6�1 Service
6�1�1 Electrical Tests
Continuity and Resistance Test
The generator has four components that can be
checked using an ohmmeter:
• Exciter stator
• Exciter rotor
• Main stator
• Main rotor
Each of these components is composed of various
windings forming a complete electrical path of
relatively low resistance. Using an ohmmeter,
measure the loop resistance of each component.
Contact Baumalight for specic values for your
machine.
Note: Very small resistance values require
precision equipment to make accurate
measurements; however, a standard ohmmeter
will provide a good indication of winding continuity.
Diode Testing
Note: Stop tractor engine before performing this
procedure.
1. Remove the two main rotor leads and the three-
exciter rotor leads from the rectier assembly.
The rectier assembly is now electrically
isolated from the generator. The diodes remain
mounted and the diode leads remain connected
to the terminal posts.
2. Using an ohmmeter or a battery light continuity
tester, place one test probe on the diode lead
terminal post.
3. In succession, touch the other test probe to the
lead screw hole in each heat sink.
4. Reverse the probes and repeat the procedure.
You have now tested the three diodes connected
to this terminal post in both the forward and
reverse direction.
5. Repeat the procedure using the other diode
terminal post.
When the positive test probe is connected to
the diodes anode and the negative test probe is
connected to the diodes cathode (forward biased),
the diode will switch on and conduct electricity.
This is observed by a low resistance reading when
using an ohmmeter or the lighting of the bulb when
using a battery light continuity tester. Reversing the
test leads (reverse biased) will result in the diode
switching off and no electricity will be conducted.
The results of these tests should indicate one of
three conditions:
Good diode: Will have a much greater resistance
in one direction than the other. Typical reverse
biased resistance will be less than 10 ohms. The
battery light tester will have the light “on” in one
direction and “off” in the other.
Shorted condition: Ohmmeter reading will be zero,
or very low in both directions. The continuity tester
will have light “on” in both directions.
Open condition: Ohmmeter will have a maximum
(innity) reading in both directions. Continuity
tester light will be off in both directions.
Diode failure after a 25-hour “run-in” period is
generally traceable to external causes such as
a lightning strike, reverse current, line voltage
spikes, and the like. All 6 diodes are essentially in
the same circuit.
Since determining the remaining life on the diodes
when one fails is difcult, replace the entire rectier
assembly, rather than individual diodes, to avoid
possible continued failure.
18
This manual suits for next models
6
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