W15PTOS/D - GenPro Power Systems, Inc.
Contents
1. NOTE THE FOLLOWING INFORMATION IS FOR REFERENCE ONLY CONSULT QUALIFIED SERVICE PERSON FOR FURTHER TESTING AND REPAIR Testing of Rectifiers Unbolt the rectifier diode stud from the mounting clamp Move rectifier away from the metal stud 1 Connect black lead of meter to stud of rectifier and red lead to the solder terminal Meter should read a low resistance 2 Now reverse the lead on rectifier terminals Meter should read open circuit of infinite resis tance A shorted diode will give low resistance reading in both directions An open diode will give a high resistance infinite reading in both directions Handling Procedures for Rectifier Diodes 1 Rectifier diodes should be handled in a manner which avoids the possibility of sudden shocks being applied such as those encountered in dropping from a work bench to a hard floor Damage done to the rectifier by such shocks may not be detected by subsequent testing yet may cause poor system reliability 2 Any lead trimming or forming operations should be done with care to avoid damaging the leads or the glass header seals 3 Leads should never be bent or twisted If lead forming is necessary the lead should be supported so that no Testing Stator 1 Instrument required Volt Ohmmeter Set on Ohm X1 scale 2 Check Ohmmeter by touching leads together Reading should be zero 3 Tag and lift control wires from stator winding s to be checked 4 First check2. When the normal power fails the generator is attached to the tractor by means of the power take off shaft WARNING Personal Injury Be sure the safety shields are in place and retained Start the tractor and adjust the speed until the Voltage meter on the generator panel reads the proper Voltage 235 volts to 245 volts Check the connected load to assure that all heavy electrical equipment is disconnected Move the transfer switch handle to the emergency position connecting the load to the generator Switch on all required electrical equipment within rated capacity of the generator then readjust tractor speed to maintain the proper frequency NOTE Equipment Damage If the load includes motors turn them on one at time highest starting current motor first next highest second etc If the circuit breaker of the generator control panel trips during operation the connected load is greater than the rated generator capacity the load by disconnecting any nonessential equipment during emergency conditions and reset the breaker to resume power feed When the normal commercial power is restored for at least 15 minutes without interruption the transfer switch can be returned to the normal position and the tractor drive generator shut down Reduce speed gradually to minimize stress in drive line If the generator is mounted on an off highway trailer such as the Winco trailer it should be stored in a garage b
3. LIGHTS DANGER PERSONAL INJURY IF THE GENERATOR IS TO BE USED AS A STANDBY POWER SOURCE A SPECIAL DISCON NECT SWITCH MUST BE INSTALLED TO SEPA RATE THE GENERATOR AND THE COMMERCIAL POWER LINES THE DISCONNECT MUST 150 LATE THE GENERATOR FROM THE COMMERCIAL POWER LINES AND THE LOAD WHEN THE GEN ERATOR IS ON STANDBY AND MUST ISOLATE THE COMMERCIAL POWER LINES FROM THE LOAD AND THE GENERATOR WHEN THE GEN ERATOR IS SUPPLYING POWER SEE FIGURE 6 TYPICAL INSTALLATION FOR SUPPLYING ONLY ESSENTIAL CIRCUITS WITH EMERGENCY POWER COMMERCIAL POWER INPUT WATT HOUR METER TO RANGE D CRITICAL 120 VOLT LOADS NON AIR CONDITIONER CRITICAL 120 VOLT LOADS REFRIGERATOR FURNACE OTHER APPLIANCES TO LIGHTS TO LIGHTS EMERGENCY DISTRIBUTION PANEL Figure 6 60706 179 8100 PROCEDURE FOR USE 6 Keep meter at the proper voltage by adjusting tractor 1 Set the manual transfer to mid or normal up speed position 7 Thereturn of normal power will be indicated by the 2 Connect the power take off shaft securely to the lamp on the front of transfer switch applicable only when alternator and the tractor Position as near to a straight the transfer switch is equipped with indicating lamps or line as possible your electrician has installed them After sufficient time to 3 Slowly adjust power take off up to maintain the assure that power restoration isn t temporary return the the proper voltage readin
4. if stator winding s are grounded a Connect one lead of Ohmmeter to ground b Touch other lead to each stator wire Meter should stay at infinite not move c If reading is indicated stator is grounded and should be replaced d Check all three windings 5 Second check stator windings for opens oymptom when generator was running no voltage on one line to neutral bending occurs closer than 1 8 inch to the rectifier body and that header seals are not fractured or broken If this seal is broken it removes mechanical support for the lead and allows entry of moisture into the rectifier almost assuring early failure 4 Care must be taken during all soldering operations It is unsafe to exceed the general specification to which diodes are tested for solder ability This is 10 2 seconds at a temperature of 230 5 C at a point 1 16 1 32 inch from the diode body This is not as restric tive as it may sound since 230 C is 446 and 60 40 solder melts at 375 F and with proper procedure and soldering tools a solder joint can be made in 4 to 7 seconds Also solder joints are almost never made this close to the diode body Heat sinks such as a pair of needle nose pliers or alligator clips can be attached to the lead between the solder joint and the diode body to further reduce the possibility of heat damage Also precautions should be taken to prevent solder or flux bridging which causes a conductive path acros
5. MINECO PINGO ING GENERATORS OPERATOR INSTRUCTION MANUAL COMPACT SERIES TRACTOR DRIVE ALTERNATORS W15PTOS D MINECO A Division of DTES Dyna Technology nc 60706 179 8100 TABLE OF CONTENTS INTRODUCTION SAFETY INFORMATION FOUNDATION MOUNTING TRAILER MOUNTING LOAD DISCONNECT PLUG INSTALLATION OPERATING THE ALTERNATOR MAINTENANCE REQUIREMENTS OPERATION OF TRACTOR DRIVEN ALTERNATOR PROCEDURE FOR USE PTO ALIGNMENT LUBRICATION TESTING OF RECTIFIERS HANDLING PROCEDURES FOR RECTIFIER DIODES TESTING STATOR WINDING RESISTANCES SERVICE DIAGNOSIS RECEPTACLE PANEL ASSEMBLY ILLUSTRATION WIRING DIAGRAM COMPLETE UNIT ASSEMBLY ILLUSTRATION TWO WHEEL TRANSPORT WINCO LIMITED WARRANTY Copy you model and serial number here MODEL No other Winco generator has the same serial number as yours It is important that you record the SERIAL NUMBER number and other vital information here If you PURCHASE DATE should ever need to contact us about this unit it will help us to respond to your needs faster DEALER CAUTION FOLLOW THE INSTRUCTIONS IN THE OWNER S MANUAL SPECIFICALLY WHEN PUTTING THIS ALTER NATOR INTO SERVICE IMPORTANT ALL STANDBY POWER PLANTS INCLUDING TRACTOR DRIVEN ALTERNATORS SHOULD BE PERIODI CALLY EXERCISED FOR PROPER MAINTENANCE OF YOUR TRACTOR DRIVEN ALTERNATOR IT SHOULD BE OPERATED FOR ONE HOUR CARRYING RATED LOAD AT LEAST TWICE A YEAR THIS WILL ASSURE THAT YOU
6. R ALTERNATOR IS OPERATING CONDITION AND READY FOR USE WHEN EMERGENCY CONDITION DEVELOPS PARTS LIST PARTS DRAWINGS AND WIRING DIAGRAM PERTAINING TO YOUR UNIT ARE ENCLOSED WITH THIS MANUAL This manual covers the latest compact portable tractor driven Power Take Off PTO generator set model from Winco This 15 000 watt generator is designed to provide120 240V single phase electrical power for standby and utility service when commercial power interrupted inaccessible or impractical This PTO unit has a cast iron gear cases with a 1 3 8 6 spline 540 rpm input shafts and brushless heavy duty 3600 rpm 2 pole low waveform distortion genera tors This compact PTO generator units is designed to provide reliable electrical power for customers who already have a compact utility tractor with 24 to 40 horsepower 540 rom PTO shaft The PTO unit is a cost effective way of providing needed electrical power without the cost or added maintenance of a dedicated drive engine Primary applica tions for these PTOs are for infrequent or medium duty loads where the unit will normally be operated less than 50 to100 hours per year Typical uses might be for farm ranch or home standby or portable field power away from convenient utility or where running an extension cord is impractical The compact PTO units are built to last but are not intended for prime power continuous or sole source applications All PTO units have a full contro
7. an isolation power transfer switch and PTO generator is not a typical do it yourself project Consult a qualified licensed electrician or contractor The installation must be safe and comply with all national state and local codes See page 11 a Never operate the PTO drive generator without having it properly mounted to a concrete base or approved trailer b Never connect the PTO generator to an existing electrical system without installing an isolation transfer switch c Always insure the drive shaft is straight and level before operating the generator 8 OPERATION drive shafts tumbling bars have many inherent dangers extreme caution must be exer cised when using them a NEVER allow children around a drive shaft when it is in operation b Keep all safety guards and shields in place and securely tightened c Never operate a drive shaft that has been damaged or had the safety shield removed d Never step over a drive shaft while it is running e Never wear a necktie loose articles of clothing or anything else that can be caught in moving parts f Never try to stop a turning drive shaft with your hand or your foot INSTALLATION FOUNDATION MOUNTING Mount the generator on a foundation if it is to be used as a permanent or standby power source See TRAILER MOUNTING if generator will be used as a portable power source Figure 1 When planning a foundation consider the following points A The foundatio
8. and follow all warnings on the unit labels and in the manuals ANSI SAFETY DEFINITIONS DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word is to be limited to the most extreme situations WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices NOTE CAUTION is also used on the unit labels and in this manual to indicate a situation that could result in serious damage or destruction of the equipment and possible personal injury 60706 179 8100 GENERATOR SAFETY INFORMATION 1 ELECTRIC SHOCK The output voltage present this equipment can cause a fatal electric shock This equipment must be operated by a responsible person a Do not allow anyone to operate the generator without proper instruction b Guard against electric shock c Avoid contact with live terminals or receptacles d Use extreme care if operating this unit in rain or snow e Use only three prong grounded plugs and extension cords f Be sure the unit is properly grounded to an external ground rod driven into the earth g Do not make or break electrical connection under load 2 FIRE HAZARD Gasoline diesel and othe
9. arn or machine shed in a dry and clean location The generator should be covered with a tarpaulin to prevent the entrance of dust chaff and or moisture The generator may be stored on end provided the generator is on a clean Figure 3 60706 179 8100 dry elevated surface such as a board Do not have it resting on a dirt surface Figure 3 MAINTENANCE REQUIREMENTS 1 Maintain proper oil level in the PTO gear case See page 5 for list of recommended vendors Do not overfill maintain level to the center of clear site gauge approxi mately four 4 inches from the bottom of the gear case on the right side Figure 4 OIL BREATHER amp PORT CAUTION Equipment Damage Do not overfill generator gear case Overfilling causes overheating and oil seal failure Ol LEVEL CHECK PLUG OIL DRAIN PLUG Figure 4 2 Inspect for loose or broken wiring connections Make sure that wiring con nections are not loose at the generator end circuit breakers and receptacles 3 not allow dirt or chaff to collect in the interior of the generator or the ventilation openings Inspect for indica tion of the entrance of mice or insects into the generator The inlet and outlet openings are louvered but possible damage to the louvers could occur Mice can destroy the generator winding WARNING Equipment Damage DO NOT CLEAN THE GENERATOR WHILE IT IS RUNNING CAUTION Equipment Damage Most electrical equip
10. ch may have occurred during shipment Any damage noted should be promptly reported to the carrier in order that a claim can be filed to recover the cost of the damage If at all possible this damage should be noted on the freight bill at the time of delivery If the damage appears to be of a major nature the generator should not be operated until the fault has been corrected Tractor driven generators are designed to deliver voltage and current similar to that of the normal power line Equipment that can be operated on normal power can also be operated by the generator provided that the capacity of the generator is not exceeded It should be remembered that the power line for all practical purposes is backed by an unlimited genera tor When not in use the generator should be stored in a clean dry location All types of mechanical equipment suffer from long periods of storage without use The generator should be used at frequent intervals to prevent deterioration and detect possible fault before an emergency condition develops Page 1 SAFETY INFORMATION This generator set has been designed and manufac tured to allow safe reliable performance Poor mainte nance improper or careless use can result in potential deadly hazards from electrical shock exhaust gas asphyxiation or fire Please read all safety instructions carefully before installation or use Keep these instruc tions handy for future reference Take special note
11. e stator Include generator model and serial number on the order Same as above Same as above Test and replace if defective Realign within 10 degrees drive line halves Page 8 RECEPTACLE TORQUE LUGS TO 45 INCH LBS INSURE THERE ARE NO WIRE STRANDS IN THREADS BEFORE TIGHTENING TORQUE TO 16 INCH LBS 01 03 04 06 07 09 10 NI PART NUMBER 300079 3 91370 000 99280 001 62487 003 300136 94378 000 63708 000 50766 000 91286 001 57030 005 300080 1 300137 WIRING DIAGRAM NEUTRAL TO GROUND BOND REMOVE FOR ISOLATED NEUTRAL OPERATION Pr Page 9 DESCRIPTION Control Box Bottom Front Back Voltmeter Grommet Loom Receptacle NEMA 14 60R Neutral Stand Off Ground Lug Duplex Receptacle NEMA 5 20 Circuit Breaker 20 Amp 120 Volt Circuit Breaker 60 Amp 240 Volt Control Box Cover Plug NEMA 14 60P Shipped Loose 60706 179 8100 COMPLETE UNIT ASSEMBLY REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION 91370 000 Voltmeter 12 99839 001 Generator 300080 1 Control Box Mecc Alte Spa Cover Model S20F 230 A Z 2568 Decal 300086 1 Drive Shaft Guard Z 9941 Decal 63966 407 Name Plate Kit Z 2553 Decal 98478 000 Winco Decal 300074 6 Right Side Frame 99841 001 Gear Case Support 300077 5 Rear Frame 300323 112 Capacitor Z 2516 Decal 31 5 mf 425 V 300323 212 Capacitor 15209 000 Decal 35 mf 450 V 300074 5 Left Side Frame 300153 Gea
12. ection Defective diode s on rotor Open excitor circuit in stator Grounded or shorted rotor winding Loss of residual magnetism Usually occurs only after disassembly of field frame or severe mechanical stress abuse Shorted stator winding This can be identified by the use of an internal growler at a competent rewinding shop Grounded stator Check winding by test lamp or high potential tester from stator leads to lamination Open stator circuit Measure circuit between leads with an ohmmeter Should have a circuit between any pair of leads Defective Capacitors VOLTAGE UNSTEADY LIGHTS FLICKERING PTO drive line alignment Drive line knuckles out of sync See Figure 5 60706 179 8100 REMEDY Check for overload on the tractor or undersized Check tractor governor Tight or defective throttle levers and joints Worn or defective tractor engine see engine manufacturers check list Increase size of line wiring Might also be the result of loose connection indicated by excessive heating at the loose connection terminal Replace as required Test and replace if defective Repair or replace as required Readjust or Replace as required Clean screens make sure interior of generator is unobstructed Clean and tighten generator and receptacle connections Replace defective diode s Repair or replace statorassembly Replace grounded rotor assembly Back flash the 120 volt circuit with 12 volts DC Replac
13. eed 10 For a power take off shaft length of 42 inches 10 is approximately 7 inch misalignment For m zonr extended distance the maximum misalignment would increase 2 inches for each foot For example For a 4 foot PTO shaft the maximum misalignment is 8 inches Figure 5 from a straight line a bese ce Fae LUBRICATION 2 generator bearings are factory lubricated 1 Check the generator gear case oil level before each sealed and require no further lubrication use of the generator See Figure 4 Maintain the oil level before each use of the generator Maintain the oil level at 3 splined generator input shaft should be cleaned oil level plug height The generator is shipped with and lubricated with a thin film of grease before and after lubricant in the gear case each use of the generator See Figure 6 for lubrication Specifications for gear case lubricant are API Service schedule GL 5 EP Rated Grade SAE 85W 90 140 Amount 1 4 The drive shaft tumbling bar requires greasing The following kinds of oil are recommended for use in the Keep the universal joints in the coupling shaft tree Tom generator gear case grease and dirt buildup See Figure 6 for lubrication Mobil SAE 85W90 140 API Service GL 5 schedule Sunoco DX XL80W90 140 Kendal Three Star 85W 140 Amoco 85W140 or equivalent pint NOTE Do not over lubricate the universal joints Figure 6 60706 179 8100 Page 6
14. g on the meter 235 to 245 transfer switch to normal power 10 20 minutes volts 8 Place the alternator circuit breaker in off position 4 Plug 4 wire load cord set into receptacle Place Do not remove plug before opening the breaker transfer switch in the emergency position 9 Slowly reduce power take off speed to a minimum 5 Place the load circuit breaker in the position If and disengage the power take off Some tractors have a the breaker trips move manual transfer switch to off or brake on the power take off that stops the shaft instantly normal position Check for short circuit or grounded Stopping the alternator rotor instantly from rated speed connection in the load cable to the double throw switch may result in a broken shaft or other drive line failures and repair A breaker that trips from overload or short 10 Exercise PTO alternator for one hour under load at circuit must be reset by moving to off before reclosing least twice a year DANGER Personal Injury TRACTOR MUST BE SHUT OFF AND THE POWER TAKE OFF MUST BE DISENGAGED AT THIS TIME PTO ALIGNMENT Position the alternator in such a manner that the power take off shaft is as near to direct line in all directions as possible This will increase the life of the power take off shaft reduce light flicker reduce wear on bearings of both the power take off and the alternator and reduce vibration The maximum angle from a straight line should not exc
15. l panel with features like large frequency meter mainline circuit breaker convenience and full load 4 wire receptacles The full load matching plug is also included for customers load connection cord set Traditional Winco power convenience and reliability are standard features of this new series of compact PTO genera tors FEATURES BY MODEL TRACTOR PTO HP INPUT GEAR SHAFT LUBE W15PTOS C 36 30 MOTOR STARTING MAX RATED 1 3 86SPL 1604 8 HP MOTOR STARTING CODE G CAPACITOR START WATTS AMPS 120 240 FEATURES 18 000 15 000 83 60 2 938959 FEATURES LISTED BELOW BY REFERENCE NUMBER WITH EXPLANATION 1 Brushless low harmonic design with skewed rotor and damper windings for minimal load noise 2 Capacitor Excitation 3 Dual voltage 120 240 volt output 4 4 wire Load connection plug for convenient full load 120 240 volt output cordset 5 15Amp duplex convenience receptacle 6 Large face Frequency meter for setting proper speed INTRODUCTION The words generator and alternator are used inter changeably but have the same meaning This manual covers standby generators driven by the power take off of a compact tractor This generator use a external voltage regulator excitation system All generators are carefully inspected tested and pack aged for shipment at the factory The generator should be unpacked as early as possible upon receipt and inspected for damage whi
16. ligence accident or which have been repaired or altered by other than persons authorized by Winco Winco shall not be liable for loss damage or expense directly or indirectly from the use of its product nor for the fitness of product for any specific application or particular purpose Winco shall not be liable for any incidental and consequential damage There is no other express warranty Winco hereby disclaims any and all implied warranties including but not limited to those of merchantability and fitness for a particular purpose to the extent permitted by law This warranty is effective for all compact PTO driven alternators manufactured after August 15 1998 If this alternator is used for standby service this warranty is void unless a multi ole double throw switch is installed between the alternator and the service entrance switch Do not operate PTO alternator without the shield installed WINGO INC A Division of Dyna Technology nc 225 SOUTH CORDOVA LE CENTER MN 56057 PHONE 507 357 6831 FAX 507 357 4857 60706 179 8100 WINGO INC A Division of Dyna Technology nc 225 SOUTH CORDOVA AVE LE CENTER MN 56057 1 507 357 6831 60706 179 8100 60706 179 8100
17. ment in North America operates satisfactorily at frequencies between 59 and 61 Hz cycles per second Operating the generator at frequencies outside that range may cause damage to the generator and or to electrical equipment driven by the generator OPERATION OF TRACTOR DRIVEN ALTERNATORS When the alternator is not in use it must be maintained in a clean and dry condition The inside of the panel frame and air inlet and outlet must be free from dirt chaff and moisture including condensation When connection is made at the meter pole a double throw manual isolation power transfer switch must be used Normal power is connected to the top the load at the center and the alternator at the bottom of the switch Warranty is void if an isolation transfer switch is not used check instruction manual on transfer switch Page 4 ELECTRICAL CONNECTIONS CAUTION Only qualified electricians should install electrical wiring Wiring must conform to all applicable na tional state and local codes Reference National Fire Protection Association Manual No 70 National Electrical Code TYPICAL INSTALLATION FOR SUPPLYING ALL CIRCUITS WITH EMERGENCY POWER CONNERCIAL POWER INPUT WATT HOUR METER LINE RATED DISCONNECT TRANSFER SWITCH TO RANGE TO WATER HTR REFRIGERATOR FURNACE ll OTHER APPLIANCES TO LIGHTS TO LIGHTS TO LIGHTS AIR CONDITIONER MAIN DISTRIBUTION PANEL Page 5 TO WATER TO
18. n location should enable aligning the drive shaft tumbling bar in a straight or nearly straight line between the power take off and the generator input shaft Misalignment must be less than 10 degrees during generator operation even though the mechanical design of the tumbling bar would allow greater misalignment B The foundation must be solid enough to absorb gen erator starting and reflected load torque during operation C The foundation surface should be flat D Space is required around the generator for mounting switching devices making connections and for servicing E All four generator mounting pads must rest firmly on the foundation Install shims if necessary to even out the foundation under the mounting pads then bolt the genera tor firmly in place Page 2 TRAILER MOUNTING Mount the generator a trailer if you plan to use it as a portable power source See Figure 1 When selecting or building a trailer to mount the generator consider the following points A The trailer construction must be strong enough to support the generator B The design of the trailer must enable the trailer to remain stable during operation and to resist tipping caused by generator starting and reflected load torque WARNING Personal Injury amp Equipment Damage TRAILER MAY TIP OVER AND CAUSE INJURIES IF WHEELS ARE NOT SPACED FAR ENOUGH APART C The trailer height and mounting position of the generator on the
19. orrect slots and oriented in accordance with the diagram above or you will not be able to close the top cover fully 6 Place top plastic cover over assembly and partially tighten the bakalite assembly screw Realign blades straight so they fit into the top bakelite housing properly and tighten the assembly screw 7 Assemble cable clamp over the outer jacket of the wire and tighten the two clamp screws Special Note For small size round less than 3 4 and flat cables the wire clamp may be inverted WARNING Failure to wire as instructed may cause personal injury or damage to device or equipment To be installed or checked by an electrician or qualified person only OPERATING THE ALTERNATOR WARNING Personal Injury When working on or around these generators do not wear loose fitting clothing or any articles that may get caught in moving parts A properly rated and installed double throw manual power isolation transfer switch must be used with a standby generator The transfer switch isolates the load from the power line and allows you to safely operate your loads without endangering the power line repair crew See page 11 60706 179 8100 The load connected to the normal terminals of the transfer switch is energized by the normal power line when the switch Is in the normal position The generator connected to the emergency terminals of the switch furnishes power when the switch 1 in the emergency mode position
20. r Case 300079 3 Control Panel Bottom Not Illustrated 60706 179 8100 Page 10 TWO WHEEL TRANSPORT CON OOK WN DESCRIPTION SUPPORT TONGUE 2 HITCH TONGUE QTY 2 TONGUE AXLE QTY 2 SUPPORT AXLE SUPPORT PTO SHAFT SUPPORT PTO SHAFT TIRE RIM PNEUMATIC QTY 2 PART NO 300081 300082 300083 300085 300164 300161 1 300161 2 43657 000 Page 11 60706 179 8100 WINGO ING ONE YEAR P T O DRIVEN ALTERNATOR LIMITED WARRANTY Winco Inc hereinafter referred to as Winco warrants for a period of one year to the original user that each Winco PTO driven alternator is free from defects in material and factory workmanship if properly installed serviced and operated under normal conditions according to Winco s published instructions Manufacturer s obligation under this warranty is limited to correcting without any labor or material charge to the user for the first year at its factory or at its autho rized repair centers any part or parts which shall be returned and which upon examination shall disclose to Winco s satisfaction to have been originally defective in material or in workmanship All transportation charges on parts or units submitted for replacement or repair to the factory or authorized repair centers under this warranty must be borne by the purchaser This warranty does not apply to items which are subject to normal wear or any part or parts which have been subject to misuse neg
21. r fuels always present a hazard of possible explosion and or fire a Keep fire extinguisher nearby and know its proper use Fire extinguishers rated ABC by NFPA are appropriate 3 DEADLY EXHAUST GAS Exhaust fumes from any engine contain carbon monoxide an invisible odorless and deadly gas that must be mixed with fresh air a Operate only in well ventilated areas b Never operate indoors 4 NOISE HAZARD Excessive noise is not only tiring but continual exposure can lead to loss of hearing a Use hearing protection equipment when working around this equipment for long periods of time b Keep your neighbors in mind when permanently installing this equipment 5 CLEANLINESS Keep the generator and surrounding clean a Remove all grease ice snow or materials that create slippery conditions around the unit b Remove any rags or other material that could create potential fire hazards 6 SERVICING EQUIPMENT All service including the installation or replacement of service parts should be performed only by a qualified technician a Use only factory approved replacement parts b Do not work on this equipment when fatigued C Use extreme caution when working on electrical components High output voltages from this equip ment can cause serious injury or death d Always avoid hot mufflers exhaust manifolds and engine parts They all can cause severe burns in stantly 60706 179 8100 7 INSTALLATION Installing
22. s the case of the rectifiers As a precaution all flux should be removed by using alcohol and a small brush Pay particular attention to assure that glass header seals are free of all flux Stator 6 Wires 3 Windings 1 Phase This armature has two power windings and one excitation auxiliary winding 1 Connect ohmmeter one lead to T1 red Other lead to T2 green Meter should read near zero Then other lead to T3 black Meter should read infinite Then other lead to Z1 white Meter should read infinite 2 Connect one lead to T3 black Other lead to T4 yellow Meter should read near zero Then other lead to Z1 white Meter should read infinite 3 Connect one lead to Z1 white Other lead to Z2 brown Meter should read near zero TRACTOR DRIVE WINDING RESISTANCES ROTATING FIELD TRACTOR DRIVE POWER 1 2 0 0893 W15PTOS C Page 7 STATOR POWER T3 T4 0 0893 CAPACITOR AUX 450 VAC 21 22 0 503 101 5 MFD 60706 179 8100 SERVICE DIAGNOSIS POSSIBLE CAUSE LOW OUTPUT VOLTAGE Low Speed 1 Undersized overloaded 2 Defective governor 3 Low power worn engine High line loss Indicated by lower voltage at load than at generator terminals Defective voltage regulator Shorted or grounded rotor coil Defective stator HIGH OUTPUT VOLTAGE Generator is spinning to fast slow tractor down EXCESSIVE HEATING Clogged ventilating inlet and or outlet NO OUTPUT VOLTAGE Broken or corroded conn
23. trailer should enable aligning the drive shaft tumbling bar in a straight or nearly straight line between the power take off and generator input shafts Misalignment must be less than 10 degrees during generator operation even though the mechanical design of the tumbling bar would allow greater misalign ment Figure 1 D The generator mounting area of the trailer bed should be flat All four generator mounting pads must rest firmly on the trailer bed Install shims if necessary to even out the bed under the mounting pads then bolt the generator firmly in place Assembly The only assembly work required after unpacking the generator is to assemble and wire the load disconnect plug which is packed in the generator carton WARNING Personal Injury DISCONNECT POWER BEFORE WIRING IMPORTANT Use copper wire only Do not use tinned conductors Sizing cable see NEC 400 5 CORD SIZE 4 4 conductor cord SO 1 25 inch dia max Page 3 20 52 AMPS Tis 220 To assemble and wire the load disconnect plug proceed as follows 1 Strip outer jacket 2 3 4 2 strip leads to lengths specified for the particular plug 3 Disassemble cable clamp and top cover 4 Remove one blade at a time insert the stripped end of the appropriate colored wire designated above and tighten the set screw 5 Fitblades through slots in bottom cover and push down until home Please note Make sure blades are in c
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