11
REV A
OPM-136
NOTE:
Do not over lubricate the universal joints.
Check the generator gearcase oil level before each use of the
generator. Maintain the oil level at the oil level plug height. The
generator is shipped with lubricant in the gearcase. Specifications for
the gearcase lubricant are:
API Serice: GL-5
Grade: SAE 85W-90-140
Amount: 0.85 Pints
The following kind of oil are recommended for use in the generator
gearcase: Mobile SAE 85W-90-140 API Service GL-5, Sunonco/
DX XL80W90-140, Kendal Three Star 85W-140, Amoco 85W140 or
equivalent.
CAUTION: EQUIPMENT DAMAGE
Do not overfill generator gearcase. Overfilling causes overheating and
oil seal failure.
Change oil at least once every twelve months or 150 hours of
operation. Change it more often if you use the generator in bad
weather. Use the following procedure to change generator gearcase oil:
1. Remove gearcase breather. Soak breather in cleaning solvent, then
allow to dry.
2. Remove oil level check plug.
3. Remove the oil drain plug, drain the oil into a clean oil resistant
container, 1 quart or larger. Check the oil for metal. Fine metal dust
Page 7
60706-199
1005-00
MAINTENANCE
General Information
The main components of the generator are: armature, field
coils, cooling fan, brushes, brush holder assembly, end
brackets, and rectifier. Before performing any maintenance
on the generator, isolate and/or disable the drive system so
the unit can not be accidentally started while being repaired.
The troubleshooting chart lists various symptoms of poor
generator operation with possible causes and the appro-
priate corrective action. You will need a volt-ohm meter or
test light to check some of the causes. For some of the
other causes you will need to check generator speed. To
check generator speed you can use a frequency meter, a
tachometer, or a 120V-60Hz electric clock and a correctly
operating wrist watch. (Run the electric clock on generator
power and compare the clock’s second hand movement
with that of the wrist watch. They should run at the same
speed. If clock runs faster, generator speed is too high,
and vice versa.)
CAUTION: Equipment Damage
Most electrical equipment in North America operates
satisfactorily at frequencies between 58.5 and 62 Hz
(cycles per second.) Operating the generator at frequen-
cies outside that range may cause damage to the genera-
tor and/or to electrical equipment driven by the generator.
Periodical Maintenance
Service/maintenance items include periodic external physi-
cal inspection for missing hardware or damage to mounting
or drive system and checking the oil level in the gear case.
It is recommended that the generator be operated at least
monthly under normal loads to familiarize operators with the
procedures and controls as well as to dry out any accumu-
lated condensation or other moisture in the generator elec-
trical windings. The maintenance and service attention
invested will insure getting the peak performance that was
designed into the unit.
Routine preventive maintenance minimizes costly repairs
and generator down-time. Before each use, inspect the
generator: gear case oil level should be correct, cooling
vents and screens should be clear, and generator mount-
ing hardware should be tight. Clean and inspect the
generator after storing it for long periods, and after using
it in extremely dusty conditions or in severe weather, such
as rain or blowing snow.
Lubrication
The generator bearings are factory lubricated and sealed,
and require no further lubrication.
The generator input shaft should be cleaned and lubricated
with a thin film of grease before installing the drive shaft and
each time it is removed.
The drive shaft (tumbling bar) requires greasing. Keep the
universal joints in the coupling shaft free from grease and
dirt buildup.
NOTE:
Do not over lubricate the universal joints.
Check the generator gear case oil level before each use of
the generator. Maintain the oil level at oil level plug height.
(See page 6 for oil level plug location.) The generator is
shipped with lubricant in the gear case. Specifications for
gear case lubricant are:
API Service: GL-5
Grade: SAE 85W-9O-140
Amount: 2 pints
The following kinds of oil are recommended for use in the
generator gear case: Mobil SAE 85W90-140 API Service GL-
5, Sunoco/DX XL80W90-140 Kendal Three Star 85W-140,
Amoco 85W140 or equivalent.
CAUTION: Equipment Damage
Do not overfill generator gear case. Overfilling causes
overheating and oil seal failure.
Change the oil at least once every six months. Change it
more often if you use the generator in bad weather. Use the
following procedure to change generator gear case oil:
1. Remove gear case breather. Soak breather in cleaning
solvent, then allow it to dry.
2. Remove oil level check plug.
3. Remove the oil drain plug, drain the oil into a clean oil
resistant container, 1 quart or larger. Check the oil for
metal. Fine metal dust in the oil does not indicate
trouble, but metal chips do. Dismantle the gear case and
look for damaged gears if you find metal chips in the oil.
4. Replace the oil drain plug. Refill the gear case through
the breather port with new oil of the recommended type.
Fill the case up to oil level check plug height. (It will take
about 2 pint.)
5. Replace the oil level check plug.
6. Replace the breather.
Cleaning and Inspection
Use a vacuum cleaner or dry low pressure compressed air
(regulated at 25-35 PSI) to clean the generator periodically.
WARNING
DO NOT CLEAN THE GENERATOR WHILE IT IS RUNNING.
Proceed as follows:
Breather Vent
0" --
1
Oil Level Plug
MAINTENANCE
GENERAL INFORMATION
The main components of the generator are: rotor and stator assembly,
cooling fan, brushes, brush holder assembly, end brackets. Before
performing any maintenance on the generator, isolate and/or disable
the drive system so the unit can not be accidentally started while being
repaired.
The trouble shooting chart lists various symptoms of poor generator
operation with possible causes and the appropriate corrective action.
You will need a volt-ohm meter or test light to check some of the
causes. For some of the other causes you will need to check generator
speed. To check generator speed, you can use a frequency meter, a
tachometer, or a 120V-60Hz electric clock and a correctly operating
wrist watch (run the electric clock and a correctly power and compare
the clock’s second hand movement with that of the wrist watch. They
should run at the same speed. If the clock runs faster, generator speed
is too high, and vice versa).
CAUTION: EQUIPMENT DAMAGE
Most electrical equipment in North America operates satisfactory at
frequencies between 58.5 and 62 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.
PERIODICAL MAINTENANCE
Service/maintenance items include periodic external physical
inspection for missing hardware or damage to mounting or drive
system and checking the oil level in the gearcase. It is recommended
that the generator be operated at least monthly under normal loads to
familiarize operators with the procedures and controls as well as to dry
out any accumulated condensation or other moisture in the generator
electrical windings. The maintenance and service attention invested will
ensure getting the peak performance that was designed to the unit.
Routine preventative maintenance minimizes costly repairs and
generator down-time. Before each use, inspect the generator: gearcase
oil level should be correct, cooling vents and screens should be
clear, and generator mounting hardware should be tight. Clean and
inspect the generator after storing it for long periods, and after using
it in extremely dusty conditions or in severe weather, such as rain or
blowing snow.
LUBRICATION
The generator bearings are factory lubricated and sealed, and require
no further lubrication.
The generator input shaft should be cleaned and lubricated with a
thin film of grease before installing the drive shaft and each time it is
removed.
The drive shaft (tumbling bar) requires greasing. Keep the universal
joints in the coupling shaft free from grease and dirt build-up.