Winco W100PTOS-3, Installation & Operator'S Manual

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15
60706-160/I
MAINTENANCE
CAUTION: EQUIPMENT DAMAGE
Most electrical equipment 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.
GENERAL
Routine preventative maintenance minimizes costly
repairs and generator downtime. Before each use,
inspect the generator: gear case 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 splined generator input shaft should be cleaned and
lubricated with thin film of grease before and after each
use of the generator.
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.
See illustration below for recommended lubrication
schedule for the coupling shaft.
Check the generator gear case oil level before each use
of the generator. Maintain the oil level at oil level plug
height. The generator is shipped with lubricant in the
gearcase. Specifications for the gearcase lubricant are:
API Service: GL-5
Grade: SAE 85W-90-140
Amount: 2.75 Pint
CAUTION: EQUIPMENT DAMAGE
Do not overfill generator gearcase. 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 the generator
gearcase oil.
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5. Shut off the engine.
4. Disconnect drive shaft (tumbling bar) power take-off end
first, then generator end.
MAINTENANCE
The following chart lists various symptoms of poor generator
operation with possible causes for them 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 the generator
speed you can use the frequency meter on the generator
control panel.
CAUTION: Equipment Damage
Most electrical equipment in North America operates satisfac-
torily 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.
GENERAL
Routine preventive maintenance minimizes costly repairs and
generator downtime. Before each use, inspect the generator:
gear case 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 condi-
tions 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 splined generator input shaft should be cleaned and
lubricated with a thin film of grease before and after each use
of the generator.
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.
See Figure 8 for recommended lubrication schedule for the
coupling shaft.
Check the generator gear case oil level before each use of the
generator. Maintain the oil level at oil level plug height. (Figure
6 illustrates 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: 1 pint
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 over-
heating 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 follow-
ing procedure to change generator gear case oil (see Figure
6):
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 1 pint.)
Figure 8
1. Remove gearcase breather. Soak breather in cleaning
solvent, then allow to dry.
2. Remove oil level plug. See illustration below.
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 gearcase
and look for damaged gears if you find metal chips in
the oil.
4. Replace the oil drain plug. Refill the gearcase through
the breather port with new oil of the recommended
type. Fill the case up to the oil level check plug height.
About 1 pint.
5. Replace the oil level check plug.
6. Replace the breather.
CLEANING & INSPECTING THE
GENERATOR
Use a vacuum cleaner or dry low pressure compressed
air (regulated at 25-35PSI) to clean the generator
periodically.
WARNING: EQUIPMENT DAMAGE
Do NOT clean the generator while it is running.
Proceed as follows:
1. Remove ventilated control box cover. Vacuum or blow
vents and screen clear of dust or debris. Wash them
down with cleaning solvent if necessary.
2. Remove cooling fan shroud. Vacuum or blow dust
from screen and fan blades. Wipe them off with
cleaning solvent if necessary.
3. Vacuum or blow dust and other debris from inside
generator and control box.
4. With the panel cover removed, inspect the wiring for
correct routing, fraying insulation, and secure
connections.
5. Replace panel cover and cooling fan shroud.
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6. Make sure that the electrical loads to be powered by the
generator will not exceed the current ratings of the generator,
receptacle, or cord set which will supply the current.
7. Check all electrical connections in the system to be
energized by the generator. Make sure the connections are
correct and tight and the load disconnect plug (if provided) is
fully seated in the receptacle.
8. Make sure all loads are turned off. Do not start the generator
under load.
GENERATOR STARTING PROCEDURE
1. With the power take-off drive disengaged, start the engine
which will drive the generator. Run the engine long enough to
warm it up before proceeding, so that it will run smoothly and
achieve full power under generator load.
2. With engine idling, engage the power take-off drive.
3. Watch the frequency meter on the generator and slowly
increase engine speed until the frequency reaches approxi-
mately 60 Hz. The voltage output of the generator is controlled
by an Automatic Voltage Regulator (AVR). Before turning on
any load check your voltage output from the generator using a
volt/ohm meter. If the voltage is either high or low adjust the
voltage level by turning the voltage adjustment screw on the
AVR. The AVR is located inside the generator control cabinet.
Once the proper voltage level is set the AVR should bring the
voltage back to the same level each time the unit is started up.
But as a precaution it should be checked each time you use
the generator. As quick check you can plug in a troublelight
and check for normal brightness.
4. With engine and generator running smoothly, switch on the
electrical load while watching the frequency meter.
NOTE: Equipment Damage
If the load includes motors turn them on one at a time, highest
starting current motor first, next highest second, etc.
Adjust engine throttle to keep generator output under load at
60 Hz. If the engine is equipped a with governor, it may
automatically adjust the throttle as the load changes and keep
the generator output at the proper level. However, some
governors are not sensitive enough to maintain proper output
under changing loads, and in such cases the frequency will
have to be monitored closely and manually adjusted .
GENERATOR SHUTDOWN PROCEDURE
1. Switch off electrical load.
2. Reduce speed of engine driving generator to idle.
3. Disengage power take-off drive, and allow generator to
coast to a stop.
WARNING: Personal Injury
Never try to manually stop the generator. Always let it coast
until it stops.
3. Make sure the drive shaft (tumbling bar) is assembled with
its universal joint knuckles “synchronized,” as illustrated in
Figure 7. If knuckles are not synchronized, the bar will chatter
when rotating, which will cause the generator output voltage to
flicker.
DANGER: Personal Injury
POWER TAKE-OFF MUST BE DISENGAGED AT THIS TIME.
4. Couple the tractor to the generator with the drive shaft
(tumbling bar). Couple the tumbling bar to the generator input
shaft first, then to the power take-off shaft. Check alignment of
tractor, power take-off shaft (tumbling bar), and generator input
shaft should form a straight (or nearly straight) line, with less
than 15° misalignment between the shafts. Misalignment will,
stress the drive line and cause generator output voltage to
flicker.
CAUTION:
Make sure that all tumbling bar lock pins are engaged and
that all safety shields are in place before operating the PTO
generator.
5. Make sure no binding exists in generator or gear box. If
binding is found, locate the cause and correct it before
proceeding.
Figure 7
Figure 6