8
REV C
60706-241
GENERATOR STARTING PROCEDURE
1. Set the manual transfer to mid or normal (up) position.
2. 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.
3. With engine idling, engage the power take-off drive.
4. Watch the voltmeter on the generator and slowly increase engine
speed until the output reaches approximately 240 to 245 volts, in green
portion of voltmeter scale.
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.
5. Plug 4 wire load cord set into receptacle. Place transfer switch in the
emergency position.
6. Place the load circuit breaker in the “on” position. If the breaker trips,
move manual transfer switch to “off” or normal position. Check for short
circuit or grounded connection in the load cable to the double throw
switch and repair. A breaker that trips from overload or short circuit
must be reset by moving to “off” before re-closing.
7. With engine and generator running smoothly, switch on the electrical
load while watching the voltmeter. Readjust engine throttle to keep
generator output under load at 240V (in green portion of voltmeter
scale). If engine is equipped with speed governor, it may automatically
readjust 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 load, and in such cases the
throttle will have to be manually readjusted.
WARNING: PERSONAL INJURY:
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.
6. Make sure that the electrical loads to be driven by the generator will
not draw more current than the 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 are tight.
8. Make sure all loads are turned off. Do not start the generator under
load.
9. Verify any special conditions specific to your application.
PRE-START CHECKS
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.
1. Visually inspect the generator. Check for:
a. Correct mounting.
b. Physical damage.
c. Debris in cooling vents and screens. (Could cause generator to
overheat)
IMPORTANT:
The manufacturer recommends that, if the generator has been stored
for any length of time, before using it, the operator remove the control
box cover and cooling fan screen, then inspect the generator for rodent
nests or other objects that could cause generator binding and/or
overheating. See ‘Cleaning’ portion of the Maintenance section.
2. Check Gearcase oil level. (See drawing) Case should be filled with
oil to plug marked ‘OIL LEVEL’. Fill or remove oil as required.
NOTE: Either too little or too much
oil can harm the equipment.
See ‘Lubrication” portion of
Maintenance for oil specifications.
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. Drive shafts shipped
new from Winco are always synchronized and tethered so they can not
be taken apart.
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, tractor, power take-off shaft
(tumbling bar), and generator input shaft should form a straight (or
nearly straight) line, with less than 5° misalignment between the shafts.
Misalignment will cause generator output voltage to flicker.
Page 5
60706-180
0310-00
A properly rated and installed double throw manual power
isolation transfer switch must be used with a standby genera-
tor. The transfer switch isolates the load from the power line
and allows you to safely operate your loads without endanger-
ing the power line repair crew. See page 4.
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 is in the emergency mode position.
There are two ways to install a manual transfer switch. The
first shown on the left side of page 4 is to install the switch
between the watt-hour meter and the normal distribution panel.
As with any system you must install an entrance rated breaker
before the manual transfer switch. The manual transfer switch
must in all cases be equal to or greater than the rating of the
entrance rated breaker.
The second way to install the system is to purchase and install
an emergency distribution panel and move the circuits you
wish to back up to the new distribution panel. In this case the
manual transfer switch only has to be sized to the amperage of
the circuit breaker in the main distribution panel that is feeding
it. See the right hand drawing on page 4
Before deciding which system to install, first determine which
loads you can safely run on your PTO generator and the cost
of buying a large manual transfer switch versus the cost of a
smaller switch and the additional distribution panel.
The final item that you are going to have to assembly/wire is
the plug that will be used to connect the generator to the
manual transfer switch. You should have found this load plug
in a small box when you unpacked the PTO generator. If you
need additional plugs for multiple sites you can order additional
plugs from your Winco dealer, the part number is “300137”.
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.
Figure 2
To assemble and wire the load disconnect plug, proceed as
follows:
1. Strip outer jacket 2-3/4”.
2. Cut and 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. Fit blades through slots in bottom cover and push
down until home. Please note: Make sure blades
are in correct 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 bakelite 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.
PRE-START CHECKS
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.
1. Visually inspect the generator. Check for:
a Correct mounting
b. Physical damage
c. Debris in cooling vents and screens (could
cause generator to overheat).
IMPORTANT
: The manufacturer recommends that, if the gen-
erator has been stored for any length of time, before using it,
the operator remove the control box cover and cooling fan
screen, then inspect the generator for rodent nests or other ob-
jects that could cause generator binding and/or overheating.
See “Cleaning” portion of Maintenance section.
2. Check gear case oil level. (See
Figure 4.) Case should be filled
with oil to plug marked “OIL
LEVEL.” Fill or remove oil as
required.
NOTE
: EITHER TOO LITTLE OR
TOO MUCH OIL CAN HARM THE
EQUIPMENT.
See “Lubrication” portion of
Maintenance for oil specifications.
Page 6
60706-180
0310-00
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 chat-
ter when rotating, which will cause the generator output volt-
age to flicker. Drive shafts shipped new from Winco are al-
ways synchronized and tethered so they can not be taken
apart.
DANGER: Personal Injury
POWER TAKE-OFF MUST BE DISENGAGED AT THIS TIME.
4. Couple the tractor to the generator with the drive shaft (tum-
bling bar). Couple the tumbling bar to the generator input
shaft first, then to the power take-off shaft. Check align-
ment, tractor, power take-off shaft (tumbling bar), and gen-
erator input shaft should form a straight (or nearly straight)
line, with less than 10° misalignment between the shafts.
Misalignment will 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 pro-
ceeding.
6. Make sure that the electrical loads to be driven by the gen-
erator will not draw more current than the ratings of the gen-
erator receptacle or cord set which will supply the current.
7. Check all electrical connections in the system to be ener-
gized by the generator. Make sure the connections are cor-
rect and are tight.
8. Make sure all loads are turned off. Do not start the genera-
tor under load.
GENERATOR STARTING
PROCEDURE
1. Set the manual transfer to mid or normal (up)
position.
2. 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.
3. With engine idling, engage the power take-off drive.
4. Watch the voltmeter on the generator and slowly increase
engine speed until the output reaches approximately 240 to
245 volts, in green portion of voltmeter scale.
5. Plug 4 wire load cord set into receptacle. Place transfer
switch in the emergency position.
6. Place the load circuit breaker in the “on” position. If the
breaker trips, move manual transfer switch to “off” or
normal position. Check for short circuit or grounded
connection in the load cable to the double throw switch and
repair. A breaker that trips from overload or short circuit
must be reset by moving to “off” before reclosing.
7. With engine and generator running smoothly, switch on the
electrical load while watching the voltmeter. Readjust en-
gine throttle to keep generator output under load at 240V
(in green portion of voltmeter scale). If engine is equipped
with speed governor, it may automatically readjust the
throttle as the load changes and keep the generator output
at the proper level. However, some governors are not sen-
sitive enough to maintain proper output under changing
load, and in such cases the throttle will have to be manually
readjusted .
NOTE: Equipment Damage
If the load includes motors turn them on one at a time,
highest starting current motor first, next highest second,
etc.
8. The return of normal power will be indicated by the
lamp on the front of transfer switch; (applicable only when
the transfer switch is equipped with indicating lamps or
your electrician has installed them). After sufficient time to
assure that power restoration isn’t temporary, return the
transfer switch to normal power (10 - 20 minutes).
9. Place the alternator circuit breaker in “off” position. Do not
remove plug before opening the breaker.
10. Slowly reduce power take-off speed to a minimum and
disengage the power take-off. Some tractors have a brake
on the power take-off that stops the shaft instantly. Stop-
ping the alternator rotor instantly from rated speed may
result in a broken shaft or other drive line failures.
WARNING: Personal Injury
Never try to manually stop the generator. Always let it
coast until it stops.
11. Shut off the engine.
12. Disconnect drive shaft (tumbling bar)
power take-off end first, then generator end.
13. Exercise PTO alternator for one hour under load at least
twice a year.
