manual - Winco Inc.
Contents
1. 088 Ohms G1 to N amp G3 to N 025 0275 Ohms 60706 130 51101 000 480 000 479 000 45633 000 40552 000 21867 000 20039 000 9549 000 636 000 48178 000 44342 000 6376 000 5113 000 40746 000 43781 000 54806 000 61367 002 23404 000 51046 003 46912 000 46913 000 44318 000 20136 000 20137 000 46545 000 20159 000 20139 000 420 430 431 432 440 441A 441 B 442 443 444 447 448 449 460T 460B 462 463 467 468 469 470 471 472 491 610 NH Hex Nut Armature Assembly Armature Bearing Field Shell amp Coil Assembly Field Coil Field Coil Pole Shoe Pole Shoe Retainer Field Shell AC Brush Lead Shield Brush Q Brush Rack Assembly Brush Rack Assembly Brush Holder Condenser Rectifier Ground Strap Spacer Brush Holder Spacer Mounting Plate Brush Holder Q End Cover Base Wiring Harness N I Not Illustrated Page 11 ms ek Phy 12 20160 000 64794 000 64794 001 50215 000 61368 002 64787 000 64787 001 43473 000 43474 000 61153 001 24981 000 23478 000 53949 000 53977 000 53977 001 23500 002 41221 000 91452 000 41387 007 23532 000 52559 000 53975 000 23500 000 55438 023 51147 000 64543 000 7150 01 REF 130 134 137 138 140 141 142 144 146 147 148 149 150 151 152 153 154 155 156 157 158 7150 01 Gear Box Assembly 54661 DESCRIPTION Gear Box Assembly P2. AINE 94 O Chassis Mount PTO Generators INCORPORATED OWNERS MANUAL INSTALLATION AND OPERATION INSTRUCTIONS ECV2510 3 ECV2512 3 0 81 7 38 E 10 31 9 00 26 31 SIDE VIEW 90 625 QTY 4 8 51 61 125 KEYED INPUT DRIVE SHAFT TOP VIEW Y 0 75 pa 10 50 m 7 02 1 12 00 Te dea Note Unit shown is the ECV2512 the only 23 50 COVER REMOVAL dimension that changes on the ECV2510 is the location of the input shaft DRIVE END VIEW SAFETY FIRST READ THIS MANUAL BEFORE OPERATING YOUR GENERATOR 60706 130 Read and understand all instructions in this manual before starting and operating the generator set USING THIS MANUAL PROPER USE AND INSTALLATION Congratulations on your choice of a Winco generator yeu must be sure your new generator set is You have selected a high quality precision engineered Properly serviced before operating generator set designed and tested to give you years of Operated in a well ventilated area satisfactory service Exhaust gases are dispersed safely To get the best performance from your new generator it Wired by a qualified electrician is important that you carefully read and follow the operating Operated only for its designed pu
3. WINCO does not warrant products which have been installed in such a manner as notto protectthem from the adverse environmental conditions water mud insects etc or have notbeen kept clean WINCO reserves the right to change or improve its products without incurring any obligations to a make such changes or improvements on products purchased previously INCO INCORPORATED 225 South Cordova Avenue 60706 130 Le Center Minnesota 56057 507 357 6821
4. worn down to 3 8 Replace brushes in complete sets never singly When replacing brushes be careful to reconnect the lead wires properly Poor contact or skipping between brush and slip ring is caused by oil and grit flint or other hard substance on the brush or by the brush not being properly shaped to fit the slip rings Remedy these defects by fitting the brushes to the slip ring curvature Place 00 sandpaper under the brushes with the abrasive side to the brushes and work it back and forth until the brushes are the same shape as the slip rings B Slip rings The four continuous copper rings located on the end of the armature are the generator output slip rings For proper generator output the surface of the slip rings must have a smooth shiny highly polished finish Normal brush seating will transfer a shiny black finish that will seat the copper surface This finish should not be removed unless it becomes dull or begins to build up Under sustained use it is advisable to check and if necessary polish the ring surfaces with a crocus cloth to maintain the smooth finish C Electrical Testing Testing generator fields for opens and grounds 1 Disconnect field leads from rectifier 2 Set multimeter to read resistance and connect the meter leads to the field leads If field is open meter will read infinite resistance very high ohms Repair or replace field if itis open Typical resistance for these fields va
5. TEST LEAD 60706 130 4 Reverse the meter leads black lead to the DC POS and red to the AC terminals each in turn An opposite reading should be observed 5 Connect the red ohmmeter lead to the negative DC terminal 6 Connect the black lead to each of the AC terminals in turn Either a high or low resistance reading will be obtained 7 Reverse the meter leads black lead to the DC NEG and red to the AC terminals each in turn An opposite reading should be observed 8 Check each terminal to the case An open circuit very high resistance reading should be observed A battery pow ered test light is used Follow the same procedures described above A good diode element will allow current to pass to the light in the test lamp when the leads are connected in the forward direction 9 Ifthe rectifier fails any of the above tests it should be considered defective and replaced Condenser Testing Condensers are built into the generator circuit to minimize radio interference during operation If a condenser shorts out it will also short out the generator output To determine whether a condenser is shorted stop the generator and disconnect the condenser lead wire from the brush holder Using a multimeter on the R x 100 scale check the resis tance of the condenser Normal response is a sharp swing of the meter towards low resistance and then a steady rise towards high resistance open circuit If the capacitor
6. before operating the PTO generator 1 See vehicle manufacturers instructions for operating procedures The generator should be turning at specified rpm and producing correct voltage and frequency If the generator fails to operate as speci fied stop the engine and refer to the trouble shooting section of this manual 2 With the engine running smoothly and at the desired speed check the no load voltage and frequency Generator leads G1 to G3 should read 240 Volts nominal 240 TO 255 volts Leads G1 to GN and G3 to GN both should read a nominal 120 volts 120 to 127 volts at 60 Hz It may be necessary to adjust the voltage regulator to obtain the proper voltage The voltage regulator is located on the left hand side of the generator end cover Final voltage adjustments must be done on the voltage regulator The regulator may not effect the no load voltage to any degree 7150 01 Page 4 Notice KKK AK If for any reason during the check out procedure the voltage and frequency are not correct stop the engine and refer to the troubleshooting procedures After verifying the voltage and frequency are correct prepare for final wiring of the generator by disabling the drive system and or engine The generator can now be connected to the load circuits G GENERATOR ELECTRICAL POWER CONNECTIONS ALL wiring should be done by a licensed electrician and should conform to the national electrical code and with state and local re
7. is shorted it will show as a constant low resistance Otherwise restart the generator without the capacitor con nected to recheck the generator for output If the generator then provides power the condenser was at fault and should be replaced If the generator doesn t provide power the problem was not caused by that condenser reconnect the lead wire If these tests have not located the trouble remove the armature and have it tested for opens shorts and grounds on a growler 4 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 60706 130 Page 7 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 3 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 90 140 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 Amoc
8. reading lower than one meg ohm the armature is grounded Dirt between the slip rings and on the insulator surface can cause ground ing If grounding was indicated carefully clean all dirt off the slip rings and their insulators and then recheck it Replace the armature if it is grounded and unrepairable Open Test Set meter to read low resistance R x 1 ohms Holding one meter lead on surface of slip ring No 1 touch other meter lead to surface of slip ring No 2 while observing the meter Meter should indicate continuity low resistance less than one ohm is typical If the meter indicates open circuit infinite resistance part of armature winding is open This may be caused by a repairable defect in the connection at the slip ring however generally an open armature will have to be replaced Continue reading the continuity between slip ring No 2 to No 3 and No 2 and No 4 All the slip rings should have continuity to slip ring number 2 the neutral ring Testing Rectifiers The field excitation is supplied through a full wave bridge rectifier This type of rectifier has four terminals two AC a DC positive and a DC negative A rectifier may be tested in the following manner 1 2 Page6 Disconnect all leads from rectifier Connect the red ohmmeter lead to the positive DC terminal Connect the black lead to each of the AC terminals in turn Either a high or low resistance reading will be obtained RED
9. 12 months from the date of shipment transportation charges prepaid to your nearest factory authorized service station or the WINCO factory Thereis no other express warranty To the extent permitted by law any and all warranties including those of merchantability and fitness for a particular purpose are limited to 12 months from date of shipment and liability for incidental or consequential damages or expenses is excluded Some states do not allow limitations on the duration of an implied warranty and some states do not allow the exclusion or limitation of incidental or consequential damages so that above limitation or exclusion may notapply to you This warranty gives you specific legal rights you may have other rights which vary from state to state This warranty is limited to bench labor and parts only no allowance will be made for travel time or removal and reinstallation in the truck body This warranty covers only the generator as it was delivered to the Original Equipment Manufacturer WINCO does not warrant drive lines or certain other component parts of the product installed by others since such items are warranted by their manufacturers WINCO does not warrant modifications or alterations which were not made or authorized by the WINCO factory and which affect the stability or reliability of the product WINCO does not warrant products which have been exposed to misuse and or negligence or have been involved in an accident
10. TION Voltage Regulator Mounting Bracket Grommet Machine Screw Lockwasher Flat Washer Hex Nut Sleeving Circuit Breaker Cover avis Page 9 PART NBR 98884 002 64790 000 9336 000 16165 000 484 000 598 000 6372 000 64620 002 91286 003 64791 001 7150 01 GENERATOR ILLUSTRATION 158812 7150 01 Page 10 60706 130 REF GENERATOR REPLACEMENT PARTS LIST DESCRIPTION QTY PART NBR REF DESCRIPTION QTY PART NBR 001 CapScrew5 16 18x2 3 4 002 Lockwasher 5 16 003 Lockwasher Split Type 004 Machine Screw 005 Lockwasher 11 16 Int 006 Flat Washer 007 Lockwasher 008 Hex Nut 1 2 20 009 Lockwasher 010 Cap Screw 1 2 13 x 1 011 Machine Screw 012 Lockwasher 013 Hex Nut 8 32 014 Machine Screw 015 Cap Screw 7 16 20 x1 3 4 016 Cap Screw 7 16 20 x 1 1 2 400 Generator 401 Fan Assembly 411 End Bracket 412 OijlSeal 413 Bearing 414 Retainer Plate 415 Gasket 416 Spacer 417 Pinion Gear 418 Key 419 Lockwasher wA A Generator Specifications kW 20 Volts 120 240 Amps 83 PH 1 Hz 60 Input 1000 1182 RPM Generator 3600 RPM Resistances Field Coils rectifier circuit 17 1 18 8 Ohms Excitor Volts 92 Amps 2 4 Field Coils regulator circuit 11 2 12 6 Ohms Excitor Volts 55 Amps 2 8 full load Armature Q Winding 080
11. amage is noted at time of delivery require that the person making the delivery make note of the loss or damage on the freight bill or sign the consigner s memo of the loss or damage Contact the carrier for claim procedures 3 Remove the four bolts which hold down the generator feet to the pallet 4 Lift the generator from the pallet by means of the lifting eye on the top of the generator 7150 01 Page2 When loss or damage is noted after delivery segregate the damaged material and contact the carrier for claim procedures Concealed damage means damage to the contents of a package which is not evident when the package is deliv ered by the carrier but which is discovered later The carrier or carriers are responsible for merchandise lost or damaged in transit The title to the goods rests with the consignee when the goods are shipped FOB factory and only the consignee can legally file claims Two years are allowed in which to file suit after a claim is disallowed in writing by the carrier INSTALLATION RRR KKK RRR EEEE E E EEEE 2 A RNING Before proceeding with the installation be sure the drive line and engine are disabled and cannot accidentally operate while the generator is being installed Before beginning the installation process recheck the voltage power rating and physical size and drive line rating and speed horsepower etc Be certain they can handle the intended load and are compat
12. e is aligned to within 5 degrees 10 degrees Max The 2510 2512 PTO units will require about 50 Hp to maintain full output be sure that the auxiliary drive on the vehicle transmission and the gear reduction box is capable of the expected mechanical load It is generally recommended that the drive shaft be balanced to minimize drive line vibration and stress Make sure no binding exists in generator or gear box If binding is found locate the cause and correct it before proceeding E PRE WIRE SYSTEM CHECK 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 Before wiring the generator to the distribution load circuits the installation and operation of the drive system and generator should be checked to insure proper drive line engine and generator operation Use the following check List to verify correct installation before starting the engine 1 Drive line straight and tight 2 Unit mounting base and hardware solid and bolts properly torqued 3 Ventilation clear and protected 4 Clearance on all sides and service access on both ends 5 Generator output leads protected from grounding After completing the above checklist the generator is ready for the initial start up test F INITIAL START AND TEST PROCEDURE CAUTION Make sure that all tumbling bar lock pins are engaged and that all safety shields are in place
13. eep clear of the drive line and exhaust runs 3 Mounting Support Frame loading frame type and strength should be taken into consideration when installing an emergency rescue generator under a truck 4 Moisture and Dirt Protection from adverse weather conditions and road spray must be provided without restricting adequate ventilation for cooling All electrical equipment should be protected from excessive moisture Failure to do so will result in deterioration of the insulation and will result in short circuits and grounds Foreign materials such as dust sand tint and abrasive materials have a tendency to cause excessive wear particularly the brushes It is important that the unit be installed in a reasonably clean location for best service life Careful planning will eliminate costly rework 5 Heat and Cold All generators radiate considerable heat when they are running In addition these units are generally mounted in a somewhat restricted location which precludes natural cooling Allow space for cool ing air to sweep across the generator shell It is impor tant that the temperature of the ambient air around the unit not exceed 105 degrees Fahrenheit while operat ing Additional cooling louvers or fans may be neces sary if adequate cooling flow is not naturally provided B MOUNTING THE GENERATOR SYSTEM The generator should be bolted solid to a heavy steel cross channel or plate It is recommended that the generator be mou
14. ers 7 Shorted or open field coils Shorted or open armature Engine speed too slow 1 Generator overloaded Inadequate engine 3 horsepower Incorrect field excitation 4 No load output low Defective voltage regulator 5 Voltage regulator set too high Tumbling bar coupling shaft 1 misalignment Engine speed not constant 2 Tumbling bar U joints not 3 synchronized Power take off misalignment 1 excessive Loose mounting nuts and bolts2 or hold down studs Universal joints in coupling 3 shaft worn or dry Defective bearings 4 Generator overloaded Shorted turns in field or stator windings po Defective seal gasket or plug in gear case ow On N N II CORRECTIVE ACTION Circuit breaker open 1 Reset circuit breakers replace if defective Defective voltmeter 2 Check output with another meter replace meter if defective Short circuit in the load 3 Disconnect the load Check voltage at cord set Check motors appliances and load leads for short circuit Repair short Remove panel cover and check all wiring and connections Tighten and or repair where necessary Test rectifier Replace if defective Clean and polish Use 00 sandpaper or crocus cloth never use emery paper Check brushes for swelling replace defective brushes clean brush holders Measure coil resistance Replace coils if open or shorted Measure between slip ring
15. exhaust gas asphyxiation or fire Please read all safety instructions carefully before installation or use Keep these instructions handy for future reference Take special note 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 1 ELECTRIC SHOCK The output voltage present in 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 t
16. gulations The generator power output leads are marked G1 A amp B G3 A amp B and GN A amp B We use parallel leads from the generator to reduce the wire size and make them eaiser to handle The A amp B wires are always paired together A main line circuit breaker must be installed in the load distrubution panel on the vehicle The G1 and G3 wires are routed to the mainline circuit breaker in the distribution panel The neutral lead GN is run to the neutral terminal in the distribution panel Note Most codes require that the neutral conductor be bonded grounded directly to the frame of the generator Check local codes to insure compliance Refer to the national electrical code NEC for portable mobile equipment No further electrical connections are required The load current carrying wires must be sized to handle the maximum load current without excessive voltage drop By NEC code conductors must be heavy enough to handle the full current rating of the main line circuit breaker or fuse in the load distribution panel protecting the conduc tors All wires should be installed in rigid or flexible conduit Because of the many different types of wiring service feeder and distribution panels used on rescue equipment no specific wiring instructions can be provided KKAKKKAKK KKK KRK 1A RNING If auxiliary shore commercial power may also be con nected to the load for demonstration training or alter
17. ible with the required vehicle equipment voltage phase and current ratings Plans for installation should be prepared with proper attention to me chanical and electrical engineering detail to assure a satis factory system installation The information in this manual is offered as a guide to finalizing your installation plans The installation sequence is summarized below A Plan the installation 1 Space required for installation and service access Protected location close to electrical connections Mounting frame Clear of moisture and dirt Shielded from excess heat and cold SR Mounting the generator system Clear protected source of ventilation of generator Drive line aligned within 5 degrees 10 degrees max Pre wire system check Initial system start up Generator electrical power connections Final system check TOMNmMmO OM A PLAN THE INSTALLATION 1 Space Required The space required should allow for ample working room around and in back of generator A general rule to follow is 12 inches minimum clear ance all around the unit This allows a service person to repair and remove generator parts in the event service is needed In general all service can be performed from the rear generator cover or the front gear case 60706 130 2 Location Locate as close to electrical service as pos sible This will reduce the cost of electrical and minimize the losses in the power conductors Position the unit to k
18. inion Gear Seal Bearing Shaft Input Drive Woodruff Key Gear input Drive Gasket Cover Backing Plate Safety Shield Gear Driven Bearing Gasket Retainer Gasket Retainer Snap Ring Gear Case amp Cover Matched Breather Shaft Driven Roll Pin ill a a re h Page 12 1000 RPM PART NBR 54661 001 44833 000 20029 000 64562 000 46296 000 1774 000 44832 000 20016 000 N A N A 46546 000 54665 000 46299 000 46295 000 46298 000 46286 000 20133 000 54662 000 40716 000 20128 000 4133 000 1181 RPM PART NBR 64557 000 N A 20029 000 64562 000 64556 000 1774 000 46546 000 20016 000 N A N A N A N A 46299 000 64580 000 N A N A N A 64558 000 40716 000 N A 4133 000 60706 130 z991 SS JIN ONNOHO dAv 9 pocos a YOLVINDAY JOVLIOA C90AV YAISVE 7150 01 Page 13 60706 130 WINCO CHASSIS MOUNT PTO GENERATORS 12 MONTH 500 HOUR STANDARD LIMITED WARRANTY WINCO Inc warrants for 12 months or 500 hours which ever occurs first from date of shipment that it will repair or replace at its option for the original user the whole or any part of the product found upon examination by WINCO atits factory at 225 South Cordova Avenue Le Center Minnesota or by any factory authorized service station to be defective in material or workmanship under normal use and service For warranty service return the product within
19. jury or death d Always avoid hot mufflers exhaust manifolds and engine parts They all can cause severe burns instantly INSTALLATION Installing a PTO generator is not a do it yourself project Consult a qualified licensed electrician or contractor The installation must comply with all national state and local codes a Never operate the PTO drive generator without having it properly mounted 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 OPERATION PTO drive shafts Tumbling Bars have many inherent dangers extereme caution must be exercised 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 7150 01 DESCRIPTION The WINCO ECV2510 2512 PTO drive generator will provide 120 240V single phase 60Hz electrical service when direct driven The ECV2510 requires a 1000 RPM input shaft speed and the ECV2512 requires a 1182 RPM input shaft s
20. nate source power an isolation switch must be installed An isolation switch will prevent feed back of commercial power into the generator or generator power into commercial line When the load is connected to the generator there must be absolutely no feedback from the generator to the power line or from the power line to the generator during any operating condition When correctly connected the design of the wiring control system prevents an possibility of feedback Improper installation can create a serious hazard that could result in equipment damage serious personal injury or death 60706 130 H FINAL SYSTEM CHECK 1 Recheck voltages at mainline circuit breaker Voltages should match readings taken at the pre wire check out If problems are noted consult troubleshooting section or factory Turn on the mainline circuit breaker 3 Turn on each load individually first to insure that each load will work properly 4 Turn on all the loads and recheck voltages It may be necessary at this time to adjust the voltage using the voltage regulator mounted on the generator end cover to obtain the proper full load voltage 5 Turn off all the loads and make sure that the no load voltage has stayed within the proper range 6 If all voltages and frequencies stay within the proper range this completes your initial start up procedure OPERATION N Since the generator is self excited and externally regulated there is no need for
21. nted on a steel sub frame which facilitates easy removal of the generator for better service access to the chassis or for generator repair Shock mounting the generator or mounting frame is generally not recommended do to possible harmonic vibration drive misalignment and mounting stress C VENTILATION OF GENERATOR This is an air cooled generator This unit is equipped with a suction fan to cool the armature and field coils Therefore it will be necessary to insure that the hot air discharge plume gets out of the mounting area D DRIVE LINE AND LUBRICATION Check gear case oil level Case should be filled with oil to plug marked OIL LEVEL Fill or remove oil as re quired NOTE EITHER TOO LITTLE OR TOO MUCH OIL CAN HARM THE EQUIPMENT See Lubrication portion of Maintenance for oil specifica tions 60706 130 Page 3 UN OIL FILL LEVEL 1181 RPM _GEARCASE N t gt amp Ze SUIS ES Ss OIL FILL LEVEL 1000 RPM GEARCASE Make sure the drive shaft tumbling bar is assembled with its universal joint knuckles synchronized as illustrated in If knuckles are not synchronized the bar will chatter when rotating which will cause the generator output voltage to flicker PL Synchronized 1 ps co CE 2s A i l a CZ _s S O 7150 01 The PTO drive shaft should be maintained in as straight a line as possible Install the generator so the drive lin
22. o 85W140 or equivalent CAUTION Equipment Damage Do not overfill generator gear case Overfiling 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 1 pint 5 Replace the oil level check plug 6 Replace the breather 7150 01 SYMPTOM CAUSE S No output voltage Low voltage High voltage Output voltage flickering or fluctuation Excessive vibration Generator overheating Oil leak 7150 01 Po O 90 i om Engine speed too fast Poor ventilation Loose plug in gear case TROUBLE SHOOTING TABLE Loose or broken wires or 4 connections in control box Defective rectifier Dirty slip rings Brushes binding in hold
23. o an 8 external ground rod driven into the earth g Do not make or break electrical connection under load 2 FIRE HAZARD Gasoline diesel and other fuels always present a hazard of possible explosion and or fire a Keep a fire extinguisher nearby and know its proper use Fire extinguishers rated ABC by NFPA are appropriate 60706 130 Page 1 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 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 CLEANLINESS Keep the generator and surrounding area 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 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 equipment can cause serious in
24. operational controls for the generator Once the regulator is set it should never have to be adjusted The vehicle manufacturer will provide operation manual for the governor operation and control panel operation MAINTENANCE General Information The main components of the generator are armature field coils cooling fan brushes brush holder assembly end brackets rectifier and voltage regulator 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 59 and 61 Hz cycles per second Operating the generator at frequencies outside that range may cause damage to the generator and or to elec
25. peed NOTE The prime mover which drives the generator must be capable of delivering approximately 2 HP per 1000 watts output from the generator Observe input RPM specifications The generator may be under chassis mounted and driven from a truck transmission with a PTO drive installed in it This generator is a rotating armature design with com pound field coil windings Normal excitation is accom plished via the Q winding in the armature and a full wave bridge rectifier An automatic voltage regulator is installed on the generator to maintain the correct voltage when the unit is under load To reduce maintenance problems the coupling between the generator input shaft and rotor consists of precision helical gearing rather than a chain link drive The input shaft is 1 1 8 in diameter smooth shaft with a key way and center drilled for a roll pin Both must be used at all times WINCO thoroughly tests each of these generators before shipment All are continuous duty rated IMPORTANT THE MANUFACTURER STRONGLY RECOMMENDS RUNNING THE GENERATOR UNDER LOAD AT LEAST ONCE A MONTH IN ORDER TO EVAPO RATE ANY ACCUMULATED MOISTURE CONDENSA TION UNPACKING CAUTION Equipment Damage DO NOT invert generator during unpacking The Gear case contains oil which will leak out if inverted during unpacking Unpack the generator as follows 1 Remove the carton 2 Inspect the generator carefully for freight loss or dam age If loss or d
26. rposes instructions in this manual Used only by operators who understand its operation Should you experience a problem please follow the Properly maintained Things To Check near the end of this manual The warranty listed in this manual describes what you can expect from COPY YOUR MODEL AND SERIAL NUMBER HERE No other WINCO generator has the same serial number as yours It is important that you record the number and other TABLE OF CONTENTS vital information here if you should ever need to contact us on this unit it will help us to respond to your needs faster WINCO should you need service assistance in the future INTRODUCTION i MODEL GUIDETO PRODUCT SAFETY 1 BASICINFORMATION SERIAL NUMBER Description 2 PREPARING THE UNIT Unpacking the unit 2 Assembly INSTALLATION Plan the Installation Mounting Ventilation Drive Line amp Lubrication Pre Wire Checklist Initial Start ELECTRICALCONNECTIONS FINALSYSTEMCHECK MAINTENANCE General Information Periodical Maintenance Generator Maintenance Lubrication TROUBLE SHOOTING TABLE PART LIST Automatic Voltage Regulator 9 Generator Parts List 10 Gear Box Part List 12 WIRING DIAGRAM 13 12 MONTH WARRANTY 14 PURCHASE DATE N DEALER RREO ON oa aa SAFETY INFORMATION 3 This generator set has been designed and manufactured to allow safe reliable performance Poor maintenance improper or careless use can result in potential deadly hazards from electrical shock
27. ry from 17 1 to 18 8 ohms 3 Leaving one meter lead connected to the field connect the other meter lead to the field shell If meter indicates 7150 01 7150 01 continuity any reading should be infinite resistance The field is grounded and should be repaired or replaced To determine which of the fields is grounded cut the connec tor between the two coils and retest to determine which coil has the low resistance path Disconnect field leads F1 amp F2 from regulator Set multimeter to read resistance and connect the meter leads to the field leads If field is open meter will read infinite resistance very high ohms Repair or replace field if it is open Typical resistance for these fields vary from 11 2 to 12 1 ohms Leaving one meter lead connected to the field connect the other meter lead to the field shell If meter indicates continuity any reading should be infinite resistance the field is grounded and should be repaired or replaced To determine which of the fields is grounded cut the connec tor between the two coils and retest to determine which coil has the low resistance path Testing the Armature for Opens and Grounds Remove all brushes Ground fault test set multimeter to read high resistance meg ohms Holding one meter lead against a clean spot on the armature shaft touch the other lead to each of the slip rings one at a time while observing the meter If meter indicates continuity any
28. s for open or shorts Replace arm if defective Check engine speed Increase RPM if necessary Reduce load if it is higher than the rated capacity of the generator See generator nameplate Generator requires 2 HP 1000 watts output Check for worn brushes and weak or broken brush springs replace as required Check input AC voltage to rectifier Check rectifier output DC voltage to positive DC brush If no DC voltage is present at the brush replace the rectifier Check for dirty slip rings Clean them if they are dirty Check regulator for output Repair or replace as required Check engine speed for correct input RPM Have qualified service technician adjust the regulator Reduce tumbling bar misalignment to less than 15 degrees Engine governor may be worn or improperly adjusted Set or repair defective governor Reassemble tumbling bar Correct misalignment It should be less than 15 degrees Tighten mounting nuts and bolts repair hold down stud mountings Repair or replace defective parts Check for possible causes Replace defective bearings Clean ventilation and cooling fan screens Reduce load then check voltage and current Replace defective components Tighten plug Replace seal s gaskets or plugs Maintain correct oil level Page 8 60706 130 REF 001 002 003 004 005 006 007 008 009 010 60706 130 AUTOMATIC VOLTAGE REGULATOR ASSEMBLY gt Ay o DESCRIP
29. trical 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 60706 130 Page 5 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 electri cal windings The maintenance and service attention in vested will insure getting the peak performence 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 Generator Maintenance A Brushes Under ordinary circumstances brushes will operate for ex tremely long periods without requiring replacement They should be inspected after the first 500 hours of operation and after every 200 hours of operation thereafter Remove brushes one at a time and check for length be sure that each moves freely in the brush holder Brushes should be replaced when
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