W10PTOS/A - Winco Inc.
Transcription
W10PTOS/A - Winco Inc.
COMPACT SERIES TRACTOR DRIVE GENERATOR W10PTOS/A TABLE OF CONTENTS SAFETY INFORMATION SPECIFICATIONS UNPACKING INSTALLATION FOUNDATION MOUNTING TRAILER MOUNTING THREE POINT HITCH MOUNTING ELECTRICAL CONNECTIONS LOAD DISCONNECT PLUG INSTALLATION PRE-START CHECKLIST GENERATOR STARTING PROCEDURE PTO ALIGNMENT STORAGE & MAINTENANCE REQUIREMENTS LUBRICATION SERVICE DIAGNOSIS COMPLETE UNIT ASSEMBLY ILLUSTRATION WIRING DIAGRAM RECEPTACLE PANEL ASSEMBLY TWO WHEEL TRANSPORT WINCO LIMITED WARRANTY 3 4 4 4 4 5 5 6 7 7 8 8 9 9 10 11 12 14 15 16 MODEL ______________________________________ Copy you 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 vital information here. If you should ever need to contact us about this unit it will help us to respond to your needs faster. SERIAL NUMBER _____________________________ PURCHASE DATE _____________________________ DEALER _____________________________________ CAUTION FOLLOW THE INSTRUCTIONS IN THE OWNER’S MANUAL SPECIFICALLY WHEN PUTTING THIS PTO GENERATOR INTO SERVICE. IMPORTANT ALL STANDBY POWER PLANTS INCLUDING TRACTOR DRIVEN GENERATORS SHOULD BE PERIODICALLY EXERCISED. FOR PROPER MAINTENANCE OF YOUR TRACTOR DRIVEN GENERATOR, IT SHOULD BE OPERATED FOR ONE HOUR CARRYING RATED LOAD AT LEAST TWICE A YEAR. THIS WILL ASSURE THAT YOUR PTO GENERATOR IS IN OPERATING CONDITION AND READY FOR USE WHEN THE NEED ARISES. 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 model from Winco. This 10,000 watt generator is designed to provide120/240V single phase electrical power for standby and utility service when commercial power is interrupted, inaccessible or impractical. This PTO unit has a cast iron gear case with a 1-3/8” – 6 spline, 540 rpm rated input shaft (unit operating speed is 515 RPM) and brushless, heavy-duty 3600 rpm, 2 pole, low waveform distortion generator. This compact PTO generator unit is designed to provide reliable electrical power for customers who already have a compact utility tractor with 20 to 30 horsepower and a 540 rpm rated 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 applications 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. 60706-241 3225-00 SAFETY INFORMATION 4. NOISE HAZARD - Excessive noise is not only tiring, but continual exposure can lead to loss of hearing. 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, 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. __________________________________________________ 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. Remove all grease, ice, snow or materials that create slippery conditions around the unit. Remove any rags or other material that could create potential fire hazards. a. Use only factory approved repair 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 injury or death. 7. INSTALLATION- Installing a PTO generator is not a “do-ityourself” 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 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. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. ___________________________________________________ a. b. 6. SERVICING EQUIPMENT- All service, including the installation or replacement of service parts, should be performed only by a qualified technician. WARNING: a. b. c. d. e. f. g. Use hearing protection equipment when working around this equipment for long periods of time. Keep your neighbors in mind when permanently installing this equipment. 5. CLEANLINESS- Keep the generator and surrounding area clean. __________________________________________________ a. b. Do not allow anyone to operate the generator without proper instruction. Guard against electric shock. Avoid contact with live terminals or receptacles. Use extreme care if operating this unit in rain or snow. Use only three-prong grounded plugs and extension cords. Be sure the unit is properly grounded to an external ground rod driven into the earth. Do not make or break electrical connection under load. 8. OPERATION - PTO drive shafts (Tumbling Bars) have many inherent dangers, extreme 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. g. ALWAYS connect the shield anti-rotation chain to the tractor safety shield 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. 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. 3225-00 60706-241 DESCRIPTION UNPACKING The WINCO rotating field power take-off generators are designed primarily for hobby/small farm use as a standby electrical power supply, utilizing the power take-off of a tractor or truck as the prime mover. This PTO drive generator will provide 120/240V single phase, 60Hz electrical service when properly driven. CAUTION: Equipment Damage DO NOT invert generator during unpacking. The Gearcase contains oil which will leak out if inverted during unpacking. Unpack the generator as follows: 1. Remove the carton. 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. 2. Examine the unit for damage. 3. Find the small subpack carton packed in the large carton. Be careful not to throw away the subpack carton with the large carton. This generator may be mounted in many different fashions. The three most popular are foundation mounted, trailer mount or 3point hitch mounted, for used as a standby or portable electrical power source. Your application will dictate how you may want to mount it. 4. Open the subpack carton and make sure it contains: a. Generator instruction manual b. Load disconnect plug (disassembled, in bag) This generator includes a color coded voltmeter to warn against high or low voltage, and two output power receptacles with individual circuit breakers for your protection. 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 a 1 3/8 in. diameter 6 spline shaft. 5. Remove the four bolts which hold the generator feet to the pallet. 6. Lift the generator from the pallet by means of the lifting eye on the top of the generator. The factory thoroughly tests each generator before shipment. All are continuous duty rated. 7. Inspect the generator carefully for freight loss or damage. If loss or damage 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 consignee’s memo of the loss or damage. Contact the carrier for claim procedures. IMPORTANT: THE MANUFACTURER STRONGLY RECOMMENDS RUNNING THE GENERATOR UNDER LOAD AT LEAST ONCE A MONTH IN ORDER TO EVAPORATE ANY ACCUMULATED MOISTURE CONDENSATION AND TO KEEP THE UNIT IN GOOD WORKING ORDER. When loss or damage is noted after delivery, segregate the damaged material, and contact the carrier for claim procedures. SPECIFICATIONS “Concealed damage” means damage to the contents of a package which is not evident when the package is delivered 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. Model Number W10PTOS/ Wattage 10000 Amperage 42 Input Speed 515 RPM Generator Speed 3600 RPM Input Shaft 1 3/8” - 6 spline Tractor PTO Hp Required 20 Gear Lube Volume 16 ounces Type 85/90W-140 Features * Brushless, low harmonic design with skewed rotor and damper windings for minimal load noise * Capacitor Excitation * Dual voltage - 120/240 volt output * 4 wire Load connection plug for convenient full load 120/ 240 volt output cord set * 15 Amp duplex convenience receptacle * Large face Voltmeter for proper speed setting and adjustment 60706-241 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” or “THREE POINT HITCH MOUNTING” if generator will be used as a portable power source. When planning a foundation consider the following points: A. The foundation 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 5 degrees during generator operation, even though the mechanical design of the tumbling bar would allow greater misalignment. 3225-00 the shouldheight enable aligning the drive shaft (tumbling bar)on C.trailer The trailer and mounting position of the generator inthe a straight or nearly straight line the between the power take-off trailer should enable aligning drive shaft (tumbling bar) the trailer should enable aligning the drive shaft (tumbling bar) and generator input shafts. Misalignment must be lesstake-off than 10 straightorornearly nearly straight linebetween between thepower power inina astraight straight line the take-off degrees during input generator operation, even though mechaniandgenerator generator shafts. Misalignment mustbebethe less than10 5 and input shafts. Misalignment must less than cal design of theenable tumbling bar would allow greater misalignthe trailer should aligning the drive shaft (tumbling bar) degrees during generator operation, even though the mechanical degrees during generator operation, even though the mechaniinment. adesign straight or nearly straight line between the power take-off ofof the tumbling bar would allow greater misalignment. cal design the tumbling bar would allow greater misalignand generator input shafts. Misalignment must be less than 10 ment. degrees during generator operation, even though the mechaniD. generator mounting area of of thethe trailer bed should bebe flat. D.The The generator mounting area trailer bed should flat. cal design of the tumbling bar would allow greater misalignD. The generator mounting area of the trailer bed should be ment. All four generator mounting pads must rest firmly on the trailer flat. All fourInstall generator padstomust on under the trailer bed. shimsmounting if necessary evenrest outfirmly the bed the shims if necessary to the even out the bed under D.bed. The Install generator mounting area of trailer bed should bethe mounting pads, then bolt the generator firmly in place. All four generator mounting pads must rest firmly on the trailer flat. mounting pads, then bolt the generator firmly in place. bed. Install shims if necessary to even out the bed under the mounting pads, then boltPOINT the generator firmly in place. WINCO THREE HITCH AllWINCO four generator mounting pads must rest firmly on the trailer THREE POINT HITCH bed. Install shims if necessary to even out the bed under the WINCOpads, THREE POINT HITCH mounting then bolt the generator firmly in place. B. The foundation must be solid enough to absorb generator starting and reflected load torque during operation. B. The foundation must be solid enough to absorb generator and reflected torque during operation. B. starting The Thefoundation foundation mustload beshould solid enough C. surface be flat. to absorb generator starting and reflected load torque during B. The foundation must be solid enough tooperation. absorb generator C. The foundation surface should be flat. D.starting Space and is required around the generator for mounting reflected load torque during operation. C. The foundation surface should be flat. switching devices, making connections, and for servicing. D. Space is required around the generator for mounting C. The foundation surface should be flat. making connections, and for servicing. D.switching Space isdevices, required around the generator forevenly mounting E. The generator mounting bracket must rest and switching devices, making connections, and for servicing. WINCO D. Space around the generator mountingto even firmly isonrequired the foundation. Install shims iffor necessary E. The generator mounting bracket must rest evenly and out the foundation under the mounting and padsfor then bolt the switching devices, making connections, servicing. the foundation. shims if necessary even E. firmly The on generator mountingInstall bracket must rest evenlytoand firmly generator firmly in place. out the foundation under the mounting pads then bolt the founon the foundation. Install shims if necessary to even out the E. The generator mounting bracket must rest evenly and generator in place.pads then bolt the generator firmly in dation under firmly the mounting firmly on theMOUNTING foundation. Install shims if necessary to even TRAILER place. out the foundation under the mounting pads then bolt the THREE POINT HITCH TRAILER MOUNTING generator firmly in place. Mount the generator on a trailer if you plan to use it as a TRAILER MOUNTING portable power source. When selecting or building a trailer to Mount the generator onNumber a trailer TDM76 if you plan to use it as a TRAILER MOUNTING Optional Trailer Part mount the generator, consider the following points: portable power source. When selecting or building a trailer to mount the consider theif following points: Mount thegenerator, generator on a trailer you planenough to use ittoas a portable A. The construction mustif be support Mount thetrailer generator on a trailer youstrong plan to use it as a power source. When selecting or building a traileratotrailer mount portable power source. When selecting or building to the the generator. A. The trailer construction must bepoints: strong enough to support generator, consider the following mount the generator, consider the following points: the generator. B. The design of the trailer must enable the trailer to remain A. trailer construction must be strong enough tobysupport during operation, and tobe resist tipping caused A.stable TheThe trailer construction must strong enough to support B. The design of the trailer must enable the trailer to remain the generator. generator starting and reflected load torque. the generator. stable during operation, and to resist tipping caused by generator startingofand load torque. B. The design the reflected trailer must enable theDamage trailer to remain Injury Equipment B.WARNING: The design Personal of the trailer must&enable the trailer to remain Optional -Point Hitch Part Number TPH0 stable during operation, and to resist tippingcaused caused by generator Optional 3-Point Hitch Part Number TPH240 stable duringMAY operation, and AND to resist tipping TRAILER TIP OVER CAUSE INJURIESby IF WARNING: Personal Injury & Equipment Damage Optional -Point Hitch Part Number TPH0 starting and reflected load torque. WHEELS ARE NOT FARtorque. ENOUGH APART. generator starting and SPACED reflected load WARNING: Injury & Equipment Damage WARNING:Personal Personal Injury & Equipment Damage TRAILER MAY TIP OVER AND CAUSE INJURIES IF WHEN USING THE 3-POINT HITCH ASSEMBLY ALL WHEN USING THE 3-POINT HITCH ASSEMBLY ALLTHREE THREE WHEELS ARE NOT SPACED FAR ENOUGH APART. WARNING: Personal Injury & Equipment Damage WARNING: Personal Injury & Equipment Damage WARNING: Personal Injury & Equipment Damage Optional -Point Hitch Part Number TPH0 FAILPOINTS MUST BE ATTACHED TO THE TRACTOR. POINTS MUST BE ATTACHED TO THE TRACTOR. WHEN USING THE 3-POINT HITCH ASSEMBLY ALL FAILURE THREE TRAILER MAY TIP OVER AND CAUSE INJURIES IF WHEELS TRAILER MAY TIP OVER AND CAUSE INJURIES IF URE TO SO DO WILL SO WILL CAUSE GENERATOR TO WHEN TIP TO DO THETHE GENERATOR TO TIP POINTS MUST BE CAUSE ATTACHED TO THE TRACTOR. FAILARE NOT SPACED FAR ENOUGH APART. APART. WHEELS ARE NOT SPACED FAR ENOUGH WHEN LIFTING IT DAMAGING BOTH THE T-BAR AND THE WARNING: Personal Injury & Equipment Damage LIFTING ITSO DAMAGING BOTH THE T-BAR AND TO THETIP GENURE TO DO WILL CAUSE THE GENERATOR WHEN USING THE 3-POINT HITCH ASSEMBLY ALL THREE GENERATOR. ERATOR. WHEN LIFTING IT DAMAGING BOTH THE T-BAR AND THE POINTS MUST BE ATTACHED TO THE TRACTOR. FAILGENERATOR. URE TO DO SO WILL CAUSE THE GENERATOR TO TIP A.A.The three point hitch must be attached to to thethe tractor at at allall The three point hitch must be attached tractor times during operation. WHEN LIFTING IT DAMAGING BOTH THE T-BAR AND THE duringpoint operation. A.times The three hitch must be attached to the tractor at all GENERATOR. times during operation. B.B.When operating thethe generator thethe three point hitch and When operating generator three point hitch and generator must be sitting on flat level ground. All four deck A. generator The three must point hitch must be attached to the tractor at all bethe sitting on flat the level ground. fourand deck pads B. When operating generator three pointAll hitch times during operation. pads must be in constant contact with the ground at all This will must be in constant contact with the ground at all times. generator must be sitting on flat level ground. All four deck times.the This will reduce thethe vibration in both the reduce vibration in both generator the generator tumbling pads must be in constant contact with theand ground at all bar. and the tumbling B. When operating thebar. generator the three point hitch and times. This will reduce the vibration in both the generator generator mustthe begenerator sitting on must flat level ground. All four C. be bolted to the threedeck point andFor thesafety tumbling bar. C. For deck safetyusing theingenerator must bewith bolted the three pads must be constant contact the to ground at allpoint hitch all four mounting bolts times. This will reduce themounting vibrationbolts in both the generator hitch deck using all four C. For safety the generator must be bolted to the three point and the tumbling bar. hitch deck using all four mounting bolts C. For safety the generator must be bolted to the three point hitch deck using all four mounting bolts Optional Trailer Part Number TDM7 Optional Trailer Part Number TDM7 C. The trailer height and mounting position of the generator on C. The trailer height and mounting position of the generator on Optional Trailer Part Number TDM7 0310-00 C. The trailer height and mounting position of the generator on 3225-00 0310-00 Page 3 Page3 60706-180 60706-241 60706-180 ELECTRICAL CONNECTIONS ELECTRICAL CONNECTIONS DANGER: PERSONAL INJURY IFDANGER: THE GENERATOR IS TOINJURY BE USED AS A STANDBY PERSONAL POWER SOURCE, A MANUAL TRANSFER SWITCH MUST IF THE GENERATOR IS TO BE USED AS A STANDBY BE INSTALLED TO SEPARATE GENERATOR AND THE POWER SOURCE, A MANUALTHE TRANSFER SWITCH COMMERCIAL POWER LINES. THE SWITCH MUST ISOLATE MUST BE INSTALLED TO SEPARATE THE GENERATOR THE GENERATOR FROM THE COMMERCIAL POWER LINES AND THE COMMERCIAL POWER LINES. THE SWITCH AND THE LOAD WHEN THE GENERATOR ONCOMSTANDBY, MUST ISOLATE THE GENERATOR FROMIS THE AND MUST POWER ISOLATELINES THE COMMERCIAL POWER MERCIAL AND THE LOAD WHENLINES THE FROM THE LOAD AND THE GENERATOR WHEN THE GENGENERATOR IS ON STANDBY, AND MUST ISOLATE ERATOR IS SUPPLYING POWER. SEE FIGURE THE COMMERCIAL POWER LINES FROM THE 6LOAD CAUTION: Only qualified electricians should install electrical wiring. Only qualified electricians should install electrical wiring. Wiring must conform to all applicable national, state, and Wiring must conform to all applicable national, state, and lolocal codes. (Reference: National Fire Protection Associacal codes. (Reference: National Fire Protection Association tion Manual No. 70, National Electrical Code.) Manual No. 70, National Electrical Code.) CAUTION: AND THE GENERATOR WHEN THE GENERATOR IS SUPPLYING POWER. SEE FIGURE 6 FIGURE 6 60706-180 Page 4 60706-241 Figure 0310-00 3225-00 A properly rated and installed double throw manual power isolaA properly rated and manual powerThe tion transfer switch mustinstalled be useddouble with a throw standby generator. isolation transfer switch must be used with a standby transfer switch isolates the load from the power line and generaallows tor.to The transfer switch the load from the power line you safely operate your isolates loads without endangering the power and allows youSee to safely your loads without endangerline repair crew. page operate 6. ing the power line repair crew. See page 4. The load, connected to the normal terminals of the transfer switch, energized by the normal power line when thetransfer switch is The is load, connected to the normal terminals of the in switch, the normal position. by The connected to the is energized thegenerator, normal power line when theemerswitch gency the switch, furnishes power when the is in terminals the normalofposition. The generator, connected to switch the is emergency in the emergency mode position. 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 thetwo leftways side of to install the switch between Thereonare to page install6aismanual transfer switch. The the watt-hour meter the normal panel. with first shown on the and left side of pagedistribution 4 is to install the As switch any systemthe youwatt-hour must install an entrance rated breaker before the between meter and the normal distribution panel. manual transfer switch.you The manual switchrated mustbreaker in all As with any system must installtransfer an entrance cases bethe equal to or greater the The ratingmanual of the entrance rated before manual transfer than switch. transfer switch breaker. 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 anThe emergency distribution and move circuits you second way to installpanel the system is tothe purchase and wish install to an back up to the distribution new distribution In this the manual emergency panelpanel. and move thecase circuits you transfer switch be sized to the panel. amperage of the circuit wish to backonly up tohas thetonew distribution In this case the breaker the mainswitch distribution panel that is feeding See the of manualintransfer only has to be sized to the it. amperage right 6. distribution panel that is feeding thehand circuitdrawing breakeroninpage the main it. See the right hand drawing on page 4 Before deciding which system to install, first determine which loads youdeciding can safely run system on your to PTO generator and the cost Before which install, first determine which of loads buying a large manual versus theand costthe of cost a you can safely runtransfer on yourswitch PTO generator smaller switch and the additional distribution panel.the cost of a of buying a large manual transfer switch versus smaller switch and the additional distribution panel. The final item that you are going to have to assemble/wire is the plug willitem be used to connect thetogenerator to the manual is Thethat final that you are going have to assembly/wire transfer switch. You have foundthe thisgenerator load plugtointhe a small the plug that will beshould used to connect box when transfer you unpacked PTO generator. If youthis need addimanual switch.the You should have found load plug tional sites you can the order additional plugsIf from in a plugs small for boxmultiple when you unpacked PTO generator. you your Winco dealer,plugs the part number is “300137”. need additional for multiple sites you can order additional plugs from your Winco dealer, the part number is “300137”. To assemble and wire the load disconnect plug, proceed as folTo assemble and wire the load disconnect plug, proceed as lows: follows: outer jacket 2-3/4”. 1. 1. StripStrip outer jacket 2-3/4”. 2. Cut and strip leads to lengths specified for the 2. Cut and strip leads to lengths specified for the particular particular plug.plug. Disassemble cable clamp cover. 3. 3. Disassemble cable clamp andand top top cover. 4. Remove one blade at a time, insert the stripped end 4. Remove one blade at a time, insert the stripped end of the appropriate colored wire designated above, of the appropriate colored wire designated above, and tighten the set screw. and Fit tighten thethrough set screw. 5. blades slots in bottom cover and push 5. Fit blades through slots in bottom and push down until home. Please note:cover Make sure blades Make sure blades with down home. slots Please areuntil in correct andnote: oriented in accordance are the in correct slots and or oriented accordance diagram above you willinnot be able towith close the diagram above or you will not be able to close the top cover fully. the top cover 6. Place top fully. plastic cover over assembly and partially 6. Place top plastic cover assembly over assembly and partially tighten the bakelite screw. Realign blades they fit screw. into the Realign top bakelite tighten the straight bakelite (so assembly housing properly) and blades straight (so they fit tighten into thethe topassembly bakelite screw. 7. Assemble cable clamp over the outer jacket of the housing properly) and tighten the assembly screw. wire and tighten the two clamp screws. Special 7. Assemble cable clamp over the outer jacket of the Note: sizethe round (less than 3/4”) and flat cables, the wireFor andsmall tighten two clamp screws. may be inverted. Special wire Note:clamp For small size round (less than 3/4”) and flat cables, the wire clamp may be inverted. WARNING - Personal Injury: Failure to wire as instructed may cause personal injury or WARNING: Failure to wire as instructed may cause damage to device or equipment. To be installed or checked personal injury or damage to device or equipment. To be by an electrician or qualified person only. installed or checked by an electrician or qualified person only. PRE-START CHECKS PRE-START CHECKS WARNING: Personal Injury When workingPersonal on or around these generators, do not wear WARNING: Injury loose clothing or anythese articles that maydo get Whenfitting working on or around generators, notcaught wear in moving parts. loose fitting clothing or any articles that may get caught in moving parts. 1. Visually inspect the generator. Check for: 1. Visually inspect the generator. Check for: a Correct mounting Correct b. Physical damage a mounting b. Physical c. Debris in cooling vents and screens (could damage cause generator overheat). c. Debris in cooling vents to and screens (could WARNING: Personal Injury DISCONNECT POWER BEFORE WARNING: Personal Injury WIRING DISCONNECT POWER BEFORE WIRING IMPORTANT: Use copper wire only. Do not use tinned conductors. Sizing Use cablecopper - see NEC 400-5.Do not use tinned IMPORTANT: wire only. conductors. Sizing cable - see NEC 400-5. CORD SIZE: #4/4 conductor cord SO, 1.25 inch dia. max. CORD SIZE: #4/4 conductor cord SO, 1.25 inch dia. max. cause generator to overheat). IMPORTANT: The manufacturer that, if the generator IMPORTANT: The recommends manufacturer recommends that, if thehas genbeen stored for any length of time, before using it,using the operator has been stored for any length of time, before it, erator remove the control box cover and and cooling fanfan screen, the operator remove the control box cover cooling then inspect the generator for rodent nestsnests or other objects screen, then inspect the generator for rodent or other obthat cause generator binding and/or overheating. See jectscould that could cause generator binding and/or overheating. “Cleaning” portion of Maintenance section. See “Cleaning” portion of Maintenance section. Check oil (See 2. 2. Check geargear casecase oil level. level. (See Figure Figure 4.) Case should4.) be filled should be filled with with Case oil to plug marked “OIL oil toFill plug LEVEL.” ormarked remove“OIL oil as LEVEL.” Fill or remove oil required. as required. NOTE: EITHER TOO LITTLE OR NOTE: EITHER TOO MUCH OILTOO CANLITTLE HARM THE OR TOO MUCH OIL CAN HARM EQUIPMENT. THE EQUIPMENT See “Lubrication” portion of See “Lubrication” portion of MainMaintenance for oil specifications. tenance for oil specifications. Figure 2 0310-00 3225-00 Page 5 60706-180 60706-241 3.3. Make sure thethe drive shaft (tumbling bar) is is assembled with Make sure drive shaft (tumbling bar) assembled its with universal joint knuckles “synchronized,” as illustrated its universal joint knuckles “synchronized,” as il- in Figure 7. If knuckles synchronized, the bar will chatlustrated in Figure are 7. Ifnot knuckles are not synchronized, terthe when which willrotating, cause the generator output barrotating, will chatter when which will cause the voltage to flicker. Drive shafts shipped new from Winco are algenerator output voltage to flicker. Drive shafts shipped ways synchronized and tethered so they can not be taken new from Winco are always synchronized and tethered apart. so they can not be taken apart. DANGER: Personal Injury DANGER: Injury POWERPersonal TAKE-OFF MUST BE DISENGAGED AT THIS TIME. POWER TAKE-OFF MUST BE DISENGAGED AT THIS TIME. 4. Couple the tractor to the generator with the drive shaft (tum4. bling Couple tractor the generator the drive shaft bar). the Couple thetotumbling bar to with the generator input (tumbling bar). Couple the tumbling bar to the generashaft first, then to the power take-off shaft. Check aligntor input shaft first,take-off then to shaft the power take-off shaft. ment, tractor, power (tumbling bar), and genCheck alignment, tractor, power take-off (tumbling erator input shaft should form a straight (orshaft nearly straight) bar), and generator shaft should form athe straight line, with less than 10°input misalignment between shafts. (or nearly straight) line,generator with less output than 5°voltage misalignment Misalignment will cause to flicker. between the shafts. Misalignment will cause generator output voltage to flicker. CAUTION: Make sure that all tumbling bar lock pins are engaged and that WARNING - Personal all safety shields are inInjury place before operating the PTO Make sure that all tumbling bar lock pins are engaged and generator. 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 pro5. ceeding. 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 gen- erator will not draw more current than the ratings of the gen6.erator Make sure that or thecord electrical loadswill to supply be driven the receptacle set which theby current. generator will not draw more current than the ratings of the generator receptacle or cord set system which will supply 7. Check all electrical connections in the to be enerthe current. gized by the generator. Make sure the connections are correct and are tight. 7. Check all electrical connections in the system to be energized the generator. sure connections 8. Make sure allby loads are turnedMake off. Do notthe start the generaare correct and are tight. tor under load. 8. Make sure all loads are turned off. Do not start the gen- 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 60706-241 Set the manual transfer mid or normal (up) 4. 1.Watch voltmeter on theto generator and slowly increase position. engine speed until the output reaches approximately 240 to 245 volts, in green portion of voltmeter scale. 2. With the power take-off drive disengaged, start the engine which willcord driveset the generator. RunPlace the engine long 5. Plug 4 wire load into receptacle. transfer enough to emergency warm it up before proceeding, so that it will switch in the position. run smoothly and achieve full power under generator load. 6. Place the load circuit breaker in the “on” position. If the breaker trips, move manual transfer switch to “off” or 3. With engine idling, engage the power take-off drive. normal position. Check for short circuit or grounded connection in the load cable to the double throw switch and 4. Watch the voltmeter on the generator and slowly repair. A breaker that trips from overload or short circuit increase engine speed until the output reaches approximust be reset moving to in “off” before reclosing. mately 240 by to 245 volts, green portion of voltmeter 7. With engine and generator running smoothly, switch on the scale. electrical load while watching the voltmeter. Readjust engine throttle to keep generator output under load at 240V CAUTION: Equipment Damage (in green portion of voltmeter scale). If engine is equipped Most electrical equipment in North America operates satwith speed governor, it may automatically readjust the isfactorily at frequencies between 59 and 61 Hz (cycles per throttle as the load changes and keep the generator output second). Operating the generator at frequencies outside at the proper level. However, some governors are not senthat range may cause damage to the generator and/or to sitive enough to maintain proper output under changing electrical equipment driven by the generator. load, and in such cases the throttle will have to be manually readjusted . 5. Plug 4 wire load cord set into receptacle. Place transfer switch in the emergency position. NOTE: Equipment Damage If the load includes motors turn them on one at a time, 6. Place the load circuit breaker in the “on” position. If highest starting current motor first, next highest second, the breaker trips, move manual transfer switch to “off” etc. or normal position. Check for short circuit or grounded connection in the load cable to the double throw switch 8. The return of normal power will be indicated by the and repair. A breaker that trips from overload or short lamp on the front transfer switch;to(applicable when circuit must be of reset by moving “off” beforeonly reclosing. the transfer switch is equipped with indicating lamps or electrician them). After sufficient timeon to 7.yourWith engine has and installed generator running smoothly, switch assure that power restoration isn’t temporary, return the the electrical load while watching the voltmeter. Readtransfer switchthrottle to normal power (10 - 20 output minutes). just engine to keep generator under load at 240V (in green portion of voltmeter scale). If engine is equipped with speed mayposition. automatically 9. Place the alternator circuit governor, breaker init“off” Do not readjust throttle as thethe load changes and keep the remove plugthe before opening breaker. generator output at the proper level. However, some governors not sensitive enough maintain proper 10. Slowly reduceare power take-off speed to to a minimum and output under changing load,Some and intractors such cases disengage the power take-off. have the a brake will take-off have to that be manually on throttle the power stops thereadjusted. shaft instantly. Stopping the alternator rotor instantly from rated speed may NOTE: Equipment Damage result in a broken shaft or other drive line failures. If the load includes motors turn them on one at a time, highest starting current motor first, next highest second, etc WARNING: Personal Injury Never try to manually stop the generator. Always let it 8. until The return of normal power will be indicated by the coast it stops. lamp on the front of transfer switch; (applicable only when the engine. transfer switch is equipped with indicating 11. Shut off the lamps or your electrician has installed them). After sufficient timedrive to assure that powerbar) restoration isn’t tempo12. Disconnect shaft (tumbling rary,take-off return the switch to normal power endtransfer first, then generator end.power (10 - 20 minutes). GENERATOR erator under load. STARTING PROCEDURE 60706-180 to warm it up before proceeding, so that it will run smoothly GENERATOR STARTING and achieve full power under generator load. PROCEDURE 3. With engine idling, engage the power take-off drive. 13. Exercise PTO alternator for one hour under load at least 9. Place the alternator circuit breaker in “off” position. Do twice a year. not remove plug before opening the breaker. Page 6 0310-00 3225-00 3. 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. Stopping the alternator rotor instantly from rated speed may result in a broken shaft or other drive line failures. WARNING: Personal Injury The splined generator input shaft should be cleaned and lubricated with a thin film of grease before and after each use of the generator. See Figure 6 for lubrication schedC. ule. The splined generator input shaft should be cleaned and lubricated with a thin film of grease before and after each use of the generator. See (tumbling Figure 6 for lubrication 4. The drive shaft bar) requires schedule. greasing. Keep the universal joints in the coupling shaft free from grease and D. dirt Thebuildup. drive shaft (tumbling bar) requires greasing. Keep the universal joints in the coupling shaft free from grease and dirt buildup.Do not over lubricate NOTE: the universal joints. 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. STORAGE MAINTENANCE STORAGE& & MAINTENANCE IfIfthe thegenerator generatorisismounted mountedon onan anoff-highway off-hightrailer, such such as theasWinco trailer,trailer, it should way trailer, the Winco it be stored a garage, or machine shed shouldinbe stored inbarn a garage, barn or ma-in a dry and clean location. The generator chine shed in a dry and clean location.should The be coveredshould with a be tarpaulin to with prevent the generator covered a tarpaulin entrance of the dust, chaff, and/or moisture. to prevent entrance of dust, chaff, and/or moisture. The generator may be stored on end, provided the on abe clean, dryonelevated Thegenerator generatorismay stored end, surface such as a board. Do have dry it resting provided the generator is on not a clean, elon a dirt surface. (Figure 3) evated surface such as a board. Do not have it resting on a dirt surface. (Figure 3) MAINTENANCE REQUIREMENTS MAINTENANCE REQUIREMENTS LUBRICATION 1.LUBRICATION Check the generator gear case oil level before each use of the generator. See Figure 4. Maintain the oil level before A. each Check theofgenerator gear case oil level use the generator. Maintain the before oil leveleach at oiluse level of the generator. Seegenerator Figure 4. isMaintain level before plug height. The shippedthe withoillubricant in the each usecase. of theSpecifications generator. Maintain oil level at oilare: levelAPI plug gear for gearthe case lubricant height. The GL-5 generator is shipped withSAE lubricant in the gear case. Service: EP Rated, Grade: 85W-90-140, Specifications case lubricant are: Service: Amount: 1 for pint.gear The following kinds of API oil are recom-GL-5 EP Rated, Grade: Amount: 1 pint. The following mended forSAE use 85W-90-140, in the generator gear case: kinds of Mobil oil areSAE recommended useService in the generator gear case: 85W90-140for API GL-5 Sunoco/DX Mobil SAE 85W90-140 API Service GL-5 XL80W90-140 Kendal Sunoco/DX ThreeXL80W90-140 Star 85W-140 Amoco Kendal85W140 Three Star 85W-140 or equivalent Amoco 85W140 or equivalent CAUTION: Equipment Damage CAUTION: Equipment Damage Do not overfill generator gear case. Overfilling causes Do not overfill generator case. Overfilling causes overheatoverheating and oil sealgear failure. ing and oil seal failure. 2. The generator bearings are factory lubricated and sealed, B. and Therequire generator bearings are factory lubricated and sealed, no further lubrication. and require no further lubrication. 3. The splined generator input shaft should be cleaned and lubricated with a thin film of grease before and after each use of the generator. See Figure 6 for lubrication schedule. 4. The drive shaft (tumbling bar) requires greasing. Keep the universal joints in the coupling shaft free from grease and dirt buildup. 3225-00 NOTE: Do not over lubricate NOTE: Do not over lubricate the universal joints. CLEANING CLEANING 1. Inspect for loose or broken wiring connections. Make sure A. Inspect for loose or broken wiring connections. Make sure that wiring connections are not loose at the generator end, that wiring connections are not loose at the generator end, circuit Page 7 0310-00 circuit breakers, and receptacles. breakers, and receptacles. 2. Do not allow dirt or chaff to collect in the interior of the B. Do not allow dirt or chaff to collect in the interior of the generator or the ventilation openings. Inspect for indicagenerator or the ventilation openings. Inspect for indication of tion of the entrance of mice or insects into the generator. the entrance of mice or insects into the generator. The inlet and The inlet and outlet openings are louvered, but possible outlet openings are louvered, but possible damage to the louvers damage to the louvers could occur. Mice can destroy the could occur. Mice can destroy the generator winding. generator winding. WARNING: Equipment Damage WARNING: Equipment Damage DO NOT CLEAN THE GENERATOR WHILE RUNNING. DO NOT CLEAN THE GENERATOR WHILE ITIT ISIS RUNNING. 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. 60706-241 SERVICE DIAGNOSIS REMEDY POSSIBLE CAUSE LOW OUTPUT VOLTAGE Low Speed 1. 2. Undersized/overloaded. Defective governor. 3. Low power - worn engine. 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.) High line loss. Indicated by lower voltage at load than at generator terminals. Increase size of line wiring. Might also be the result of loose connection indicated by excessive heating at the loose connection terminal. Shorted or grounded rotor coil. Test and replace if defective. Repair or replace as required Defective stator HIGH OUTPUT VOLTAGE Generator is spinning too fast, slow tractor down. Readjust or Replace as required EXCESSIVE HEATING Clean screens, make sure interior of generator is unobstructed. Clogged ventilating inlet and/or outlet. NO OUTPUT VOLTAGE Broken or corroded connection. Clean and tighten generator and receptacle connections. Defective diode(s) on rotor. Replace defective diode(s). Open excitor circuit in stator Repair or replace stator assembly. Grounded or shorted rotor winding. Replace grounded rotor assembly. Loss of residual magnetism. Usually occurs only after disassembly of field frame or severe mechanical stress/abuse. Back flash the 120 volt circuit with 12 volts DC Shorted stator winding. This can be identified by the use of an internal “growler” at a competent rewinding shop. Replace stator. (Include generator model and serial number on the order.) Grounded stator. Check winding by test lamp or high potential tester from stator leads to lamination. Same as above. Open stator circuit. Measure circuit between leads with an ohmmeter. Should have a circuit between any pair of leads. Same as above. Defective Capacitors Test and replace if defective. VOLTAGE UNSTEADY/ LIGHTS FLICKERING PTO drive line alignment. Realign within 10 degrees. Drive line knuckles out of sync. (See Figure 5.) Resync drive line halves. 60706-180 60706-241 Page 8 10 0310-00 3225-00 ILLUSTRATED PARTS LIST COMPLETE ASSEMBLY 3225-00 11 60706-241 REF # PART NUMBER QTY DESCRIPTION 1 16406-007 1 2 99839-002 1 3 15209-003 1 4 Z2553 1 5 300137 1 Formed Base Generator with Gear Case Mecc Alte Model: S20W-1302 M5 Decal Electrical Shock Decal Operators Instructions NEMA 14-60P Plug 6 7 8 9 10 21698-001 300080-3 Z2568 300086-2 98479-000 9 1 1 1 1 Torx Screw Top Cover Decal Danger PTO Drive Shaft Guard Decal Winco #1 11 12 13 14 NI NI NI 53113-002 63966-009 99841-003 16335-015 Z9941 91369-003 Not Illustrated 2 1 1 1 1 1 Decal Winco Nameplete Gear Case Support Generator Support Decal Oil Fill Hole Decal 515 RPM WIRING DIAGRAM Voltmeter Generator 20A Breaker GND 1 4 2 3 Nuetral to Ground Bond 20 Amp Rcpt N 40A 240V Breaker H G3 G3 G3 G1 G1 G1 N H H GND 60 Amp Rcpt Ground Lug 60706-241 12 3225-00 GENERATOR END ASSEMBLY REF # PART NUMBER QTY 99839-002 1 19 54665-000 1 26 300323-208 2 27 300323-207 2 65 99839-112 1 DESCRIPTION Complete Generator End with Gear Case 6205-2RS Bearing Varistor Diode 45 mf Capacitor GENERATOR SPECIFICATIONS: STATOR: ROTOR: CAPACITOR LEADS 3225-00 0.145 Ohms 5.67 Ohms 1.31 Ohms 13 60706-241 RECEPTACLE PANEL ASSEMBLY 5 1 2 6 3 7 N 4 H N H H 8 G3 ON GND OFF G1 REF # PART NUMBER QTY DESCRIPTION 1 2 3 4 5 300080-3 91286-001 63708-000 57030-007 91370-000 1 1 1 1 1 Top Cover 20 Amp 1-Pole Circuit Breaker Ground Lug 45 Amp 240 VAC Circuit Breaker Voltmeter 6 7 8 300079-5 50766-000 300136 1 1 1 Control Box NEMA 5-20R Receptacle NEMA 14-60R Receptacle 60706-241 14 3225-00 TWO WHEEL TRANSPORT 1 2 3 4 5 6 7 8 DESCRIPTION PART NO. SUPPORT, TONGUE (QTY. 2) HITCH, TONGUE (QTY. 2) TONGUE AXLE (QTY. 2) SUPPORT, AXLE SUPPORT, PTO SHAFT SUPPORT, PTO SHAFT TIRE/RIM, PNEUMATIC (QTY. 2) 300081 300082 300083 300085 300164 300161-1 300161-2 43657-000 3225-00 15 0310-00 Page 11 60706-241 60706-180 PTO GENERATOR 1 MONTH LIMITED WARRANTY WINCO, Inc., warrants for twelve months 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 at its factory at 225 South Cordova Avenue, Le Center, Minnesota, or by any factoryauthorized service station, to be defective in material or workmanship under normal standby use. For warranty service, return the product within 12 months from the date of purchase, transportation charges prepaid, to your nearest factory-authorized service station or the WINCO factory. There is 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 not apply 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 of the PTO unit. WINCO does not warrant drive lines, trailer tires, receptacles, 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. WINCO does not warrant products which have been installed in such a manner as not to protect them from the adverse environmental conditions (water, mud, insects, etc.) or have not been kept clean. WINCO reserves the right to change or improve its products without incurring any obligations to make such changes or improvements on products purchased previously. WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057 SERVICE DEPT. 0310-00 (507) 357-6831 wincogen.com 60706-180 60706-241 16 3225-00