Winco ECV2512-3 - Manual (Page 7)

Page 5 60706-130 7150-01
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.
2. 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
Since the generator is self excited and externally regulated,
there is no need for 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 electrical equipment driven by the generator.
Periodical Maintenance
Service/maintenance items include periodic external physi-
cal inspection for missing hardware or damage to mounting
or drive system and checking the oil level in the gear case. It
is recommended that the generator be operated at least
monthly under normal loads to familiarize operators with the
procedures and controls as well as to dry out any accumu-
lated condensation or other moisture in the generator 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
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 it is open. Typical resistance for these fields vary 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