Winco Rotating Armature Design Troubleshooting Guide - Manual

GENERAL INFORMATION
The main components of the generator are: armature, field
coils, cooling fan, brushes, brush holder assembly, end brack-
ets, 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 appropri-
ate 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 tachom-
eter, or a 120V-60Hz electric clock and a correctly operat-
ing 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 physical
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 proce-
dures and controls as well as to dry out any accumulated
condensation or other moisture in the generator electrical
windings. The maintenance and service attention invested
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 mounting
hardware should be tight. Clean and inspect the generator
after storing it for long periods, and after using it in ex-
tremely 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.
ELECTRICAL TESTING
A. Testing generator fields for opens and grounds.
1. Disconnect field leads from rectifier or the regulator.
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.
3. Leaving one meter lead connected to the field, connect
theother meter lead to the field shell. If meter indicates
continuity (any reading -should be infinite resistance). The
TROUBLESHOOTING
ROTATING ARMATURE
GENERATORS