Operators Manual

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Contents Page #

1 General Description ........................................................................................... 2

2 Safety Precautions ............................................................................................. 2
3 Connection & Start-up ....................................................................................... 3
4 Electrical Specifications .................................................................................... 4
4.1 Generator Specifications ................................................................................... 4
4.2 Rotating Rectifier................................................................................................ 4
4.3 Voltage Regulator............................................................................................... 4
4.4 Wiring Diagram ................................................................................................... 5
4.5 Connection Diagram .......................................................................................... 6
4.6 Wiring to Load .................................................................................................... 6
4.7 PTO Power Monitor ............................................... Error! Bookmark not defined.
4.8 Flashing the Field ............................................................................................... 8
4.9 Insulation Test .................................................................................................... 8
5 Mechanical Specifications ................................................................................. 9
5.1 PTO Requirements ............................................................................................. 9
5.2 Operating Conditions......................................................................................... 9
5.3 Direction of Rotation .......................................................................................... 9
5.4 Generator Layout.............................................................................................. 10
5.5 Gear Box Oil...................................................................................................... 11
5.6 Storage .............................................................................................................. 11
6 Trouble Shooting.............................................................................................. 12
7 Replacement Parts ........................................................................................... 12
8 Warranty ............................................................................................................ 13
9 Options .............................................................................................................. 13

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1 General Description

The TigerPower PTO series generators are self-exciting, brushless, synchronous

generators. This series is available in single-phase and three-phase, 20kW - 100kW.
Its rugged design makes it ideal for agricultural use or other applications where
tractor power is available. It is equipped with an all in one Power Monitor (Single
phase only, three phase units have frequency and volt meters). It has a 110V
duplex convenience outlet and a 240V welder type outlet (Do not use for 120V
loads) in addition to the 240V full power outlet. The unit is equipped with individual
circuit breakers for each power outlet. It contains lifetime pre-lubricated bearings.

2 Safety Precautions

WARNING Failure to follow these instructions may result in personal injury or death.
Extreme caution must be used when operating this unit. There are both
mechanical and electrical hazards present. Be sure to read the entire operators
manual prior to operation of the unit.

Electrical Hazards.
• Make sure the PTO is never engaged prior to proper connection of all power
cords.
• Never operate the generator or handle any electrical connection while wet,
barefoot or while it is raining.
• Keep all electrical cords in good condition.
• Never engage the PTO with loads applied.
• Do not touch the generator load leads or electrical connections when
generator is in operation.
• Disconnect all electrical loads prior to working on unit. Only qualified
personnel should attempt to perform repairs.
• Always provide adequate ventilation.
• Do not operate generator with protective covers, guards or terminal box cover
removed.
• Do not use the 50A receptacle for 120V loads there is no neutral connection.
Mechanical Hazards.
• Do not wear loose clothing while operating the PTO.
• Make sure no objects or persons can come in contact with any moving parts
while generator is in operation.
• Do not operate the PTO shaft at severe drive angles.
• Keep the generator and tractor drive shafts as parallel as possible.

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3 Connection & Start-up

Read and carefully follow the Safety Precautions prior to operation of this unit.
Failure to do so could result in personal injury or death. Failure to follow the
connection and start-up procedure could result in damage to the generator or loads
connected to it and could void the warranty.
1. Position PTO generator as close to load as possible.
2. Make all electrical connections. On 3∅ systems make sure phase rotation
is correct or damage may occur. Connect 120/240 loads to main output;
50A receptacle is for 240V only loads. (See section “Wiring to Load”)
3. Inspect for damaged cords, plugs or wires.
4. Turn all breakers on the generator to the off position.
5. Connect PTO shaft between generator and tractor. (See illustrations below)
6. Make sure no persons or objects can come into contact with moving parts
during operation.
7. Make sure that double-throw switch is in the “Utility” position.
8. Turn Main Breaker on.
9. Start tractor and engage PTO.
10. Adjust throttle until the AC frequency is at 62Hz, the voltage should be
between 230V and 245V.
11. Turn on PTO breakers to energize outlets.
12. Switch double-throw switch to the “Generator” position.
13. After loads have been connected readjust the throttle until the AC
frequency is between 59Hz and 62Hz.

Correct Incorrect

Correct Incorrect

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4 Electrical Specifications

4.1 Generator Specifications

Model # Rated Surge Voltage Phase Main Breaker

Output KVA
PTO20 20kW 60KVA 120/240 1 80A
PTO30 30kW 90KVA 120/240 1 125A
PTO30-3 30kW 90KVA 208/240/480 3 100/90/50A
PTO40 40kW 120KVA 120/240 1 180A
PTO40-3 40kW 120KVA 208/240/480 3 150/125/60A
PTO60 60kW 180KVA 120/240 1 250A
PTO60-3 60kW 180KVA 208/240/480 3 200/175/90A
PTO75 75kW 225KVA 120/240 1 300A
PTO75-3 75kW 225KVA 208/240/480 3 250/225/125A
PTO100 100kW 300KVA 120/240 1 400A
PTO100-3 100kW 300KVA 208/240/480 3 350/300/150A

• Electronic voltage regulator ±2% • 20A single-pole circuit breaker

• Insulation class H, double dip • 50A two-pole circuit breaker
varnished and tropicalized • Convenience power outlets
• All copper windings • (1) 20A, 125V Duplex (NEMA 5-20)
• Main Circuit breaker • (1) 50A, 250V ONLY! (NEMA 15-50)
• Brushless

4.2 Rotating Rectifier

If the rotating diodes are damaged the generator will no longer produce voltage.
In order to test the diodes they each need to be unbolted (isolated) and tested. If
any diode is found to be damaged it can be replaced. Replacement must only be
done by a trained technician.

4.3 Voltage Regulator

The voltage regulator is a half wave voltage regulator. It has a

regulation accuracy of >±2% from no load to full load. Its input
range is 180VAC – 260VAC. It has frequency compensation of
3V/Hz droop below 55Hz. It has internal filtering for EMI
suppression. Adjustments: CAUTION: adjustments must be
made by qualified personnel only! Electrical shock hazards are
present when working on the machine, use extreme caution! This
voltage regulator has an adjustment potentiometer to adjust
voltage. Run PTO with no load and adjust speed to 60Hz. Adjust
potentiometer clockwise to increase voltage, counter clockwise to Model may vary.
decrease voltage. Test under load.

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4.4 Wiring Diagram

4 Lead

12 Lead

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4.5 Connection Diagram

4 Lead

12 Lead

4.6 Wiring to Load

A qualified electrician must connect the generator to an electrical service. An

approved double-throw transfer switch must be used. This prevents power from
being back-fed into the generator when utility is restored which could destroy the
generator as well as cause injury or death to the operator. When connecting the
generator cord set into the double-throw connect the wires as follows:
Three Phase
Single Phase
Full Power Outlet
N-Neutral
G-Ground
1-Line 1
3-Line 3
2-Line 2 (High Leg on Three Phase 120/240v)

Warning: Prior to transferring the load to the generator, verify that the voltages
from line to line and from the lines to neutral are correct at the generator terminals in
the double-throw. For 3∅ units verify that phase rotation is identical to utility.
NOTE: Code requires mobile generator sets to have a dedicated equipment-
grounding conductor from the generator chassis to the building grounding electrode
system.

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4.7 PTO Power Monitor

Features:
• Display of Hz, AC Volts & kW
• At-A-Glance easy readability
• High nighttime visibility
• Microprocessor based design
• 11 Frequency Ranges
• Simplifies throttle adjustment
• Accurate 8-cycle averaging
• HZ display updates 60x per second
• Voltage & kW update 10x per second
• LED Self test on start-up

Frequency Ranges:
< 54Hz Blinking 54Hz 56Hz 57Hz 58Hz 60Hz

62Hz 63Hz 64Hz 66Hz > 66Hz Blinking < 100VAC

Theory of Operation
When the PTO generator begins producing voltage the PTO Power Monitor will first
go through its LED startup test. This consists of the entire display turning on then off
then each of the 5 HZ LED’s sequence on then off from left to right. After this the
voltage and kW will be displayed and after a second the frequency will be displayed.
If the input voltage is low (below ~65V) the display will turn off.

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4.8 Flashing the Field

It is possible to loose the residual magnetism of the exciter field poles. This will
result in loss of output voltage. It can be a result of the generator being unused for
an extended period of time or by the presence of a strong neutralizing magnetic
field. Only qualified personnel should carry out the following instructions to restore
the residual magnetism.

Field Flashing Procedure (read entire procedure before starting):

1. Disconnect all loads connected to the generator.
2. Disconnect F1 & F2 wires from the voltage regulator.
3. Apply a 6-12VDC supply to the F1 & F2 field wires (F1
+ & F2
-).
4. Disconnect DC supply after approximately 3 to 5 seconds. If connected
longer overheating and subsequent damage to the exciter can occur.
5. Reconnect F1 & F2 wires to the voltage regulator.
6. Run unit and adjust voltage regulator for proper output voltage.
7. Re-flash the field if output voltage does not build up.

4.9 Insulation Test

After the generator is stored for an extended period of time in a humid place it is
recommended to measure the insulation resistance of the armature windings before
putting the machine into operation. Only qualified personnel should carry out the
following procedure. All connections must be removed from the stator wires as well
as the field wires. The stator winding’s insulation should be measured with a
Megohmmeter connected between each of the stator leads and the frame of the
machine with the Megohmmeter set to 500V. If any of the windings measure less
than .5 Ohm, the machine must be dried until the minimum resistance is maintained.
Once each winding has reached this value the generator can be reconnected and
placed in service. If the minimum resistance cannot be reached contact an
authorized service center for repairs.

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5 Mechanical Specifications

5.1 PTO Requirements

Model # Min HP req. Input Input Weight

for full load RPM Spline (lbs/kgs)
PTO20 40 540 6 325 / 147
PTO30 60 540 6 450 / 204
PTO30-3 60 540 6 450 / 204
PTO40 80 540 6 625 / 284
PTO40-3 80 540 6 650 / 295
PTO60 120 540 6 1000 / 454
PTO60-3 120 540 6 1000 / 454
PTO75 150 1000 21 1750 / 794
PTO75-3 170 1000 21 1800 / 817
PTO100 200 1000 21 1900 / 862
PTO100-3 200 1000 21 1950 / 885

5.2 Operating Conditions

• Altitude: Not to exceed 3280ft. (1000m)

• Ambient temperature range: -59° F to 104° F (-15°C to 40°C)
• Max. relative humidity: 90%
Note: If altitude and ambient temperature exceed the above limit, the unit will not
be capable of producing the rated output power.

5.3 Direction of Rotation

This unit contains a radial fan with flat blades, which allows for rotation in either
direction.

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5.4 Generator Layout

Units may vary depending on size.

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A - Control box I - Front bearing

B - Exciter Field J - Vent screen
C - Stator K - SAE housing
D - Rear bearing L - Adapter ring
E - Diodes M- Keyed coupler
F - Rotating Exciter N - Gear box
G - Rotor O- PTO shield
H - Fan

5.5 Gear Box Oil (75-90W Synthetic)

A - Gearbox oil fill hole / vent cap

B - Gearbox oil level sight glass
C - Gearbox oil drain

The gearbox oil level should be routinely checked. To check the oil level, set the
generator on a level surface.
20-60kW Units: Look at the sight glass, the oil should be up to the indicator. To
add oil, remove the vent cap at the top of the gearbox. To drain the oil, use the drain
plug at the bottom.
75-100kW Units: Remove the side fill plug, the oil should be up to the bottom of
the fill hole. To drain the oil, use the drain plug at the bottom.
* DO NOT OVERFILL GEARBOX WITH OIL!

5.6 Storage

The generator should be stored in a dry ventilated area.

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6 Trouble Shooting

Problem Possible Cause Remedies

Low Frequency (< 59Hz) Drive speed is too low Increase throttle
High Frequency ( > 62Hz) Drive speed is too high Decrease throttle
Frequency Oscillation Speed Oscillation Adjust the tractor governor
Low Voltage Voltage Regulator out of Adjust VR / Replace
adjustment / Damaged
High Voltage Voltage Regulator out of Adjust VR / Replace
adjustment / Damaged
No Output Voltage Main Breaker Tripped / Off Reset / Turn Main Breaker On
Trouble with rotating Test / replace faulty diodes
diodes
Voltage Regulator Replace VR
Damaged
Loss of residual magnetism Flash field
Short circuit in windings or Check the winding resistance
open circuit / repair faulty windings.
Windings grounded Check the winding’s insulation
resistance to ground / repair
faulty windings.

7 Replacement Parts

Qty. Description Part Number

1 20A, 125V Duplex Receptacle (NEMA 5-20R) 690-520R
1 50A, 250V Receptacle (NEMA 6-50R) 690-650R
1 Power Monitor 502-POWERMON
2 Power Plug 590-SY6320G1
1 Power Plug Cover 350amp Cover
1 20A, single-pole circuit breaker 180-QC1020
1 50A, two-pole circuit breaker 180-QC2050
1 300V AC meter 500-3300
1 60Hz meter 502-360
1 Rectifier Assembly CALL
1 Bearing, Front CALL
1 Bearing, Rear CALL
1 Gear box oil fill / vent cap 600-8600.142.00
1 Sight glass CALL
1 Gear box oil drain plug CALL
~1qt. SAE 75W-90 Synthetic EP Gear Oil 540-7590S
1 PTO Shield 600-21903
1 Voltage Regulator 720-VR3.1
1 PTO Operators Manual 495-PTOMANUAL

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8 Warranty

• 5 Year Parts and Labor

• For Warranty Coverage see page 14.

9 Options

• Cord Set (below top-left) 30-75kW 600-2/0Cord101(103)

available 10’ & 20’ 100kW 600-4/0Cord101(103)

• PTO Shaft (below top-right) 20-60kW 600-W2400540

75kW(1000RPM) 600-W24001000
100kW(1000RPM) 600-W25001000
• Trailer (below bottom) 20-60kW 918-PTOSD
75-100kW 918-PTOHD (Extra Heavy Duty)

Cord Set PTO Shaft

PTO Trailer

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10 Warranty Coverage

PTO Warranty.
Five Year TigerPower P.T.O.
Driven Standby Generator
Limited Warranty
Dyna-Tech Industries, LTD warrants to the original purchaser that the product delivered
herewith, so far as it has been manufactured, engineered or assembled by Dyna-Tech
Industries, LTD, is free from defects in material and workmanship, and will perform
under normal stand-by use and service for a period of five years from date of shipment
from Dyna-Tech Industries, LTD.

Dyna-Tech Industries, LTD liability under the warranty specifies herein shall be limited
to the replacement or repair of the product, at the option of Dyna-Tech Industries, LTD,
or its authorized service station. This warranty does not apply to accessories supplied,
but not manufactured by Dyna-Tech Industries, LTD, which in such cases, the original
equipment manufacturer’s warranty will be applicable. This warranty does not obligate
Dyna-Tech Industries LTD to bear the cost of labor or transportation charges in
connection with the repair or replacement of defective products, nor shall it apply to a
product upon which modifications, repairs or alterations have been made. This warranty
shall apply only when the equipment or product has been properly installed, serviced
and operated under normal stand-by conditions, in accordance with the instructions
provided for the specific units.

Dyna-Tech Industries, LTD shall not be liable for any claim greater in amount than the
purchase price of the product, in respect of which such claim is made, and in no event
shall Dyna-Tech Industries, LTD be liable for any special, indirect or consequential
damages.

THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE DESCRIBED

HEREIN. NO WARRANTIES SHALL BE IMPLIED OR OTHERWISE CREATED
UNDER THE UNIFORM COMMERCIAL CODE, INCLUDING, BUT NOT LIMITED TO,
A WARRANTY OF MERCHANTABILITY, AND A WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE.

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 For Warranty Information Contact:

602 E. Evergreen Rd., Lebanon, PA 17042

(800) 779-8809
http://www.tiger-power.com

www.tiger-power.com