60706 199_25PTO OPM 199 25PTO

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User Manual: 60706-199_25PTO-OPM

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25PTOS-3
GENERATOR

INSTALLATION AND
OPERATORS
MANUAL
WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057 507-357-6821
SERVICE DEPT. 507-357-6831
www.wincogen.com

TABLE OF CONTENTS

SAVE THESE INSTRUCTIONS

SAVE THESE INSTRUCTIONS
2
INTRODUCTION2
SPECIFICATIONS3

This manual contains important instructions that should be followed
during installation and maintenance of the generator. Read and
understand all instructions in the manual before starting and operating
the generator.

25PTOS

USING THIS MANUAL
Congratulations on your choice of a WINCO generator. You have
selected a high-quality, precision-engineered generator designed and
tested to give you years of satisfactory service.

SAFETY3
IMPORTANT SAFETY INSTRUCTIONS
ANSI SAFETY DEFINITIONS

TESTING POLICY
PREPARING THE UNIT
UNPACKING

4
4

To get the best performance from your new generator, it is important
that you carefully read and follow the operating instructions in this
manual.

INSTALLATION4

Should you experience a problem please follow the “Troubleshooting
Tables” near the end of this manual. The warranty listed in the manual
describes what you can expect from WINCO should you need service
assistance in the future.

FOUNDATION MOUNTING
TRAILER MOUNTING
THREE-POINT HITCH KIT

ELECTRICAL CONNECTIONS
5
OPERATION7
PRE-START CHECKS
7
GENERATOR PROCEDURES
8

INTRODUCTION
The WINCO rotating armature power take-off generators are designed
primarily for 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.

START-UP
SHUTDOWN

MAINTENANCE8
GENERAL INFORMATION
PERIODICAL MAINTENANCE
LUBRICATION
CLEANING & INSPECTION
GENERATOR STORAGE
GENERATOR TESTING
ELECTRICAL TESTING
TESTING ARMATURE FOR OPENS AND GROUNDS
TESTING RECTIFIERS
CONDENSER TESTING

TROUBLE SHOOTING TABLE
36 MONTH LIMITED WARRANTY

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 foundation mounted for use as standby power
source, or trailer mounted, and used as portable electrical power
sources for areas where commercial power is not readily available,
such as out buildings.

11
12

This generator includes a color coded voltmeter to warn against high
or low voltage, three output power receptacles, an overload protection
circuit, and an electronic excitation circuit. 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 1/8 in. diameter smooth shaft with a keyway and
center drilled for a roll pin. Both must be used at all times.

COPY YOUR MODEL AND SERIAL NUMBER HERE
No other WINCO generator has the same serial number as yours.
If you should ever need to contact us on this unit, it will help us to
respond to your needs faster.

The factory thoroughly tests each generator before shipment.
All are continuous duty rated.

MODEL __________________________________________________

IMPORTANT: THE MANUFACTURER STRONGLY RECOMMENDS
RUNNING THE GENERATOR UNDER LOAD AT
LEAST ONCE A MONTH IN ORDER TO EVAPORATE ANY
ACCUMULATED MOISTURE CONDENSATION.

SERIAL NUMBER _________________________________________
PURCHASE DATE _________________________________________
DEALER NAME ___________________________________________
DEALER PHONE # ________________________________________

60706-199

2

REV B

SPECIFICATIONS

F. Be sure the unit is properly grounded to an external ground rod
	  driven into the earth.

25PTOS

2. FIRE HAZARD -

Watts					25,000
Amps					104
Input Speed				540 RPM
Generator Speed			
3600 RPM
Input Shaft				
1 1/8” - keyed
Required Tractor PTO HP 50
Gear Lube
Volume				 2 Pints
Type					85/90W-140

A. Keep a fire extinguisher nearby  and know its proper use. Fire
	  extinguishers rated ABC by NFPA are appropriate.
3. NOISE HAZARD Excessive noise is not only tiring, but continual exposure can lead to
loss of hearing.
A. Use hearing protection when working around this
	  equipment for long periods of time.
B. Keep your neighbors in mind when permanently installing this
	 equipment.

SAFETY

IMPORTANT SAFETY INSTRUCTIONS

4. CLEANLINESS -

SAVE THESE INSTRUCTIONS

Keep the generator and surrounding area clean.

This manual contains important information that should be understood
and followed before the installation, operation and maintenance of the
generator. Failure to follow the safety instructions in this manual could
result in serious injury or death. Keep this manual available for future
reference.

A. Remove all grease, ice, snow or materials that create slippery
	  conditions around the unit.
B. Remove any rags or other materials that could create a
potential fire hazard.
C. Carefully clean up any gas or oil spills before starting the unit.

ANSI SAFETY DEFINITIONS

5. SERVICING EQUIPMENT -

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.

All service, including the installation or replacement of service parts,
should be performed only by a qualified technician.
A. Use only factory approved repair parts.
B. Do not work on this equipment fatigued.
C. Use extreme caution when working on electrical components.
	  High output voltages from this equipment can cause serious
	  injury or death.
D. Installing a 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.

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 be used to alert
against unsafe practices.

6. INSTALLATION -

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.

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.

1. ELECTRIC SHOCK -

   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.

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.

REV B

8. OPERATION - PTO drive shafts (tumbling bars) have many inherent
dangers, extreme caution must be exercised when using them.

3

60706-199

D. Space is required around the generator for mounting
switching devices, making connections, and for servicing.
E. The generator mounting bracket must rest evenly and

A. NEVER allow children around the 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 drive shaft with your hand or your foot.

5 degrees during generator operation, even though the mechanical
firmly on the foundation. Install shims if necessary to even
design
of the
the foundation
tumbling barunder
would the
allowmounting
greater misalignment.
out
pads then bolt the

TESTING POLICY

E.the
Forgenerator.
dimensions needed for install for your specific generator, please
refer to it’s outline drawing. The hardware needed is dependent on your
B. Theapplication.
design of the trailer must enable the trailer to remain
distinct

generator firmly in place.

B. The foundation must be solid enough to absorb generator starting
and
reflected loadMOUNTING
torque during operation.
TRAILER
C. The foundation surface should be flat.

Mount the generator on a trailer if you plan to use it as a
portable power source. When selecting or building a trailer to
D.mount
Spacethe
is required
around
the generator
for mounting
switching
generator,
consider
the following
points:

devices, making connections, and for servicing.

A. The trailer construction must be strong enough to support

stable during operation, and to resist tipping caused by
generator starting and reflected load torque.

Before any generator is shipped from the factory, it is fully checked
for performance. The generator is loaded to its full capacity, and the
voltage, current, and frequency are carefully checked.

F. The generator mounting bracket must rest evenly and firmly on the
foundation.
Install
shims if necessary
to even out the
foundation under
WARNING:
Personal
Injury & Equipment
Damage
the
mounting
pads
then
bolt
the
generator
firmly
in
place.
TRAILER MAY TIP OVER AND CAUSE INJURIES IF
WHEELS ARE NOT SPACED FAR ENOUGH APART.

Rated output of generator is based on engineering tests of typical units,
and is subject to, and limited by, the temperature, altitude, fuel, and
other conditions specified by the manufacturer of applicable engines.

TRAILER MOUNTING

Optional Trailer Part Number TDM76

PREPARING THE UNIT

WARNIN
WHEN U
POINTS
URE TO
WHEN L
GENER

A. The t
times

UNPACKING

B. When
gene
pads
times
and t

CAUTION: EQUIPMENT DAMAGE
When you unpack your new generator, be sure to remove all of the
information sheets and manual from the carton.
1. As you receive your unit, it is critical to check it for any damage. If
any damage is noted, it is always easiest to refuse the shipment and
let WINCO take care of the freight claim. If you sign for the unit, the
transfer of the ownership requires that you file the freight claim

C. For s
hitch

Mount the generator on a trailer if you plan to use it as a portable
power source. When selecting or building a trailer to mount the
generator, consider the following points:

2. Before proceeding with the preparations of your new generator
for operation, take a couple of minutes to ensure the unit you have
received is the correct model and review the specification pages in this
manual to ensure that this unit meets your job requirements.

Optional Trailer Part Number TDM75

A. The trailer construction must be strong enough to support the
C. The trailer height and mounting position of the generator on
generator.
B. The design of the trailer must enable the trailer to remain stable
Page 3
0310-00
during
operation, and to resist tipping caused by generator starting and
reflected load torque.

INSTALLATION

FOUNDATION MOUNTING

C. The trailer height and mounting position of the generator on the
trailer should enable aligning the drive shaft (tumbling bar) in a straight
or nearly straight line between the power take-off and generator input
shafts. Misalignment must be less than 5 degrees during generator
operation, even though the mechanical design of the tumbling bar
would allow greater misalignment.

Mount the generator on a foundation if it is to be used as a permanent
or standby power source. When planning a foundation consider the
following points:

D. The generator mounting area of the trailer bed should be flat.
All four generator mounting pads must rest firmly on the trailer bed.
Install shims if necessary to even out the bed under the mounting pads,
then bolt the generator firmly in place.

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

60706-199

WINC

4

REV B

ment.
D. The generator mounting area of the trailer bed should be
flat.

WARNING: PERSONAL INJURY & EQUIPMENT DAMAGE
All four generator mounting pads must rest firmly on the trailer
Trailer
tip over
cause injuries
if wheels
spaced
bed.may
Install
shimsand
if necessary
to even
out theare
bednot
under
the far
enough
apart.
mounting pads, then bolt the generator firmly in place.

generator
ion.

A properly rated and installed double throw manual power isolation
transfer switch must be used with a standby generator. The transfer
switch isolates the load from the power line and allows you to safely
operate your loads without endangering the power line repair crew. See
previous diagrams

WINCO THREE POINT HITCH

THREE-POINT HITCH KIT

unting
servicing.

Optional 3-Point Hitch Part Number TPH241

nly and
ary to even
en bolt the

The load, connected to the normal terminals of the transfer switch, is
energized by the normal power line when the switch is in the normal
position. The generator, connected to the emergency terminals of the
switch, furnishes power when the switch is in the emergency mode
position. If loss or damage is noted at time of delivery, require that

Description

the person making the delivery make note of the loss or
damage on the freight bill, or sign the consigner’s memo
The WINCO rotating armature power take-off generators There
are
are two
ways to install a manual transfer switch. The first shown
of the loss or damage. Contact the carrier for claim
designed primarily for farm use as a standby electrical power
t as a
on
the
left
side
of page 6 is to install the switch between the watt-hour
procedures.
supply, utilizing the power take-off of a tractor or truck as the
g a trailer to
prime mover. This PTO drive generator will provide, 120/240V
meter and the normal distribution panel. As with any system you must
When loss or damage is noted after delivery, segregate the
single phase, 60Hz electrical service when properly driven.
install andamaged
entrance
rated breaker before the manual transfer switch. The
material, and contact the carrier for claim proceto support
manual
transfer
switch
must in all cases be equal to or greater than the
dures.
NOTE: The prime mover which drives the generator must be
capable of delivering approximately 2 HP per 1000 watts rating of the entrance rated breaker.
“Concealed damage” means damage to the contents of a
output from the generator. Observe input RPM specifications.
to remain
package which is not evident when the package is delivered
d by
by theway
carrier,
but which
is discovered
The carrier
or
The generator may be foundation mounted for use as standby
The second
to install
the system
is to later.
purchase
and install
an
carriers are responsible for merchandise lost or damaged in
power source, or trailer mounted, and used as portable emergency
distribution
panel
and
move
the
circuits
you
wish
to
back
transit. The title to the goods rests with the consignee when
electrical power sources for areas where commercial power
WARNING:
PERSONAL
INJURY
&
EQUIPMENT
DAMAGE
up
to
the
new
distribution
panel.
In
this
case
the
manual
transfer
switch
ge
the goods are shipped FOB factory, and only the consignee
Optional 3-Point
Number
is not Hitch
readilyPart
available,
suchTPH240
as out buildings.
When using the 3-point hitch assembly all three points must be
legally
fileto
claims.
Two years of
arethe
allowed
which toinfile
S IF
only hascan
to be
sized
the amperage
circuitinbreaker
the main
suit after a claim is disallowed in writing by the carrier.
This
generator
includes
aDamage
color
voltmeter
ART.
WARNING:
Personal
Injury
attached
to the tractor.
Failure
to&doEquipment
so
will cause
thecoded
generator
to tipto warn distribution
panel that is feeding it. See the right hand drawing of the
against high
or low
voltage, three
output
power receptacles,
WHEN
USING
THE
3-POINT
HITCH
ASSEMBLY
ALL
THREE
when lifting it damagingan
both
the
t-bar
and
the
generator.
previous
diagrams
overload protection
circuit, and an
electronic excitation
POINTS MUST BE ATTACHED
TO THE TRACTOR.
FAILcircuit.
To reduce
maintenance problems,
URE TO DO SO WILL
CAUSE
THE GENERATOR
TO TIP the coupling
between
generator
inputtractor
shaft and
consists of
A. The
three
point hitch
must bethe
attached
to the
at allrotor
times
WHEN
LIFTING
IT DAMAGING
BOTH THE
T-BAR AND
THE
Before deciding
which system
to install,after
firstunpacking
determinethewhich
loads you
The only assembly
work required
generaprecision helical gearing rather than a chain link drive. The
GENERATOR.
tor run
is toon
assemble
thegenerator
load disconnect
plug,
which
is con- a large
during operation.
input shaft is a 1 1/8 in. diameter smooth shaft with a keyway
can safely
your PTO
and the
cost
of buying
in a bag in the subpack carton packed in the generator
and center drilled for a roll pin. Both must be used at all manual tained
transfer switch versus the cost of a smaller switch and the
A. The three point hitch
must be attached to the tractor at all
crate.
times.

Assembly

B. When
operating
the generator the three point hitch and generator
times
during operation.
additional distribution panel.
must be sitting on flat level
All four deck
be inbefore shipment. The bag contains an instruction sheet, 2 plug bodies, four
The ground.
factory thoroughly
testspads
each must
generator
contacts, two handle and the hardware to assembly the
B. When
operating
the
generator
thetimes.
three
point
hitch
and the
Allground
are continuous
duty rated.
constant
contact
with the
at all
This will
reduce
The onlydisconnect
assemblyplug.
workYou
required
after
the
generator is to
will need
to unpacking
purchase the
appropriate
generator must be sitting on flat level ground. All four deck
vibration
in
both
the
generator
and
the
tumbling
bar.
length
of
fine
stranded
copper
wire
for
your
application
orderin the
assemble
the
load
disconnect
plug,
which
is
contained
in ain bag
IMPORTANT:
THE
MANUFACTURER
pads must be in constant
contact
with
the ground at all STRONGLY RECOMto complete the assembly of the disconnect plug. DO NOT
MENDS
GENERATOR
UNDER LOAD AT
times. This will reduce
theRUNNING
vibration THE
in both
the generator
subpackUSE
carton
packed
in
the
generator
crate.
SO CABLE - USE SINGLE LEAD WELDING CABLE
LEAST
ONCE
A MONTH
IN three
ORDER
TO EVAPORATE
the the
tumbling
bar.
C. Forand
safety
generator
must
be bolted
to the
point
hitch deck ANY
ACCUMULATED MOISTURE CONDENSATION.
The following wire sizes are recommended for each unit.
using all four mounting bolts.
The bag contains an instruction sheet, 2 plug bodies, four contacts,
C. For safety the generator must be bolted to the three point
Generator
Size
UNPACKING
two handle
and the hardware
to assembly the disconnect plug. You will
hitch deck using all
four mounting bolts
Model
AWG
Insulation
need to purchase the appropriate length of fine stranded copper wire
CAUTION: Equipment Damage
Neoprene/THHN
for your 25PTOC
application in #4
order to complete
the assembly of the disconnect
DO NOT invert generator during unpacking. The Gearcase
plug.
DO
NOT
USE
SO
CABLE
USE
SINGLE
LEAD WELDING
contains oil which will leak out if inverted during unpacking.
If you require different inserts or contacts for local code,
CABLE WINCO has a variety of different inserts and contacts avail-

5

ELECTRICAL CONNECTIONS

Unpack the generator as follows:

generator on

CAUTION:

able. Contact the factory at 507-357-6831 for pricing.

A #4 Neoprene/THHN wire size is recommended.

1. Remove the carton.

2. Examine the unit for damage.

Only3qualified electricians should install electrical60706-180
wiring. Wiring must
Page

Find thestate,
small and
subpack
packed
in the large carton.
conform to all applicable3.national,
localcarton
codes.
(Reference:
Be careful Manual
not to throw
the subpack
carton with the
National Fire Protection Association
No.away
70, National
Electrical
large carton.
Code.)
4. Open the subpack carton and make sure it contains:

SINGLE PHASE
4 WIRE CONNECTION
CONTACTS
All 4 contacts
must be used.

DANGER: PERSONAL INJURY:
a. Generator instruction manual
If the generator is to be used as a standby power source,, a manual
b. Load
disconnectthe
plug
(disassembled,
transfer switch must be installed
to separate
generator
and thein bag)
commercial power lines.5.The
switch
must
isolate
the
generator
the
Remove the four bolts which hold down from
the generator
feet
the load
pallet.when the generator is on standby,
commercial power lines andtothe
and must isolate the commercial power lines from the load and the
6. Lift the generator from the pallet by means of the lifting eye
Figure 1
generator when the generator
is supplying
power. See the following
on the
top of the generator.
diagrams.
If you require different inserts or contacts for local code,
7. Inspect the generator carefully for freight loss or damage.
WINCO has a variety of different inserts and contacts available.
1005-00
Page 2the factory at 507-357-6831 for pricing.
60706-199
Contact

REV B

5

60706-199

WARNING: EQUIPMENT DAMAGE
Never use acid core solder. When soldering insure no excess solder
runs down on the contact surface - Solder on the contact surface will
not allow the contacts to mate properly causing them to burn up.
Each wire should be stripped back 7/8 of an inch and inserted into
one of the contacts in the plug kit. You will then either need to solder
them together
using a good gradeCONNECTIONS
of resin core solder or they can be
ELECTRICAL
crimped with an appropriate compression crimper or both.
CAUTION:

qualified
should install electrical wiring.
Approved Only
Crimping
toolselectricians
are:
Wiring must conform to all applicable national, state, and local
1. Anderson
Power
Products
codes. (Reference: National Fire Protection Association
2. ETCManual
Model HHS
hydraulic
crimper
No. 70,
National
Electrical Code.)
3. ITT Blackburn NO. 1640
DANGER: PERSONAL INJURY
4. T&B IF
(Thomas
& Betts) #TBM5
THE GENERATOR
IS TO BE USED AS A STANDBY

Figure 5

1005-00

60706-199

To complete the assembly of the disconnect plug refer to the instruction
sheet in the plug kit.
WARNING: ELECTRICAL SHOCK
DURING THE NEXT STEP, THE LOAD DISCONNECT PLUG
SHOULD NOT BE PLUGGED INTO ITS RECEPTACLE. ALSO, MAKE
SURE THAT THE EQUIPMENT TO WHICH THE PLUG LEADS
(CABLES)
ARE BEING
CONNECTED
IS NOT SWITCH
ENERGIZED (LIVE).
POWER
SOURCE,
A SPECIAL
DISCONNECT
MUST BE INSTALLED TO SEPARATE THE GENERATOR
AND
COMMERCIAL
Strip THE
the insulation
off the POWER
free end LINES.
of eachTHE
of the plug leads (cables),
DISCONNECT MUST ISOLATE THE GENERATOR FROM
and
connect
them
to
the
load
transfer
switch
(orLOAD
directly
to the load).
THE COMMERCIAL POWER LINES AND THE
WHEN
THE GENERATOR IS ON STANDBY, AND MUST ISOLATE
THE COMMERCIAL POWER LINES FROM THE LOAD AND
THE GENERATOR WHEN THE GENERATOR IS SUPPLYING
POWER. SEE FIGURE 5.

Typical Connection Methods for Generator Power Service

Typical Connection Methods for Generator Power Service
Page 4

6

60706-199

REV B

OPERATION
Output power available and load determination
Before using the generator, read and understand the following
information.
Generator output current (amperage) is internally limited by three circuit
breakers. If too much demand is placed on a generator output (if you
try to drive too many motors with it, for example), one of the circuit
breakers will trip, cutting off the output in order to protect the generator.
A 20 Amp push-to-reset circuit breaker protects the 120V duplex
receptacle output circuit. 20 Amps is the total limit for both outputs of
the duplex receptacle.
A 50 Amp push-to-reset circuit breaker protects the 240V receptacle
output circuit.

A. Correct mounting
B. Physical damage
C. Debris in cooling vents and screens (could cause generator to
  overheat)
IMPORTANT: The manufacturer recommends that, if the generator
has been stored for any length of time, before using it, the operator
removes the control box cover and cooling fan screen. Then inspect
the generator for rodent nests or other objects that could cause the
generator binding and/or overheating. See “cleaning portion of the
Maintenance section.
2. Check gearcase oil level. Case should be filled with oil to plug
marked “OIL LEVEL”. Fill or remove oil as required.
NOTE: Either too little or too much oil can harm the equipment.
See “lubrication” portion of Maintenance for oil specifications.

A large two pole (three pole for three phase) switch type main circuit
breaker protects the generator windings and output circuits, including
the load disconnect receptacle outputs. The load disconnect receptacle
on the 25PTOC is the largest gray receptacle on the generator output
panel.

8
8.

G
G

To aid in determining how much load can be applied to the generator,
and how it should be distributed among the generator output
receptacles, the following formulas may be useful. Get load voltages,
current, and wattage from the nameplates on the equipment in the
load.
Load current (in Amps) x Load voltage = Load wattage
Amps x Volts = Watts
Watt/1000 = kW

7
7.

1
1.
Figure 6
Figure 6

3. Make sure the drive shaft (tumbling bar) is assembled with
universal
joint
knuckles
“synchronized,”
as
3. Make
sure
drive
shaft
(tumbling
bar) is assembled
within
3.its
Make
sure the
the drive
shaft
(tumbling
bar) is assembled
withillustrated
its
Figure
7. Ifknuckles
knuckles
are not
synchronized,
theillustrated
bar will chatLoad wattage / Load wattage = Load current (in Amps)
its
universal
joint
knuckles
“synchronized,”
in
universal
joint
“synchronized”.
If the knucklesas
are
not
ter when
will
cause
the
generator
output
Figure
7. If rotating,
knuckles
are
not
synchronized,
the
synchronized,
the bar willwhich
chatter
when
rotating,
which
will bar
causewill
thechatvoltage
to flicker.
Example: 250W, 120V floodlight load: 250W / 120V = 2 Amps (parrots.) ter
when output
rotating,
which
will cause the generator output
generator
voltage
to flicker.
voltage to flicker.
NOTE:
Electric motors require more current to start than to run. Commonly,
the current rating given on a motor nameplate is the full load (running)
current required by the motor, not its starting current, which is a lot
higher. Motor starting current requirements vary greatly, by motor size
and type. Repulsion-induction type motors are the easiest to start,
typically using 1 1/2 to 2 1/2 times as much current to start as to run;
capacitor type motors usually require 2 to 4 times as much current
to start as to run; split-phase type motors are the hardest to start,
normally using 5 to 7 times as much current to start as to run.

PRE-START CHECKS
WARNING: PERSONAL INJURY
Figure 7
When working on or around these generators, do not wear loose fitting Figure 7
DANGER: PERSONAL INJURY
clothing or any articles that may get caught in moving parts.
DANGER:
Personal
Injury
Power take-off
must be DISENGAGED
at this time.
1. Visually inspect the generator. Check for:
POWER TAKE-OFF
DANGER:
Personal MUST
InjuryBE DISENGAGED AT THIS TIME.
POWER TAKE-OFF MUST BE DISENGAGED AT THIS TIME.
REV B
7 Couple the tractor to the generator with the60706-199
4.
drive shaft (tumbling bar).
Coupletothe
to the
the drive
generator
4. Couple
the tractor
thetumbling
generatorbar
with
shaft input
(tum-

2
2.
3
3.

4
4.

N
I
NO
If s
st
R
a
Re
ate
eqt
tha
ate
ens
su

G
G

1
1.
2
2.
3
3.

4. Couple the tractor to the generator with the drive shaft (tumbling
bar). Couple the tumbling bar to the generator input shaft first, then to
the power take-off shaft. Check alignment, tractor, power take-off shaft
(tumbling bar), and the generator input shaft should form a straight (or
nearly straight) line, with less than 15 degrees misalignment between
the shafts  Misalignment will cause generator output voltage to flicker.

WARNING: PERSONAL INJURY
Never try to manually stop the generator. Always let it coast until it
stops.
4. Shut off the engine.
5. Disconnect drive shaft. Power take-off end first, then the generator
end.

CAUTION:
Make sure that all tumbling bar lock pins are engaged and that all
safety shields are in place before operating the PTO generator.

MAINTENANCE

5. Make sure no binding exists in generator or gearbox. If binding is
found, locate the cause and correct it before proceeding.

GENERAL INFORMATION

6. Make sure that the electrical loads to be driven by the generator will
not draw more current than the ratings of the generator receptacle or
cord set which will supply the current.

The main components of the generator are: armature, field coils,
cooling fan, brushes, brush holder assembly, end brackets, and
rectifier. 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.

7. Check all electrical connections in the system to be energized by the
generator. Make sure the conenctions are correct and are tight.

The trouble shooting chart lists various symptoms of poor generator
operation with possible causes and the appropriate 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 and a correctly power and compare
the clock’s second hand movement with that of the wrist watch. They
should run at the same speed. If the clock runs faster, generator speed
is too high, and vice versa).

8. Make sure all loads are turned off. Do not start generator under load.

GENERATOR PROCEDURES
START-UP

1. With the power take-off drive disengaged, start the engine which will
drive the generator. Run the engine long enough to warm it up before
proceeding, so that it will run smoothly and achieve full power under
generator load.

CAUTION: EQUIPMENT DAMAGE
Most electrical equipment in North America operates satisfactory at
frequencies between 58.5 and 62 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.

2. With the engine idling, engage the power take-off drive.
3. Watch the voltmeter on the generator and slowly increase engine
speed until the output reaches approximately 260 Volts, in green
portion of voltmeter scale.

PERIODICAL MAINTENANCE

4. With engine and generator running smoothly, switch on the electrical
load while watching the voltmeter.

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 gearcase. 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 accumulated condensation or other moisture in the generator
electrical windings. The maintenance and service attention invested will
ensure getting the peak performance that was designed to the unit.

NOTE: EQUIPMENT DAMAGE
If the load includes motors, turn them on one at a time, highest starting
current motor first, next highest second, etc.
Readjust engine throttle to keep generator output under load at 240V
(in green portion of voltmeter scale). If engine is equipped with speed
governor, it may automatically readjust the throttle as the load changes
and keep the generator output at the proper level.

Routine preventative maintenance minimizes costly repairs and
generator down-time. Before each use, inspect the generator: gearcase
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 extremely dusty conditions or in severe weather, such as rain or
blowing snow.

SHUTDOWN

1. Switch off electrical load.
2. Reduce Speed of engine driving generator to idle.
3. Disengage power take-off drive and allow generator to coast to a
stop.

60706-199

8

REV B

LUBRICATION

5. Replace the oil level check plug.
6. Replace the breather.

The generator bearings are factory lubricated and sealed, and require
no further lubrication.

CLEANING & INSPECTION

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.

Use a vacuum cleaner or dry low pressure compressed air (regulated
at 25-35 PSI) to clean the generator periodically.

The drive shaft (tumbling bar) requires greasing. Keep the universal
joints in the coupling shaft free from grease and dirt build-up.

WARNING:
Do NOT clean the generator while it is running.

NOTE:
NOTE:
Do notDoover
lubricate
theuniversal
universal
not over
lubricate the
joints.joints.

Proceed as follows:
1. Remove control box cover. Vacuum or blow dust or debris from the
control box. Inspect all wiring for correct routing, fraying insulation, and
secure connections.

d
d
e
o
.

g
.
t
e
n
s

2. Remove end cover. Vacuum or blow dust and debris from the inside
of the generator. Inspect wiring for loose connections, fraying insulation
and correct wire routing.
3. Replace end cover and control box cover.

Check the generator gearcase oil level before each use of the

Checkgenerator.
the generator
gear case oil level before each use of
Maintain the oil level at the oil level plug height. The
the generator.
oil level
at oil level
plug height.
generator is Maintain
shipped withthe
lubricant
in the gearcase.
Specifications
for
(See page
6
for
oil
level
plug
location.)
The
generator
is
the gearcase lubricant are:
shipped with lubricant in the gear case. Specifications for Before storing the generator, apply a heavy coat of grease to the
gear case
lubricant
API Serice:
GL-5 are:
splined input shaft. Store the generator in a sheltered area, where it is

GENERATOR STORAGE

Grade: SAE 85W-90-140

protected against snow, rain, and excessive dust.

Amount: 2GL-5
Pints
API Service:
Grade: SAE 85W-9O-140
The 2
following
Amount:
pints kind of oil are recommended for use in the generator

GENERATOR TESTING

gearcase: Mobile SAE 85W-90-140 API Service GL-5, Sunonco/
DX XL80W90-140, Kendal Three Star 85W-140, Amoco 85W140 or
The following kinds of oil are recommended for use in the
equivalent.

BRUSHES

generator gear case: Mobil SAE 85W90-140 API Service GL-Under ordinary circumstances, brushes will operate for extremely llong
5, Sunoco/DX
XL80W90-140
Kendal Three Star 85W-140, periods without requiring replacement. They should be inspected after
CAUTION: EQUIPMENT
DAMAGE
the first 500 hours of operation, and after every 200 hours of operation
AmocoDo85W140
or equivalent.
not overfill generator
gearcase. Overfilling causes overheating and

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.

oil seal failure.

CAUTION: Equipment Damage

oil atgenerator
least once every
months.Overfilling
Change it more
often if
Do notChange
overfill
gearsixcase.
causes
you
use
the
generator
in
bad
weather.
Use
the
following
procedure
to
overheating and oil seal failure.
change generator gearcase oil:

Poor contact (or “skipping”) between brush and slip ring is caused by
Change the oil at least once every six months. Change it
1. Remove gearcase breather. Soak breather in cleaning solvent, then
more often if you use the generator in bad weather. Use the oil and grit, flint, or other hard substance on the brush, or by the brush
allow to dry.
not being properly shaped to fit the slip rings. Remedy these defects
following procedure to change generator gear case oil:

1.
2.
3.

by fitting the brushes to the slip ring curvature. Place #00 sandpaper
Remove gear case breather. Soak breather in cleaning 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.
solvent,
then
it to drain
dry.the oil into a clean oil resistant
3. Remove
the oilallow
drain plug,
container, 1 quart or larger. Check the oil for metal. Fine metal dust
SLIP RINGS
in the oil does
not indicate
trouble,
but metal chips do. Dismantle the
Remove
oil level
check
plug.
THe four continouous copper rings located on the end of the armature
gearcase and look for damaged gears if you find metal chips in the oil.
Remove the oil drain plug, drain the oil into a clean oil are the generator output slip rings. For proper generator output, the
surface of the slip rings must have a smooth, shiny, highly polished
4. Replacecontainer,
the oil drain plug.
Refill the
breather
resistant
1 quart
or gearcase
larger. through
Checkthethe
oil for finish. Normal brush seating will transfer a shiny black finish that will
port withFine
new oil
of the dust
recommended
Fill the not
caseindicate
up to oil level
metal.
metal
in the type.
oil does
seat the copper surface. This finish should not be removed unless it
check plug height (it will take about 2 pint).
trouble, but metal chips do. Dismantle the gear case and
becomes dull or begins to build up. Under sustained use, it is advisible
2. Remove oil level, check plug.

look for damaged gears if you find metal chips in the oil.

4.

REV B

9

Replace the oil drain plug. Refill the gear case through

60706-199

to check and if necessary, polish the ring surfaces with a crocus cloth
to maintain the smooth finish.

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 the field is open, meter will read infinite resistance
(very high ohms). Repair or replace field if it is open. Typically
resistance for these fields vary from 20.2 to 22.4 ohms.

3. Leaving one meter lead connected to the field, connect the other
meter lead to the field shell. If the meter indicates continuity, any
reading other than infinite resistance, the field is grounded and should
be repaired or replaced. To determine which of the field is grounded,
cut the connector between the two coils and retest to determine which
coil has the low resistance path.

3. Open test. Set meter to read low resistance ( R x ohms). Holding
one meter lead on the surface of slip ring No. 1, touch other meter to
lead to the surface of slip ring No. 2, while observing the meter. The
meter should indicate continuity (low resistance - less than one ohm
is typical). If the meter indicates open circuit (infinite resistance), part
of the 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 rings No. 2 to No. 3 and No. 2 to No. 4. All the slip rings
should have continuity to slip ring No. 2, the neutral ring.

TESTING RECTIFIERS
Testing 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. Tag and disconnect all leads from rectifier.
2. Connect the red ohmmeter lead to the positive DC (+) terminal.
3. Connect the black lead to each of the AC terminals in turn. Either a
high or low resistance reading will be obtained.

TESTING ARMATURE FOR OPENS AND GROUNDS
1. Remove all brushes
2. Ground faults test - set multimeter to read high resistance (megohms). 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
obsrving the meter. If meter indicates continuity (any reading lower than
one meg-ohm), the armature is grounded. Dirt between the slip rings
and no the insulator surface can cause grounding. If grounding was
indicated, carefully clean all dirt off the slip rings and their insulators
and recheck it. Replace the armature if it is grounded and unrepairable.

4. Reserve the meter leads, black lead to the DC positive (+) and the
red lead 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 terminals in turn. Either a high
or low resistance reading will be obtained.
7. Reverse the meter leads, black lead to the DC negative (-) 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 powered test light
may be used. Follow the same procedures described above. A good
diode element will allow current to pass to the light in the test lamp in
only one direction.
9. If the rectifier fails any of the above tests, it should be considered
defective and be replaced.

60706-199

10

REV B

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 resistance 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 is shorted, it will show as a
constant low resistance.

Other wise, restart the generator without the capacitor connected to
recheck the generator output. If the generator then provides power, the
condenser was at fault and should be replaced. If the generator does
not 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.

TROUBLE SHOOTING TABLE

SYMPTOM

POSSIBLE CAUSE

CORRECTIVE ACTION

Low Output Voltage

1. Engine speed too slow.
2. Generator overloaded.

1. Check engine speed. Increase RPM if necessary.
2. Reduce load if it is higher than the rated capacity of the
generator. See generator nameplate.
3. Generator requires 2.0 HP/1000 Watt output. Obtain
larger engine if necessary.
4. 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.

3. Inadequate engine horse power..
4. Incorrect field excitation. (no load/output low)

High Output Voltage

Engine speed too fast.

Check engine speed for correct input RPM.

Excessive Vibration

1. Power take-off misalignment excessive.
2. Loose mounting nuts and bolts or hold-down studs.

1. Correct misalignment. It should be less than 15°.
2.Tighten mounting nuts and bolts; repair hold-down stud
mountings.
3. Repair or replace defective parts.
4. Check for possible causes. Replace defective bearings.

3. Universal joints in coupling shaft worn or dry.
4. Defective bearings
No Output Voltage

1. Circuit breaker open.
2. Defective voltmeter.
3. Short circuit in the load..
4. Defective receptacles.
5. Loose (or broken) wires or connections in control
box.
6. Defective rectifier.
7. Dirty slip rings.
8. Brushes binding in holders.
9. Shorted or open armature.
10. Shorted or open field coils.

1. Reset circuit breakers, replace if defective.
2. Check output with another meter, replace meter if defective.
3. Disconnect the load. Check voltage at receptacle cord set.
Check motors, appliances, and load leads for short circuit,
repair short..
4. Remove panel cover and check for voltage to the
receptacles. Replace defective receptacles..
5. Remove panel cover and check all wiring and connections.
Tighten and/or replace where necessary.
6. Test rectifier. Replace if defective.
7. Clean and polish. Use 00 sandpaper or crocus cloth, never
use emery paper.
8. Check brushes for swelling; replace armature if open or
shorted.
9. Measure armature resistance. Replace armature if open or
shorted.
10. Measure between leads for open or short. Replace field
coils if defective.

Generator Overheating

1. Poor ventilation.
2. Generator overloaded.
3. Shorted turns in field or armature windings.

1. Clean ventilation and cooling fan screens.
2. Reduce load, then check voltage and current.
3. Replace defective components.

Oil Leak

1. Loose plug in gearcase.
2. Defective seal, gasket, or plug in gearcase.

1. Tighten plug.
2. Replaces seal(s), gasket or plugs. Maintain correct oil level.

REV B

11

60706-199

36 MONTH LIMITED WARRANTY
WINCO, Inc., warrants for thirty-six 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 factory-authorized service station, to be defective in material or workmanship
under normal standby use (average less than 50 hours per month) and service.
For warranty service, return the product within 36 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.
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 36 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. Note: Some states do not allow limitation on the duration of implied warranty and
some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may
not apply in every instance.  This warranty gives you specific legal rights which may vary from state to state.
EXCLUSIONS:
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.
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 INC. • 225 S. CORDOVA AVE. • LE CENTER, MN 56057 • 507-357-6821
60706-199

12

REV B



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