Winco 25PTOC-3/F User manual

READ ALL INSTRUCTIONS CAREFULLY BEFORE AlTEMPTlNG TO INSTALL, OPERATE OR SERVICE
THE
GENERATOR. PROTECT YOURSELF AND OTHERS BY OBSERVING ALL SAFETY IN-
FORMATION. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY
AND/OR PROPERTY DAMAGE!
RETAIN INSTRUCTlONS
FOR FUTURE REFERENCE.
Description
7. This generator must be properly grounded.
These rotating armature power take-off generators
are designed primarily for farm use as a standby
electrical power supply, utilizing the powertake-off
ofatractor ortruckas the primemover.Theportable
trailer-mounted unit can be used to provide electri-
cal power to machinery and out-buildings where
commercial power is not accessible.
NOTE: The primemoverwhichdrives thegenerator
mustbecapableofdeliveringapproximately2.2 H.P.
per 1000watts output from the generator.
Unpacking
NOTE: DO NOT invert generator during unpacking.
Gearcase contains oil.
Unpack the generator as follows:
1. Removestrapping from carton.
2. Lift off carton.
3. Removethe small subpack carton.
4. Open the subpack carton; it contains:
a. One generator instruction manual
b. One load disconnect plug (disassambled, in
bag).for 25PTOC-8JF One range/welding
plug, for CSABPTOC-3IC
c. One quality control inspection tag.
5. Removethe four boltswhich holddownthegen-
erator feet to the pallet. (A six inch crescent
wrench is suitable for this job.)
6. Liftthe generator fromthe pallet bymeansof the
lifting eye on the top of the generator.
7. Inspectthe generator for freight loss ordamage.
GeneraSafety Information
1. Do not allow anyone to operate the generator
without,proper instruction.
2. Guard against electric shock.
3. Avoid touching live terminals or receptacles.
4. Beextremely careful if operating this generator
in rain or snow.
5. Donot makeorbreakelectrical receptaclecon-
nections under.load.
6. Use only grounded receptacles and extension
cords.
8. Hot engine parts, moving partsi aidgenerator
output all can seriously injure the generator
operator. The operator must use caution and
remain alert when using this generator.
9. Provide safety guards for all drive systems.
10. Keepall safety guards and powershields inpo-
sition and tightly secured.
11. When operating this generator. do not wear
neckties, loose articles of clothing, or anything
else that can be caught in moving parts.
12. Engine exhaust fumes are poisonous. Do not
inhale them. Provide adequate ventilation if
prime mover for generator isgas or diesel en-
gine. Besure generator itself iswell ventilated.
13. The generator manufacturer recommends that
only qualified electrical technicians be allowed
to service (install, maintain. repair, or replace
parts) this generator, and that only factory ap-
proved repair parts be used in it.
14. Do not work on this generator when fatigued.
15. Useextremecautionwhenworkingonelectrical
components. Highgenerator output can cause
injury or death.
16. Installing andwiringa home-standbygenerator
installation is not a "do it yourself" project.
Consult
a qualified, licensedelectricianor con-
tractor. The installation must comply with all
national, state, and local codes.
17. Excessive noise is tiring, and continual expo-
sure to it can cause some degree of temporary
and permanent hearing loss. Muffle engine
noise with the best available noisesuppression
equipment;wearnoiseprotectiondeviceswhen
necessary.
18. Keepthegeneratorandtheareaaround itclean.
Remove all material that can create slippery
conditions, such as grease, water, ice, and
snow. Also remove oily ragsand other flamma-
ble material from the area.
19. Keepa fireextinguisher nearthe generator. Ex-
tinguishers rated ABC by the NFPA are appro-
priate for this use. Consult the local fire depart-
ment if you have questions regardingfire extin-
guisher ratings. Keepthe extinguisher properly
maintainedand be familiar with its proper use.
Specifications
GEN.RPM
3600
3600
INS.
B
F
PH
1
1
HZ.
60
60
INPUTRPM
540
540
AMPS
66/33
208/104
VOLTS
1201240
120/240
MODEL
-
8PTOC
25PTOC
WATTS
8000
25000

Assembly
The only assembly required after unpacking the
generator is to assemble and/or wire the plugs
packed in the subpack carton, packed in the
generator carton. The loaddisconnect plug provided
-. with 25PTOC-3lF ,is packed ina bag.
The bag contahsan instructionsheet, a plugbody,
three brass pins (largepinforneutral), and amanila
envelope. The envelope contains an allen wrench,
three retainer pins, and three set screws.
To assemble and wire the load disconnect plug,
proceed as follows (See Figure
1):
1. Cut lead cables to the required length.
2. Strip off insulation 718" back from one end of
each cut-to-length cable.
3. Start a set screw into each pin.
4. lnsertthestripped endof onecablefully intoone
of the brass pins. and tightentheset screw firmly
to secure the cable end in the pin.
CAUTION: If cable-to-pin connection is loose,
arcing and heat damage
io equipment can re-
sult.
5. Insert the brass pin (with cable) into the plug
body, and line up the retainer pin holes in the
brass pinwith those
in the plug body.
6. lnsertthe retainer pin,andtap itfirmly intoplace.
The retainer pinwill protrudeapproximately
318"
when fully seated (See Figure 1).
7. Repeat steps 4 through 6 for each brass pin.
Make sure to connect the neutral lead (cable).
identified and color coded inconformance with
iheapplicable local electrical codes, to the large
diameter pin ("N") on the plug.
WARNING: DURING THE NEXT STEP, THE
LOAD DISCONNECT PLUG SHOULD NOT
BE
PLUGGED INTO ITS RECEPTACLE. ALSO,
MAKESURETHATTHE EQUIPMENTTOWHICH
THE PLUG LEADS ARE BEING CONNECTED IS
NOT ENERGIZED (LIVE).
8. Stripthe insulationoff the free endof eachof the
plugleadsand connect them to the load transfer
switch (or directly to the load).
Installation
FOUNDATIONMOUNTING
Mount,the generator on a foundation if it is to be
used as
a leave-in standby power source.
When planning
a new foundation. consider ihefol-
lowing points (See Figure 2):
Figure 2 - Foundationfor Permanent Installation
1. The foundation location should enable aligning
the tumbling bar (couplingshaft) in
a straight (or
nearly straight) line with the power take-off and
thegenerator inputshaft. (Misalignmentmustbe
lessthan
15 degreeseventhoughthe mechanical
design of the tumbling bar would allow greater
misalignment.)
2. The foundation must besolid enough to absorb
generator starting and reflected load torque
during operation,
3. The foundation surface should be flat.
4. Space is required around the generator for
mounting switching devices, making connec-
tions, and for servicing.
5. Allfour generator mountingpadsmust restfirmly
on the foundation. Install shims
if necessary to
even out the foundation under the mounting
pads, then bolt the generator firmly in place.
TRAILER MOUNTING
Mountthe generator onatrailer ifyou planto use it
as
a portable power source.
When selecting or building a trailer to mount the
generator, considerthefollowingpoints(SeeFigure
3):
1. The trailer construction must be strong enough
to support the generator.
2. Thedesignofthetrailer mustenablethetrailer to
remainstableduring operation, and to resist tip-
ping caused by generator starting and reflected
load torque.
WARNING: TRAILER MAY TIP OVER AND
CAUSE INJURIES
IF WHEELS ARE NOT
SPACED FAR ENOUGH APART.
3. The trailer height and mounting position of the
generator on the trailer should enable aligning
thetumbling bar (couplingshaft) inastraight (or
nearly straight) line with the power take-off and
generator input shafts. (Misalignment must be
lessthan
15 degreeseventhoughthe mechanical
design of the tumbling bar would allow greater
misalignment.)

lnstallation
Opera tion
4. The generator mounting area of the trailer bed
should be flat.
5. AII fourgenerator mountingpadsmustrestfirmly
on:the trailer bed. Install shims if necessary to
evenout the bed under the mounting pads,then
bolt the generator firmly inplace.
Figure 3 - Trailer for Portable Installation
OUTPUT POWER AND LOAD DETERMINATION
The power take-off generators are supplied with
control boxes, receptacles, fuses or circuit break-
ers. The maximum load which should ever be
applied to the generator is the KW (kilowatt)orwat-
tage rating of the generator. This rating isstamped
on the generator identification nameplate. De-
pendingonthegenerator model,thismaximumload
will only be available at the Load Disconnect plug.
restricted to their design
rating. Some models have
protection for the receptacles.
tofind the load current of
different appliances.
LoadWattage Rating = Load current in amperes
120 volts
Example:
Food freezer requires 300 watts
300 watts = 2.5 amps.
120 volts
Refrigerator requires325 watts
325 watts
= 2.7 amps.
120 volts
Ten 100watt light bulbs require 1000 watts
1000 watts = 8.3 amps.
120 volts
Freezer = 2.5 amps.
Refrigerator
= 2.7 amps.
Lights
= 8.3amps.
Total Load = 13.5 amps.
Use the same methodto figure the load current for
the 240 volt electrical loads.
NOTE: Check applianceimotor nameplate for volt-
age. current, and wattage.specifications when
figuring load.current.
USING ELECTRIC MOTORS WITH
GENERATOR SETS
When using an electric motor with the generator set.
consider the starting current of the motor. All single
phase electric motors require more starting current
than running current, and starting currents vary
reatly betweendifferenttypes ofmotors. Capacitor-
&art motor starting currents are 4 to 4-112 times the
running current, and Split-Phase motor starting cur-
rents are 5 to 5-1/2 times the runnina current.
- -.
NOTE: Inapplicationswhere severaliotorsareto be
started, do not start them at the same time to avoid
overloading the generator. Start the motor that re-
quires the highest starting current first.
PRE-START CHECKS
WARNING: WHEN WORKING ON OR AROUND
THIS GENERATOR, DO NOT WEAR LOOSE FIT-
TING CLOTHING OR ANY ARTICLES THAT MAY
GET CAUGHT IN MOVING PARTS.
1. Visually inspect the generator. Check for:
. a. correct mounting
b. physical damage
. c. debris in cooling vents and screens (could
cause generator to overheat).
CAUTION: Ifthe generator has beenstored for
any length of time it is recommended that the
control box cover and the end cover be re-
moved, andthe generator inspected for rodent
nests or other foreign objects that couldcause
binding or overheating of the generator. See
"Cleaning" generator maintenance for proce-
dures.
2. Check gear case oil level. See Figure 4. Case
should be filled with oil to plug marked "OIL
LEVEL." Fill or remove oil as required.
OIL BREATHER,
@ .- >.,.
L-??
..T---T *
0 :'.>
.
.. .. c:; . o(Q 2oi--T
.: ,
0 ?: I
CAUTION: Either too little or too much oil can
harmtheequipment. See "Lubrication" portion
of Maintenance for oil specifications.
3. Make sure tumbling bar (coupling shaft) is as-
sembled with its universal joint knuckles
"synchronized." as illustrated inFigure
5. Ifknuck-
lesare not synchronized. the barwillchatterwhen
rotating, which will cause the generator output
voltage to fluctuate and can also cause tumbling
bar failure or shortened generator life.

Operation (Continued)
WARNING: POWER TAKE-OFF MUST BE DIS--
ENGAGED AT
THIS TIME.
4. Couple the generator drive (powertake-off)to the:
generator with the tumbling bar. Couple the tum-
bling bar to the generator input shaft first, then to
the powertake-off shaft. Check alignment: power
take-off shaft, tumbling bar, and generator input
shaft should form a straight (or nearly straight)
line, with less than
15" misalignmentbetween the
shafts. Misalignment will cause generator output
voltage to fluctuate or damage the tumbling bar
and generator.
WARNING: MAKE SURE THAT ALL TUMBLING
BAR LOCK
PINS ARE ENGAGEDANDTHATALL
SAFETY SHIELDS ARE
IN PLACE.
5. Make-surenobinding exists ingenerator or gear
boxby rotatingtumblingbarbyhand.
If bindingis
found, locatethe cause andcorrect itbeforepro-
ceeding.
6. Makesurethattheelectricalloadsconnectedwill
notdraw morecurrent thanthe ratingof thegen-
erator or receptacle being used.
7. Check all electrical connections inthe system to
be energized by the generator. Make sure the
connections are correct and are tight.
8. Make sure all loads are turned off.
CAUTION: Do not start the generator under
load.
speedgovernor, itmayautomatically readjustthe
throttle as the load changes and keep the gen-
erator output at
240V. However,some governors
are notsensitiveenoughto maintain
240V output
under changing load, and in such cases the
throttle will have to be manually readjusted.
IT Synchronized
-7
GENERATOR STARTING
1. With the power take-off drive disengaged, start
theenginewhichwilldrivethegenerator. Runthe
engine long enough to warm it up before pro-
ceeding. so that itwill runsmoothly and achieve
full power under generator load.
2. With engine idling, engage the power take-off
drive.
3. Watch thevoltmeter onthegenerator andslowly
increase engine speed until the output reaches
approximately
260 volts (in green portion of
voltmeter scale).
4. With engine,and generator running smoothly,
switch on the electrical load while watching the
voltmeter.
Readjust engine throttle to keep generator out-
put under load at
240V (in green portion of
voltmeter scale).
If engine is equipped with a
.
GENERATOR SHUTDOWN
1. Switch off electrical load.
2. Reducespeedofenginedriving generator to idle.
3. Disengage power take-off drive, and allow gen-
erator to coast to a stop.
WARNING: NEVER TRY TO MANUALLY STOP
THE GENERATOR - LET IT COAST UNTIL IT
STOPS!
4. Disconnect tumbling bar (couplingshaft)power
takeoff end first, then generator end.

Wiring Diagrams
ELECTRICAL CONNECTIONS
NOTE: Only qualified electricians should .install
electrical wiring. Wiring must conform to all appli-
cable national, state, and local codes, (Reference:
National FireProtectionAssociation ManualNo.
70,
National Electrical Code.)
WARNING: IFTHEGENERATORISTOBEUSEDAS
A STANDBY POWER PLANT WIRED INTO THE
EXISTING COMMERCIAL.SYSTEM, A
DISCON-
NECTSWITCH MUST BEINSTALLEDWHICH WlLL
ISOLATETHE GENERATOR FROMTHE COMMER-
CIAL POWER WHENEVER THE GENERATOR IS
NOT OPERATED, AND WlLL ISOLATETHE COM-
MERCIALPOWER FROMTHE GENERATORWHEN
CAUTION: When making standby service hook up,
THE GENERATOR ISOPERATING(SEE FIGURE 6).
make sure load to be transferred does not exceed
generator rating.
TYPICAL HOOK UP FOR
SUPPLYING ALL CIRCUITS
WlTH EMERGENCY POWER
TYPICAL HOOK UP FOR
SUPPLYING ONLY ESSENTIAL CIRCUITS
WlTH EMERGENCY POWER
To Power Line Master Switch
Wanhour ,
Emergency
Power
System
L1 L3
I-
--'- --
1
Studby
Ci.nerolor
I I
L----- -J
Te
. Watw
ktu To Air
bnditioner
Te Ughh To Refn'g.
1- Ughk To Applianc
1e Ughk To Fumace
To Powor Line Morter Switch
Watthour
Meter
Emergency
Distribution
T 1 ~3 Panel
I--
-'-------
To
a
Lights -+ , ,
To ' ' '1 TO
Lights +,
4 + Appliancer -
To -i-- "t. To
Lbhts =
.L
A
f
Furnace
I 7 1
Figure 6
-

Maintenance
GENERAL
Routine preventive maintenance minimizes costly
repairs and generator down-time. Before each use,
inspect the generator: gear case oil levelshould be
correct. coolingvents and screens should beclear,
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.
CAUTION: The manufacturer strongly recorn-
mends running the generator under load at least
once a month in order to evaporate any accumu-
lated moisture condensation.
LUBRICATION
The generator bearings are factory lubricated and
sealed, and require no further lubrication.
Splinedgenerator inputshaftshould becleanedand
lubricated with athin iiimof grease beforeandafter
each use of the generator.
Coupling shaft (tumbling,bar) requires greasing.
Keep the universal joints in the coupling shaft free
from grease and dirt buildup.
CAUTION: Do not overlubricate the universal
joints.
,-- 40 hrs.
.. . . . ..
-8 hrs. LA
Figure 7
--
Lubrication for Typical
Tumbling Bar (Coupling
Shaft)
See Figure 7 for recommendedlubricationschedule
for tumbling bar.
Check the generator gear case oil level before each
useof the generator. Maintainthe oillevelat oillevel
plug height.
Figure 5 illustrates oil level plug loca-
tion. The generator is shipped with lubricant in the
gear case. Specifications for gear case lubricant
are: API Service: GL-5
Grade: SAE 85W-90-140
Amount: 1 quart
The following kindsof oil are recommended for use
in the generator gear case: MotilSAE 85W-90-140
API Service GL-5, SunocoIDX XL80-90-140, Kendal
ThreeStar85W-140,Amoco85W-140.orequivalent.
CAUTION: Do not overfill generator gear case.
Overfillingcausesoverheatingandoilsealfailure.
Change the oil at least once every six months.
Changeitmoreoften
if you usethegenerator inbad
weather.
Use the following procedure to change generator
gear case oil.
(See Figure 5).
1. Remove gear case breather. Soak breather in
cleaning solvent, then allow it to dry.
2. Remove oil level check plug.
3. Remove the oil drain plug. Drain the oil into a
clean oil resistant container, one quart or more
capacity. Check the oil for metal. Fine metaldust
in the oil does not indicate trouble, but metal
chips do. Dismantle the gear case and look for
damaged gears
if you find metal chips inthe oil.
4. Replace the oil drain plug. Refill the gear case
through the breather port with new oil of the
recommended type. Fill the case up to oil level
check plug height. (Itwill take about one quart.)
5. Replace the oil level check plug.
6. Replace the breather.
CLEANING AND INSPECTING
Use a vacuum cleaner or dry low pressure com-
pressed air (regulated at 25-35 PSI) to clean the
generator periodically.
WARNING: DO NOT CLEAN THE GENERATOR
WHILE IT IS RUNNING.
Proceed as follows:
1. Removecontrol box cover. Vacuum or blowdust
or debris from the control box. lnspect all wiring
forcorrectrouting, fraying insulation, andsecure
connections.
2. Remove end cover. Vacuum or blow dust and
debris from the inside of the generator. lnspect
wiring for loose connections, fraying insulation
and correct routing.
3. Replace end cover and control box cover.
GENERATOR STORAGE
Before storing the generator, apply a heavycoat of
grease to the splined input shaft. Store the gen-
erator insheltered area,where itisprotectedagainst
snow, rain, and excessive dust.
BRUSHES
Underordinarycircumstances, brusheswill operate
for long periods without requiring replacement.
They should be inspected after the first 1000 hours
ofoperation,and after every 100 hoursof operation
thereafter. Removebrushesone at atime andcheck
for length: be sure that each moves freely in the
brush holder. Brushes should be replaced when
worn down to
318". 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 iscaused byoiland grit, ontheslip-ring,or
ahard substance inthe brush. It can also becaused
bythebrush not beingproperly seatedor contoured
to the slip-ring. To correct this discrepancy, the
brushes can be recontoured by placing 00
sandpaper under the brusheswith the abrasive side
to the brushes, and work it back and forth until the
brushes are seated to the slip-rings.

Maintenance (Continued)
COLLECTOR RINGSISLIP RINGS GENERATOR FIELD FOR OPENS AND GROUNDS
. The continuous copper rings located at the end of (SeeFigure 9).
the armature are the collectorrings. Forproper gen-
1. Disconnect field leads from rectifier.
erator output,the surface ofthe collector ringsmust
2. Set multimeter to read resistance, and connect
have a highly polished finish. Polish the ring sur- the meter leads to the field leads. If field isopen,
faces occasionally with a crocus cloth to maintain meterwill readinfiniteresistance. Replace field if
the finish. it is open.
Testing
ARMATURE FOR OPENS AND GROUNDS
1. Remove all brushes.
2. Grounding Test (See Figure 8).
Set multimeter to read resistance. Holding one
meter lead against
a clean spot onthe armature
shaft, touch the other lead to each of the slip
rings (one at a time) while observing the nleier.
If meter indicates continuity (zero ohms or any
reading lower than infinite resistance), the ar-
mature is grounded.
3. Testing for Opens (See Figure 8).
(Meter still set to read resistance.) Holding one
meter lead on surface of slip ring No.
1. touch
other meterleadtosurfaceof slipringNo.
2 while
observing the meter. Meter should indicate con-
tinuity (low resistance). If not (i.e.
if meter indi-
cates infinite resistance) part of armature wind-
ings are open and armature should be replaced.
4. Checkfor openbetweenslipringsNo.'s2 and 3 in
same manner as you did between rings
1 and 2
(previous paragraph).
FiguJ
TESTING ARMATURE FOR OPENS AND GROUNDS
3. Connect one meter lead to the field shell (other
lead still connected to one of the field leads).
If
meter indicates continuity (zero ohms or any
readinglowerthaninfinite resistance),thefield is
grounded and should be replaced.
F_igu&9 FIELD COIL TESTING
RECTIFIERS (See Figure 10)
The Field Excitation rectifier is a full-wave bridge
rectifier. This type of rectifier has four terminals,
TwoAC, a DC positive, and aDC negative. The recti-
,
fier is tested inthe following manner. Connect one
ohmmeter lead to the pcsitive DC terminal, and the
other lead toeachof theAC terminals inturn. A high
or low resistance reading will beobtained. Reverse
the meter leads. and anopposite readingshould be
observed. Now check from the negative terminal to
each of the AC terminals, using the same proce-
dures as above.
Check each terminal to the case. and noresistance
reading should be observed.
If a battery-powered test light is used, follow the
proceduresdescribed above.
If the rectifier isgood.
the light will come on inone direction only.
If therectifier failsanyof theabovetests, itshould be
considered defective and replaced.

Maintenance (Continued)
CONDENSER
.. .
Condensers are built into the generator circuit to
minimize radio interference during operation.
If a
:
RED (+) TEST LEAD
condensershortsout, itshortsthe generatoroutput.
Todetermine whether a condenser is shorted, stop
the generator, disconnect the lead wire from the.
brush holderto which the condenser is connected,
startthe generator and checkthe output. If the gen-
erator then provides power, the condenser was at
fault and should be replaced.
(If the generator did
not provide power after the lead wire was discon-
nected the problem was not caused
by that con-
denser. Reconnect the lead wire.)
Figure 1 1 - Wiring-gram Model

-
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cn 0,
C
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5
I
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2
3
0
iil

Figure 13 - Model

I
1
Replacement Parts List for Model..CSA8PTOC-31 C
Ref.
No.
Replacement Parts List
Description . '
Machinescrew
Lockwasher
- 5/16 split
Lockwasher
- 1/4 split
Screw
- 1/4-20 x 5/8
Lockwasher - 11/16 int. .
Washer - 1/2flat
Lockwasher
- 1/2ext.
Nut - 1/2-20 x 3/8
Lockwasher - 1/2 split
Capscrew
- 1/2-13 x 1
Machinescrew
-
#8-32 X 2-1 12
Machinescrew -
#8-32 X 5/16
Capscrew -
3/8-16 x 1-3/4
Screw
Cover
Frontcover
Upperrearpanelonly
Lowerrearpanel(left)
Lower rear panel(right)
Frontpanelonly
Voltmeter
Breaker
- 2 pole35 amp
Receptacle-250V
/
50amp (x-50R)
Circuitbreaker-
1pole15amp
Receptacle
- 120V/
15amp (5-15R)
Saddle
PartNo. Ref.
.. No.
272
401
411
412
413
414
415
416
417
418
419
420
431
432
441A
441B
442
443
444
447
449
462
463
467
468
469
471
491
610
Description
Grommet
Fanassembly
Endbracket
Oilseal
Bearing
Retainerplate
Gasket
Spacer
Piniongear
Key
Lockwasher-
1-1/4int. tooth
Nut, 1-1/4-12
Armature assembly-
lessbearings
Bearing
Fieldcoil
Fieldcoil
Poleshoe
Poleshoe retainer
Fieldshellandbrkt
Brush
A.C. (1/4x3/8)
Brush "0" (1/4x3/8)
BrushholderA.C.
Capacitor
A.C.
Rectifier
Groundstrap-copper
Barrierspacer
Brushplate(bare)
Endcover
Baseassembly
Qty .
Fgure 14 - Gearbox
Ref.
No.
130
134
137
138
140
141
142
144
146
147
118
149
150
151
152
153
154
155
156
157
158
159
-
Qty.
1
1
.1
2
1
4
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
PartNo.
55475
46547
20029
54666
46296
1774
46548
20016
56207
53332
46546
54665
46299
46295
46298
46286
20 133
55476
40716
20128
4133
24142
Description
Gearbox assembly
Piniongear (540rpm)
Seal(inputshaft)
Bearing
Shaft(inputdrive)
Woodruff key
Gear (540rpm input)
Gasket
- cover
Backingplate
Safetyshield
Gear (driven-540rpm)
Bearing
Gasket
Retainer
Gasket
Retainer
Snap ring
Gearcase
& coveronly
Breather
Shaft
(intermediatedriven) . .
Rollpin
Streetelbow, 90"

Egure 15 - Model

I
. .
Replacement Parts List for Model. 25PTOC-3 / F
Description
Machinescrew
Lockwasher
- 5/16 split
Lockwasher
- 1/4 split
Screw
- 1/4-20 x 518
Lockwasher - 11/16 int.
Washer
- 1/2flat
Lockwasher - 1/2 ext.
Nut - 1/2-20 x 318
Lockwasher - 1/2split
Capscrew- 112-13
x 1
Machinescrew
-
#8-32 x 3
Lockwasher - #8
Nut - #8-32
Machinescrew -
#8-32 x 5/16
Capscrew -
7/16 X 1-3/4
Screw
Cover
Fron! cover
Upperrearpanelonly
Lowerrearpanel(left)
Lowerrear panel(right)
Frontpanelonly
Receptacle
Voltmeter
Breaker
- 2 pole50amp
Receptacle-250V /
50 amp (x-50R)
Circuitbreaker-
1 pole 15amp
Receptacle-
120V/15amp (5-15R)
Circuit breaker -
2 pole rooamp
Maindisconnectplug
Receptaclemounting
Ref. I 1
No. I PartNo. I Qty. ( Description
269
1 58805-1 I 1 I Circuit breaker mtsplte
I
I
Fanassembly
Endbracket
Oilseal
Bearing
Retainerplate
Gasket
Spacer
Piniongear
Key
Lockwasher-
1-114int. tooth
Nut, 1-114-12
Armatureassernbly-
lessbearings
Bearing
Fieldcoil
Fieldcoil
Poleshoe
Poleshoeretainer
Fieldshellandbrkt
BrushA.C. (3/8x3/8)
Brush "Q" (114x3/8)
BrushholderA.C.
CapacitorA.C.
Rectifier
Groundstrap -copper
Fiberspacer
Spacer-brushholder
Brushmountingplate
segment (bare)
"0" ringbrushholder
Endcover
Baseassembly
Replacement Parts List
Egure 16 - Gearbox
Ref.
No.
130
134
137
138
140
141
142
144
146
147
148
149
150
151
152
153
154
155
156
157
158
159
PartNo.
55475
46547
20029
54666
46296
1774
46548
200
1 6
56207
53332
46546
54665
46299
46295
46298
46286
20133
55476
40716
20128
4133
24142
Oty.
1
1
1
2
1
4
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
Description
Gearboxassembly
Piniongear (540rpm)
Seal (inputshaft)
Bearing
Shaft (inputdrive)
Woodruff key
Gear(540rpminput)
Gasket
- cover
Backingplate
Safetyshield
Gear (driven-540
rpm)
Bearing
Gasket
Retainer
Gasket
Retainer
Snap ring
Gearcase
& coveronly
Breather
Shaft
(intermediatedriven)
Rollpin
Streetelbow.
90"

Trouble Shooting Chart
GENERAL
compare the clock's second hand movement with
that of thewrist watch. They should runat the same
The following lists various s~mptoms of poor speed. If clock runs faster, speed is too
generator operation with possible causes for them
and the appropriatecorrectiveaction. Youwill need
and vice versa).
a volt-ohm meter ortest light to check some of the CAUTION: Most electrical equipment in North
causes. For some of the ocher causesyou will need America operates at frequencies-between
59 and
to check generator speed. To check speed use a .
61 Hz (CPS)..Operating the generator at frequen-
frequency meter, a tachometer, ora 120V-60Hz elec- cies outside that range may cause damage to the
tric clock and a correctly operating wrist watch. generatorand/ortoelectrical equipment driven
by
(Run the electric clock on generator power and the generator.
SYMPTOM
No output voltage.
.
Low voltage.
High voltage.
Output voltage flickering or fluctuation.
Excessive vibration.
Generator overheating.
Oil leak.
CAUSE(S)
1. Circuit breaker.
2. Defective voltmeter.
3. Short circuit in the load.
4. -0efective receptacles.
5. Loose (or broken) wires or connections in the
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. Engine speed too slow.
Generator overloaded.
2. Inadequate engine horsepower.
3. Incorrect field excitation. .
4. Brushes not seated properly, or dirty brushes
and slip rings. (Remove brushes: check for
uneven wear or dirt on brushes or slip rings.)
Engine speed too fast.
1. Tumbling bar (coupling shaft) misalignment.
2. Engine speed not constant.
3. Loose connection in field circuit.
4. Tumbling bar U-joints not synchronized.
1. Power take-off misalignment excessive.
2. Loose mounting nuts and bolts or hold-down
studs.
3. Universal joints in coupling shaft worn or dry.
4. Defective bearings.
1. Poor ventilation.
2. Generator overloaded.
3. Shorted turns in field or armature.
1. Loose plug in gear case.
2. Defective seal, gasket. or plug in gear case.
7
CORRECTIVE ACTION
1. Reset circu~tbreakers: replace if defective.
2. Check output with another meter. replace meter
if defective.
3. Disconnect the load. Check voltage at receptacle.
Check motors, sppliances and load leads lor
short circu~t.Repa~rshort.
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 andior repair where neces-
sary.
6. Test rectifier. Replaceif defective.
7. Clean and polish. Use 00 sandpaper and crocus
cloth, never emery paper.
8. Check brushes for swelling: replace defective
brushes; clean brush holders.
9. Replace armature if open or shorted.
10. Measure between leads for open or short. Re-
place coil(s) if defective.
1. Check engine speed. Increase RPMif necessary.
Reduce load if it ishigherthan the rated capacity
of the operator (See generator nameplate.)
2. Generator requires 2.2 H.P.llOOO watts output.
Obtain larger engine if necessary.
3. Check input AC voltage to rectifier. Check recti-
fier output OC voltage.
4. Clean slip rings and seat brushes with sand-
paper. (See Maintenance).
Check engine speed for correct input RPM.
1. Reduce tumbling bar misalignment to less than
15 degrees.
2. Engine governor may be worn or improperly ad-
justed. Set or repair defective governor.
3. Check and tighten connections.
4. Reassemble tumbling bar.
1. Correct misalignment. It should be less than 15
degrees.
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.
1. Clean ventilation and cooling fan screens.
2. Reduce load. then check voltage and current.
3. Replace defective components.
1. Tighten plug.
2. Replace seal(s), gaskets or plugs. Maintain
correct oil level.

*
I
E
F
1
!
,!
2
t
Record
REPLACEMENTCOMPONENTS REQUIRED
I
Service
DATE MAINTENANCEPERFORMED
I
L

Winco warrants that for thirty-six months from date of shipment it will repair or replace
. ....
for the original user the whole orany part of the product found upon examination by Winco
at its factory at
225 South Cordova Avenue, LeCenter, Minnesota, or by any Factory-Autho-
rized 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, please return the product within one year from date of shipment,
transportation charges prepaid, to the Winco factory or to your nearest Factory-Authorized
Service Station as listed in the 'Yellow Pages' under Generator-Electric.
THERE IS NO OTHER EXPRESS WARRANTY. TOTHEEXTENTPERMITTED BY
LA\\', ANY AND ALL IMPLIED WARRANTIES, INCLUDING THOSE OF MER-
CHAXTABILITY AND FITNESS FOR A PARTICULAR PUIIPOSE, ARE LIhIITED
TO THIRTY-SIX MONTHS FROiM DATE OFSHIPMENT, AND LIABILITY FOR IN-
CIDESTALOR COSSEQUENTIAL 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 the 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.
Winco does not warrant trailer tires, tumbling bars, or certain other component parts of
the product since such items are warranted by their manufacturers.
Winco does not warrant alterations orrepairs which were made by someoneother than the
Winco factory or a Factory-Authorized Service Station 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 reserves the right to change or improve its products without incurring any obliga-
tions to make such changes or improvements on products purchased previously.
! -@ -'
INCORPPR ATED
Manulacrurmg-Eng~neerrng 8 Cusromer Service
225 South COI~OV~ Avenue
Le Center MN 56057 [phone]